AZ16. Anatomy of the world s best-selling interlock switch

Transcription

1 Optional M12 quick-connect termination Up to 3 contacts, for dual-channel reliability with signalling AZ16 Anatomy of the world s best-selling interlock switch normally-closed contacts (ensure circuit interruption) Self-lifting terminal clamps (for speedy installation) Catalog GK-1 Eighth Edition 3 threaded knock-out conduit entry points for easy installation Electricallyinsulated contacts for added safety (no potential for crossover) Molded-in, easy-to-read terminal markings (help ensure proper wiring) IP67 sealed housing (tolerant to hostile environments) Difficult-to-defeat multiple-cam actuating mechanism (mechanical life: 10 million) Integral, non-removable actuating head resists bypassing by preventing access to operating plunger Internationally accepted (CE, UL, CSA, BG, SUVA, SA, NEMKO, TUV, and others) High-strength, corrosion-resistant polymeric housing (no ground connector required) 7 lbs. of built-in key holding force resists guard opening due to shock or vibration (other holding force options) 4 actuator-key entry points, for ease of mounting And the industry's broadest range of optional features & accessories Adjustable ball latch Magnetic door latch Flex-mounted actuator keys Individually-coded actuator keys Solenoid-locking (Model AZM161) Gold contacts Signal lamps (Pilot light or built-in LED) Explosion-proof models (ATEX-compliant) Key entry closure caps Optional funnel entry Optional M12 connector Rugged, tamperresistant, stainless steel coded actuator key (Individuallycoded keys available) Optional maintained or ejecting actuator key (for application versatility) 1

2 TABLE OF CONTENTS Topic Page Alphanumeric Product Index Pictorial Product Index , 5 About Schmersal Man-Machine Safeguarding Products Selection Guides Keyed Interlock Switches Keyed Interlock Switches with Solenoid Latching Application Accessories (Safety Door Handles, Enabling Devices, Safety Foot Control, Two-Hand Controls) Emergency Cable-Pull Switches Non-Contact Safety Sensors & Compatible Safety Controllers Hinged Safety Interlock Switches Safety-Rated Limit Switches Safety Light Curtains & Beams Safety Pressure Mats Fail-to-Safe Safety Edges Safety Controllers Appendices Frequently Asked Questions Regarding Man-Machine Safeguarding Requirements & Techniques Frequently Asked Questions Regarding Safety Light Curtains Selected Machine Safeguarding Terminology Machine Safety Standards Selected Conversion Factors NEMA, UL, CSA & IEC Ingress Protection Ratings Copyright 2007 by SCHMERSAL All Rights Reserved. SCHMERSAL is continuously working to improve our product designs. Therefore we reserve the right to change product specifications/ratings and other information contained in this catalog without notice. Proper installation and use of our products remains the customer s responsibility. 2

3 ALPHANUMERIC PRODUCT INDEX Product Series Page Product Series Page AES AZ15/ AZ16zi AZ AZ17zi AZ New! AZ AZ AZM AZM AZM New! AZM AZS B New! BNS BNS BNS33S New! BNS BNS BNS30 & BNS BNS BNS BNS-B New! BZ C CSS New! CSS New! ES95 SB FWS1205/ /102 GFS MZM New! New! S SDG SHGV SE SEPK(G) New! SLC, SLG & SLB SMS SRB ST STS New! T.C 235/ TESF New! TESZ TFA/TFI New! TG TKF/TKM TV8S TVS TZF/TZM TZG TZK Z Z/T Z/T Z/T Z/T ZS71 & ZS71NA* New!* ZS ZS ZS75S (Bidirectional) ZS New! ZS ZSD

4 PICTORIAL PRODUCT INDEX Keyed Interlock Switches ST14 AZ17 & AZ17zi AZ15/16 & AZ16zi New! AZ 200 Selection Guide: Page 11 Page 12 Page 14 & 18 Page 22 & 28 Page 32 Keyed Interlock Switches with Solenoid- Latching AZM170 AZM161 New! AZM 200 New! MZM 100 Selection Guide: Page 59 Page 60 Application Accessories (Safety Door Handles, Enabling Devices, Safety Foot Switches) New! Page 66 STS New! Page 70 B25 Page 76 TG-1 Selection Guide: Page 105 Page 106 Page 112 Page 114 ZS71 ZS73 ZS75 Emergency Cable-Pull Switches Selection Guide: Page 125 Page 126 Page 130 Page 134 Non-Contact Safety Sensors & Compatible Safety Controllers BNS250 & BNS260 BNS33 & BNS33S BNS303 BNS30 & BNS300 Selection Guide: Page 153 Pages 154 & 156 Pages 158 & 162 Page 164 Page 166 ES95 SB & TVS 335 TV8S-521 T.C 235/236 Hinged Safety Interlock Switches Selection Guide: Page 207 Pages 208 & 210 Page 212 Page 214 Safety Light Curtains & Beams Selection Guide: Page 273 New! SLC, SLG & SLB Safety Category 3 Pressure Mats & Fail-to-Safe Safety Edges SMS3 Series 4 Page 263 Page 311

5 PICTORIAL PRODUCT INDEX TZG SDG AZ335 SHGV AZ415 1 Page 40 Page 44 Page 48 Page 52 Page 54 TZF/TZM TKF/TKM TZK AZM415 AZS/FWS 2 Page 82 ZSD Page 86 GFS New! Page 90 SEPK(G) New! Page 94 TFA/TFI Page 98 3 Page 116 ZS441 Page 118 ZS75S Bidirectional New! Page 122 ZS80 New! Page 124 S900 4 Page 138 Page 142 Page 146 Page 150 BNS333 BNS16 & BZ16 New! BNS-B20 New! CSS 180 New! CSS 34 5 Page 168 Pages 170 & 172 Page 174 Page 176 Page 184 New! TESF & TESZ Safety-Rated Limit Switches Z/T235/236 & Z/T335/336 Z332 C50 6 Selection Guide: Page 227 Pages 220 & 224 Pages 228, 236, 244, & 250 Page 256 Page 260 SE Series AES SRB Protect General & Specific Purpose Safety Controllers 7 Page 317 Page 189 Page 327 5

6 6 Turning Workplaces Into Safeplaces

7 ABOUT SCHMERSAL K.A. SCHMERSAL GmbH & Co. was founded as a family business in The firm initially focused on the design and manufacture of electromechanical switches for industrial applications. Our first products included heavy-duty, cast-encapsulated limit switches for (post-war) civil engineering and construction applications. This program quickly expanded to include: grey cast iron limit switches light metal limit switches robust precision limit switches spindle limit switches gear motor switches elevator switch gears CENELEC position switches miniature snap-acting switches, and command devices for machine and crane control systems. With this early post-war product program, the firm quickly established itself as a specialist in monitoring, switching, and controlling elevators, material handling systems, machine tools, and other industrial equipment. Many of these initial products satisfied unique requirements for safety switches. Such products included: explosion-proof switches for gasoline pumps door contacts and locks for personnel/freight elevators cable monitoring switches for mountain cablecar systems, and snap-acting limit switches featuring positive-opening contacts for lignite diggers, construction cranes, and other machinery. Today the product range has expanded to include a broad selection of non-contact electronic presence/position sensing sensors and switches. These are designed using state-of-the-art inductive, capacitive, magnetic and photoelectric technologies. Armed with diverse electronic and electromechanical capabilities, the firm has continued to welcome unique customer-specific problems. Operating from their modern headquarters in Wuppertal, Germany, an industrial suburb of Dusseldorf with a population of 400,000, the firm s 400 employees maintain close contact with their worldwide customer base. This close contact, coupled with a commitment to respond to the needs of their customers, continues to serve as a basis for continued new product development to meet the constantly changing market. By 1953 the company had established a reputation as a leading producer of innovative machine guarding safety switches. SYSTEM SAFETY: PROTECTION FOR MAN AND MACHINE Recent trends for a safer workplace in many industries have led the company to give this field even greater attention. Newest product developments have focused on advanced safety switches which satisfy the stringent requirements of the harmonized European Economic Community and its regulatory agencies. GLOBAL COVERAGE: Technical support and inventory in more than 22 countries. 7

8 MAN-MACHINE SAFETY THE SCHMERSAL SYSTEM: A 360 APPROACH CHANGING MAN-MACHINE SAFEGUARDING RULES For more than 50 years SCHMERSAL has dedicated itself to understanding machine safety hazards. We have made it our mission to develop defeat-resistant, fail-tosafe solutions using advanced safety switch technology. This catalog-handbook is a compilation of information that addresses the latest and most stringent industry safety standards and regulations matched with a broad selection of dependable solutions. Today worker safety is an issue of major concern to manufacturers worldwide. OSHA guidelines, more stringent ANSI standards, and the recently (1996) adopted European Machinery Directive (EMD) are evidence of the increased emphasis being given to employee safety in the workplace. The day-to-day study of modern workplace safety is filled with the minutiae of industry regulations and standards. But philosophically we look to a higher standard in the work of one of the world s greatest engineers, Leonardo da Vinci. A true Renaissance genius, he was a man whose fascination for the human body and the principles of physics resulted in his meticulous anatomical drawings, numerous intricate machines, and even a robotic knight that consisted of a system of cables and pulleys that controlled the movement of articulated limbs. Arguably the world s first ergonomic engineer, Leonardo truly understood man and his physiological relationship to machinery. Like Leonardo, we at SCHMERSAL take a 360degree approach to safety. We evaluate from every angle the potential for accidents and their prevention. We recognize the wide differences in each work station. We take into account specific guard design, as well as the environmental and physical considerations necessary to support machinery operation and provide maintenance. We even understand the frustrations and all-too-human temptation some machine operators feel to override (bypass) the safety system. Selected industry standards and guidelines aimed at achieving higher levels of safety are reviewed in the section of this Handbook/ Catalog entitled Safety Standards. Each defines minimum safety requirements to which manufacturers and employees must comply. In so doing, they present new challenges to the plant safety specialist and equipment designer especially where safety guards ancillary to the production equipment s functional design are required. NEW SAFETY CONCEPTS AND TECHNIQUES The goal of these new and emerging guidelines is to provide heightened levels of protection to machine operators, helpers, and maintenance personnel. Toward this goal they have embraced several new safety system concepts including: positive-break contacts greater tamper-resistance positive-guided relays fault detection single component failure control reliability Conventional limit switches, proximity sensors, magnet switches and Different dynamics mean different soluother classical position-sensing and tions. Different markets are subject to difcontrol devices traditionally used as safety ferent regulations. Our system of more than interlocks do not meet contemporary require200 interlock, magnetic and rope-pull switches ments. Consequently, when used in such has earned SCHMERSAL a world-wide International symbol for applications, they are regarded as unsafe. reputation for reliability, flexibility, and Positive-Break contacts dependable quality. 8

9 SAFETY-SPECIFIC COMPONENTS New switches, sensors and controls have been designed specifically for safety applications. Each is intended to overcome one or more of the limitations of conventional non-safety components and to satisfy one or more of the current safety requirements inherent in the latest industry standards and guidelines. These safety-specific components are the subject of this catalog. They include: keyed interlock switches keyed interlock switches with solenoid latching sealed non-contact safety sensors safety foot switches push/pull operated emergency cable-pull switches two-hand controls positive-break hinged safety switches safety light curtains/beams fail-to-safe safety edges safety pressure mats safety-rated limit switches safety controllers Each of these components is designed to help the safety specialist and equipment designers to better address their responsibility to ensure that machinery, built or purchased, does not expose the operators, helpers or maintenance personnel to hazards. SATISFYING YOUR NEEDS We trust that this Catalog-Handbook, its companion catalogs, and our tutorial Manual and videos, will be useful tools in the selection of suitable components to satisfy your unique application requirements. Your needs are our most important concern. We welcome your questions and comments, and would appreciate your making us aware of any machine safeguarding requirements which cannot be satisfied with available components. GUIDE TO APPLICATION SYMBOLS USED THROUGHOUT THE CATALOG Sliding Guard Applications Hinged Guard Applications Lift-off Guard Applications 9

10 10 Safer by Design

11 KEYED INTERLOCK SWITCHES 1 Switch Series SELECTION GUIDE Housing Material Envelope Dimensions Contact Configurations Catalog Page ST14 AZ17 AZ17zi AZ15/16 AZ16zi New! AZ200 TZG Glass-fiber, reinforced thermoplastic Glass-fiber, reinforced thermoplastic Glass-fiber, reinforced thermoplastic Glass-fiber, reinforced thermoplastic Glass-fiber, reinforced thermoplastic 3 4" 1 1 4" 2" 1 1 4" 1 1 4" 2 1 2" 1 1 4" 2" 3" 1 3 4" 2" 3 3 4" 1 NO & 1 NC 2 NC 1 NO & 1 NC 2 NC 1 NC 1 NO & 1 NC 2 NC 1 NO & 2 NC 3 NC 1 NO & 1 NC 2 NC 1 NO & 2 NC SDG Die-cast aluminum 1 3 4" 2" 6" 2 NO & 1 NC 44 3 NC AZ415 Die-cast aluminum 1 3 4" 3 1 2" 4" 2 NO & 2 NC PNP Safety Outputs 1 1 2" 8 3 4" 1 1 2" 1 or 3 Diagnostic 32 Outputs AZ335 Die-cast aluminum 1 1 2" 1 3 4" 4 1 2" 1 NO & 1 NC 2 NC 1 NO & 2 NC 3 NC 48 SHGV (Key Transfer System) Die-cast aluminum 1 3 4" 1 3 4" 4" 1 NO & 1 NC

12 SERIES ST14 Description The ST14 Series is designed for use with movable machine guards which must be closed for operator safety. Their twopiece, tamper-resistant design, and positive-opening NC contacts, provide a significantly higher level of safety than conventional, spring-driven switches whose contacts can weld or stick shut. Their NEMA 4 (IP67) rating make them ideal for interlocking safety guards in hostile environments. Their compact design allows use in applications where space is severely limited. Optional right-angle keys, close-radius keys and mounting brackets provide application versatility. Operation The ST14 is a two-piece, electromechanical safety interlock switch. It consists of a rugged, sealed switch mechanism and a geometrically-unique actuating key. The actuating key is typically mounted to the movable machine guard or access gate. Upon opening of the guard the NC contact(s) are forced to open by a direct (non-resilient) mechanical linkage with the actuating key. These positive-break contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contact closes upon key removal.) When the guard is closed, the actuating key forces the NC contact(s) to close, and the NO contact to re-open. Their tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Typical Applications The ST14 is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Their compact, sealed (NEMA 4) design makes them ideal where space is severely limited and/or where equipment is washeddown or subject to other hostile environments (i.e. business machines, medical equipment, food processing machinery, et al). Typical applications are the interlocking of protective gratings, access doors/guards, hinged covers, access panels and other movable guards. 12 Sub-Compact, Tamper-Resistant Movable Machine Guard Safety Interlock Switch Features & Benefits Compact design only 3 4" 1 1 4" 2". Ideal where space is limited. Positive-break NC contacts assure circuit interruption upon actuator key removal. Tamper-resistant design difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Watertight design meets NEMA 4 (IP67) washdown and immersion requirements. High-strength, stainless-steel actuator key tolerant to mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates the most hostile environments. Top and side key-entry locations provide installation flexibility. Optional key designs to meet diverse application requirements. Meets rigid safety agency standards IEC, BG, VDE, UL and CSA. Optional side-entry cable please consult factory. Part Number ST14-10/1SK ST14-20K AVAILABLE STANDARD MODELS (Actuator key must be ordered separately) Please see below. Contacts (with key inserted) 1 NO & 1 NC 2 NC Description ST14 interlock switch (Sealed switch. Contact mechanism embedded in resin.) ST14 interlock switch (Sealed switch. Contact mechanism embedded in resin.) Note: All actuator keys feature integral vibration-tolerant mounting washers. Part Number ST14-B1 ST14-B3 ST14-B5 ST14-Bracket ACTUATOR KEYS & ACCESSORIES Description Standard B1 actuator key Close-radius actuator key (for mounting key close to door hinge) Right-angle actuator key Optional switch or key mounting bracket Note: All actuator keys feature integral vibration-tolerant mounting washers. is a trademark of SCHMERSAL

13 ST14 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Actuator Key Stainless steel (defeat-resistant design) Degree of Protection IP67 Actuation Head: IP 20 Operating Temperature 4 F to +175 F Mechanical Life > 10 6 operations Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL CSA Minimum Closing Radius 5.9" (with ST14-B1 and ST14-B5 actuator key) 1.97" (with ST14-B3 actuator key) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Electrical Connection Fine silver Double-pole, double-break with electrically separated contact bridges 6A (250VAC) 0.25A (220VDC) Slow-action, positive-break NC contacts Fuse 6A (time-delay) Prewired with sealed PVC UL-style x20 AWG cable one meter long* *Other cable lengths available. Please consult factory. 1 DIMENSIONS ST 14-B1 (Standard key) Minimum key entry closing radius 150mm. Right Angle Key ST 14-B5 ST 14-Bracket Switch or Key Mounting Bracket Note: Side-entry cable available (Please consult factory) mm inch ST 14-B3 Close Radius Key Angle view Side view SWITCHING SYMBOLS & CONTACT SCHEMATICS (Colors identify factory prewiring) 3, ST14-10/1S 11 = red 12 = orange 23 = black 24 = brown ø8.31 ø 4, ST = red 12 = orange 21 = black 22 = brown For close radius keys for mounting key close to (within 50 mm) door hinge, order ST 14-B3. 13

14 SERIES AZ17 Compact Tamper-Resistant Movable Machine Guard Safety Interlock Switch Features & Benefits Compact design only 1 1 4" 1 1 4" 3". Ideal where space is limited. Insulation Displacement Connector (IDC) facilitates fast, easy installation. Watertight design meets IP67 washdown requirements. Eight optional key entry locations depending upon mounting arrangement. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Positive-break NC contacts assure interruption of safety circuit upon actuator key removal. High-strength, stainless-steel actuator key tolerant to mechanical abuse without damage. Rugged, corrosion-resistant, high-impact glass-fibre reinforced housing tolerates the most hostile environments. Padlockable key for added security during maintenance. Meets rigid IEC, BG, VDE, UL & CSA standards. Three styles of actuator key accommodates a wide variety of movable guards. Description The compact Series AZ17 is designed for use with movable machine guards/access gates which must be closed for operator safety. Their positive-opening NC contacts provide a significantly higher level of safety than conventional springdriven switches whose contacts can weld or stick shut. And their tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Their IP67 rating makes them ideal for interlocking safety guards in hostile environments. Operation The AZ17 electromechanical safety interlock switch consists of a rugged switch mechanism and a geometrically-unique actuating key. The key is mounted to the movable guard. Upon opening of the guard the NC contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. These positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contact closes upon key removal.) When the guard is closed, the actuating key forces the NC contacts to close and the NO contacts to re-open. Note: Available with optional M12x1 quick-connect. SPACE-SAVING IDC CONTACTS & CONNECTOR Typical Applications The AZ17 is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access doors/gates, hinged covers, access panels and other movable guards. 14 is a trademark of SCHMERSAL

15 AZ17 AVAILABLE MODELS AND ACCESSORIES AZ17-11zk AZ17-11zrk AZ17-02zk AVAILABLE STANDARD MODELS (Actuator key must be ordered separately) Part Number 1 NO & 1 NC 1 NO & 1 NC 2 NC AZ17-02zrk 2 NC Solenoid-latching models available. (Model AZM170) Individually-coded key models available (Model AZ17zi) (For extra security in high-risk applications) Contacts (with actuator key inserted) Note: Pre-wired (5 meter length) cable entry models available. Add suffix 2243 for front of unit cable entry or suffix for rear cable entry. Note: Optional quick-connect... add suffix ST (e.g. AZ17-11zk-ST). ACTUATOR KEYS & ACCESSORIES Part Number Description AZ17/170-B1 AZ17/170-B5 AZ17-B6 AZ17/170-B11 AZ17/170-B15 AZ17/170-B MS AZ 17-P (See installation on Page 20) Standard key (7.87" minimum closing radius) Right-angle key (7.87" minimum closing radius) Flexible, close-radius key (1.97" minimum closing radius) Elongated standard straight key (7.87" minimum closing radius) Elongated right-angle key (7.87" minimum closing radius) Standard straight key with vibration-resistant mounting (7.87" minimum closing radius) Adjustable mounting kit for parallel mounting. AZ17-B6 key required. 1 MS AZ 17-R/P (See installation on Page 20) Suffix -ST Adjustable mounting kit for parallel or perpendicular mounting. AZ17-B6 key required. Optional M12x1 quick-connect SELECTED ACTUATOR KEYS AZ17/170-B1 AZ17/170-B5 AZ17-B6 15

16 AZ17 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Actuator Key Stainless steel, Degree of Protection IP67 Holding Force zk models: 1.2 pounds zrk models: 7 pounds Travel for Positive-Break 8 mm (0.315 inches) Closing Force Approx. 12N (2.7 pounds) Operating Temperature 22 F to +175 F Mechanical Life > 10 6 operations Conformity to Standards IEC EN DIN VDE BG-GS-ET, pr EN 1088 UL & CSA Minimum Closing Radius 1.97" (with AZ17-B6 actuator key) 7.87" (with B1, B5, B11 and B15 actuator key) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Isolation Voltage Type Terminals Fine silver Double-pole, double-break with electrically separated contact bridges 4A/230VAC 2.5A/230VA (with ST quickconnect) Slow-action, positive-break NC contacts 6A (time-delay) 250V Insulation displacement contacts & connector for 18AWG flexible stranded wire (0.75 mm 2 ) SWITCHING DIAGRAMS & CONTACT SCHEMATICS AZ17-11z AZ17-02z ,2 7, , MS AZ 17 ADJUSTABLE MOUNTING KIT 16

17 AZ17 TECHNICAL DATA DIMENSIONS Switching Symbols (Colors identify factory prewired models) ø 4, , BLACK BLACK BLUE BROWN BROWN BLUE BLACK BLACK ø19.75 AZ17-02z Connections AZ17-11z Pg M AZ17-02z AZ17-11z same polarity; type four enclosure ø mm inch 0.670" (17) (Remove outer sleeve from cable) ACTUATOR KEYS AZ17/170-B1 AZ17/170-B5 AZ17/170-B , ,3.17 7, , AZ17/170-B AZ17-B6 4, , , , ,3.17 AZ17/170-B ø11.43 ø4, b a a b

18 SERIES AZ17zi Individually-Coded Movable Machine Guard Safety Interlock Switch INDIVIDUALLY-CODED ACTUATOR KEYS (15,000 CODES) Features & Benefits Highly tamper-resistant actuating mechanism difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Individually-coded actuator key (15,000 codes) provides extra security in high-risk applications. Compact design only 1 1 4" 1 1 4" 3". Ideal where space is limited. Non-removable actuating head heightens tamperresistance. Four optional key entry locations provide installation flexibility. Positive-Break NC contacts assure circuit interruption upon actuator key removal. Watertight design meets IP67 washdown requirements. High-strength, stainless-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates the most hostile environments. Wide selection of accessories to meet diverse application requirements. Padlockable key for added security during equipment maintenance. Meets rigid safety agency standards BG, UL and CSA. Description The compact Series AZ17zi are designed for use with movable machine guards which must be closed for operator safety. Their tamper-resistant design, and positive-opening NC contacts, provide a significantly higher level of safety than conventional spring-driven switches whose contacts can weld/stick shut. Their IP67 rating makes them ideal for interlocking safety guards in hostile environments. Operation The AZ17zi is a two-piece, electromechanical safety interlock switch. It consists of a rugged switch mechanism and an individually-coded, geometrically-unique actuating key. The key must be directly hard-mounted to the movable guard. Upon opening of the guard, the normally-closed (NC) contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contacts close upon key removal.) When the guard is closed, the actuating key forces the NC contacts to re-close, and any NO contacts to re-open. The tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. SPACE-SAVING IDC CONTACTS & CONNECTOR Typical Applications The AZ17zi is intended for use as a safety interlock on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, hinged covers, access panels and other movable guards. 18 is a trademark of SCHMERSAL

19 AZ17zi AVAILABLE MODELS AND ACCESSORIES AVAILABLE MODELS (Includes Individually-Coded Actuator Key and 1 2" NPT Plastic Adapter) Part Number AZ17-11zi-B1 AZ17-11zi-B5 AZ17-11zi-B6R AZ17-11zi-B6L AZ17-02zi-B1 AZ17-02zi-B5 AZ17-02zi-B6R AZ17-02zi-B6L Description Standard unit Standard unit Contacts (with actuator key inserted) 1 NO & 1 NC 2 NC Note: Standard units feature 1.2 pounds of key retention force. For unit with 7 pounds of key retention force, please add suffix r to part number. Example: AZ17-11zir-B1 Part Number MS AZ 17-P (See installation on Page 20) MS AZ 17-R/P (See installation on Page 20) OPTIONAL ACCESSORIES Mounting kits require use of the -B6 key Description Adjustable mounting kit for parallel mounting Adjustable mounting kit for parallel or perpendicular mounting 1 19

20 AZ17zi TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Actuator Key Stainless steel, Degree of Protection IP67 Key Retention Force zi models: 1.2 pounds zir models: 7 pounds Travel for Positive-Break 8 mm (0.315 inches) Closing Force Approx. 12N (2.7 pounds) Operating Temperature 22 F to +175 F Mechanical Life > 10 6 operations Conformity to Standards IEC EN DIN VDE BG-GS-ET, pr EN 1088 UL & CSA Minimum Closing Radius 1.97" (with B6L or B6R actuator key) 7.87" (with B1 or B5 actuator key) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Isolation Voltage Type Terminals Fine silver Double-pole, double-break with electrically separated contact bridges 4A/230VAC Slow-action, positive-break NC contacts 6A (time-delay) 250V Insulation displacement contacts & connector for 18AWG flexible stranded wire (0.75 mm 2 ) Note: Pre-wired (5 meter length) cable entry models available. See optional accessories. SWITCHING DIAGRAMS & CONTACT SCHEMATICS AZ17-11zi ,2 7, AZ17-02zi , MS AZ 17 ADJUSTABLE MOUNTING KIT (Eases installation and facilitates adjustments due to guard misalignment) MS AZ17-P (for parallel mounting) MS AZ17-R/P (for parallel or perpendicular mounting) 20

21 AZ17zi TECHNICAL DATA DIMENSIONS B1 Actuator Key 0.177" (4.5) R min. 7.87" (200) 0.59" (15) 0.314" (8) R min. 5.51" (140) 0.393" (10) 1.18"(30) 0.866"(22) 0.787"(20) 0.078" (2) " (33) 0.216" (5.5) 0.169" (4.3) 0.905" (23) B5 Actuator Key 0.177" (4.5) 0.59" (15) R min. 7.87" (200) 0.314" (8) R min. 5.51" (140) 1.42" (36) (13) 0.216" (5.5) 1.18"(30) 0.866"(22) 0.787"(20) 0.169" (4.3) 0.472" (12) " (23) 0.078" (2) 0.314" (8) 0.787"(20) 0.866"(22) 1.18"(30) 0.169" (4.3) Switching Symbols (Colors identify factory prewired models) B6L Actuator Key B6R Actuator Key 1.18" (30) 0.866"(22) 0.944"(21) 0.472" (12) 0.165" (4.2) ø 4,2.17 8,2.32 Pg M ø ø mm inch 0.787"(20) RED WHT GRN BLK GRN WHT RED BLK 0.314" (8) 0.433" (11) 0.157" (4) 0.944" (24) 0.236" (6) AZ17-02zi Connections AZ17-11zi 0.078" (2) 0.905" (23) 0.433" (11) R min. 1.97" (50) 0.590" (15) R min. 1.97" (50) 0.590" (15) R min. 1.97" (50) 0.314" (8) R min. 1.97" (50) AZ17-02zi AZ17-11zi 0.314"(8) same polarity; type four enclosure (Minimum radius: 50mm) 0.670" (17) (Remove outer sleeve from cable) All dimensions in inches (mm) 21

22 SERIES AZ15/16 Description The Series AZ15/16 is designed for use with movable machine guards/access gates which must be closed for operator safety. Their positive-opening NC contacts provide a significantly higher level of safety than conventional springdriven switches whose contacts can weld or stick shut. And their tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Their IP67 rating makes them ideal for interlocking safety guards in hostile environments. Tamper-Resistant Movable Machine Guard Safety Interlock Switch Features & Benefits Highly tamper-resistant actuating mechanism difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Non-removable actuating head heightens tamperresistance. Four optional key entry locations provide installation flexibility. Individually-coded actuator key option (15,000 codes) provides extra security in high-risk applications. See AZ16zi. Positive-Break NC contacts assure circuit interruption upon actuator key removal. High key-retention force (7 pounds) eliminates inadvertent opening of guard due to shock/vibration. Watertight design meets IP67 washdown requirements. High-strength, stainless-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates the most hostile environments. Wide selection of accessories to meet diverse application requirements. Padlockable key for added security during equipment maintenance. Meets rigid safety agency standards BG, UL and CSA. Explosion-proof model and M12x1 quick-connect ( ST ) available (Please consult factory). Optional Safety Controller. See Page 328. Operation The AZ15/16 electromechanical safety interlock switch consists of a rugged switch mechanism and a geometricallyunique actuating key. The key is mounted to the movable guard. Upon opening of the guard the NC contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. These positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contact closes upon key removal.) When the guard is closed, the actuating key forces the NC contacts to close and the NO contacts to re-open. Typical Applications The AZ15/16 is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access doors/gates, hinged covers, access panels and other movable guards. 22 is a trademark of SCHMERSAL

23 AZ15/16 AVAILABLE MODELS AND ACCESSORIES AVAILABLE MODELS (Includes 1 2" NPT Plastic Adapter** Actuator Key Sold Separately) Part Number AZ15-zvk (key spring returned) AZ15-zvrk (key maintained upon insertion)* AZ16-zvk (key spring returned) AZ16-zvrk (key maintained upon insertion)* AZ16-02zvk (key spring returned) AZ16-02zvrk (key maintained upon insertion)* AZ16-12zvk (key spring returned) AZ16-12zvrk (key maintained upon insertion)* AZ16-03zvk (key spring returned) AZ16-03zvrk (key maintained upon insertion)* Contacts (with actuator key inserted) 1 NC 1 NC 1 NO & 1 NC 1 NO & 1 NC 2 NC 2 NC 1 NO & 2 NC 1 NO & 2 NC 3 NC 3 NC *Feature 7 pound key retention force. For lighter key retention force (1-2 pounds) add suffix "2254". **To order unit with cordgrip instead of 1 2" NPT adapter, add suffix "CG" to part number...eg. AZ15-zvk-CG. Short-radius actuator keys available. See below. Part Number AZ15/16-B1 AZ15/16-B2 AZ15/16-B3 AZ15/16-B6 AZ15/16-B AZ15/16-B AZ15/16-B1-KRH ACTUATOR KEYS Description Standard Key (5.9" minimum closing radius) Small radius actuating key (1.8" minimum closing radius) Small radius actuating key (1.3" minimum closing radius) Flexible-movement actuating key Funnel entry adapter with elongated straight actuating key Funnel entry adapter with elongated flexible-movement actuating key Key Removal Hand-Grip Assembly with Key Retention Chain (for use with AZ15...zvrk and AZ16...zvrk) AZ15/16-BI-2024 AZ15/16-CAP M20-CG M20-1 2"P M20-1 2"M ACCESSORIES for AZ15/16 Keyed-Interlock Switches AZ15/16-BI-1747 AZ15/16-B AZ15/16-B PL-M20-24V PL-M20-120V Add suffix to basic part number when ordering AZ15/16-BI-2053 (for use with AZ16...zvrk) #6-3 8SPH (Package of 6) # " OWOH (Package of 6) SZ16/335 AZ15/16-AP Part Number MS AZ 15/16-P (See illustration Page 29) MS AZ 15/16-R/P (See illustration Page 29) Suffix -ST Description Gasketed key caps Key entry closure caps (for unused entry slots) Cord grip (cable gland) Plastic 1 /2" NPT adapter Metal 1 /2" NPT adapter Door holding magnet kit (7 pound holding force) (for use with AZ16 zvr-2254 models) 24VAC/DC pilot light kit 120VAC/DC pilot light kit Gold contacts (for AZ15/16zvr) Ball latch kit (Adjustable holding force up to 22 pounds) #6-3 8 Spanner Pan Head Tamper-resistant sheet metal screws (for actuator key mounting or switch contact cover) #10-32 One-Way Oval Head Tamper-resistant machine screws Actuator Key Lockout Device (Accepts up to 6 padlocks) Alignment Pins (Set of 2) Adjustable mounting kit for parallel mounting Adjustable mounting kit for parallel and perpendicular mounting Optional M12x1 quick-connect (2 contact models only) MS mounting kits require the use of the -B6 key 1 AZ15/ with ball catch Holding force up to 22 pounds AZ15/ with holding magnet Holding force 7 pounds Actuator Key Removal Handle AZ15/16-B1-KRH Lockout Device SZ16/335 (padlock not included) 23

24 AZ15/16 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Actuator Key Stainless steel (defeat-resistant design) Degree of Protection IP67 Travel for Positive-Break 8 mm (0.315 inches) Key Ejection Force "-zv" models: 3N ( 0.7 pounds) Key Retention Force "-zvr-2254 models: 5N (1.2 pounds) "-zvr" models: 30N (7 pounds) Closing Force Approx. 15N (3.4 pounds) Operating Temperature 22 F to +175 F Mechanical Life > 1 million operations Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL & CSA (A600, P300) TUV Minimum Closing Radius 1.3" (with B3 actuator key) 1.8" (with B2 actuator key) 5.9" (with B1 actuator key) DIMENSIONS ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Isolation Voltage Rated Impulse Withstand Voltage Type Terminals* * Units available with M12x1 quick-connect. (Please consult factory). Fine silver Double-pole, double-break with electrically separated contact bridges 2 2mm (minimum) 4A/230VAC (A600) 2.5A/230VAC (with M12x1 quickconnect) Slow-action, positive-break NC contacts Fuse 6A (time-delay) 500VAC 6kV Screw terminals with self-lifting clamps for up to 13 AWG flexible stranded wire (2.5mm 2 ) SWITCHING DIAGRAMS & CONTACT SCHEMATICS AZ16z 0 2,3 5,2 5, Make before break AZ16-02z ,3 5,5 5, AZ16-12z ,3 5,2 5, AZ16-03z 0 2,3 5,5 8 5, AZ15/ Ball Latch Kit AZ15/ Gasketed Key Caps 24

25 AZ15/16 ACTUATOR KEY SPECIFICATIONS AZ15/16-B1 Actuator Key AZ15/16-B1 Actuator Key with AZ15/ Holding Magnet Kit 1 Minimum actuating radius with actuator B1/B AZ15/16-B Actuator Key ø5, , Minimum actuating radius with actuator B1/B , Actuator B1 is standard for AZ15/16; it allows a minimum actuating radius of 150 mm. Please note that the center of rotation must be in the same plane as the upper edge of the safety switch. Ordering example: Switch, holding magnet and actuator: AZ16-zv/B AZ15/16-B2 Actuator Key AZ15/16-B2 Actuator Key with AZ15/ Holding Magnet Kit mm inch Minimum actuating radius with actuator B2/B Actuator B2 is particularly suitable for small actuating radii over the wide edge of the actuator (R=45 to 150mm). The basic setting (angle 15 ) provides a minimum radius of 45mm=1.8 in. For larger radii, the angle has to be adjusted correspondingly by turning the set screw counter-clockwise. AZ15/16-B3 Actuator Key AZ15/16-B3 Actuator Key with AZ15/ Holding Magnet Kit Minimum actuating radius with actuator B3/B Actuator B3 is particularly suitable for small actuating radii over the narrow edge of the actuator (R=32 to 150mm). The basic setting (angle 10 ) provides a minimum radius of 32mm=1.3in. For larger radii, the angle has to be adjusted correspondingly by turning the set screw clockwise. 25

26 AZ15/16 ACTUATOR KEY SPECIFICATIONS AZ15/16-B Funnel Entry Adapter (with straight actuating key) AZ15/16-B6 Flex Actuator Key a ø5, ø5, b 34, , , , ,

27 1 Safer by Design 27

28 SERIES AZ16zi Individually-Coded Movable Machine Guard Safety Interlock Switch Features & Benefits Highly tamper-resistant actuating mechanism difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Individually-coded actuator key (15,000 codes) provides extra security in high-risk applications. Non-removable actuating head heightens tamperresistance. Four optional key entry locations provide installation flexibility. Positive-Break NC contacts assure circuit interruption upon actuator key removal. Watertight design meets IP67 washdown requirements. High-strength, stainless-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates the most hostile environments. Tamper-resistant key mounting screws deter bypassing. Wide selection of accessories to meet diverse application requirements. Padlockable key for added security during equipment maintenance. Meets rigid safety agency standards BG, UL and CSA. Description The Series AZ16zi are designed for use with movable machine guards which must be closed for operator safety. Their tamper-resistant design, and positive-opening NC contacts, provide a significantly higher level of safety than conventional spring-driven switches whose contacts can weld/stick shut. Their IP67 rating makes them ideal for interlocking safety guards in hostile environments. Operation The AZ16zi is a two-piece, electromechanical safety interlock switch. It consists of a rugged switch mechanism and an individually-coded, geometrically-unique actuating key. The key must be directly hard-mounted to the movable guard. Upon opening of the guard, the normally-closed (NC) contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contacts close upon key removal.) When the guard is closed, the actuating key forces the NC contacts to re-close, and any NO contacts to re-open. The tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Typical Applications The AZ16zi is intended for use as a safety interlock on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, hinged covers, access panels and other movable guards. Patented geometrically-unique tumbler configuration 28 is a trademark of SCHMERSAL

29 AZ16zi AVAILABLE MODELS AND ACCESSORIES AVAILABLE MODELS (Includes Individually-Coded Actuator Key and 1 2" NPT Plastic Adapter) Part Number AZ16-12zi-B1 AZ16-03zi-B1 AZ16-12zi-B AZ16-03zi-B AZ16-12zi-B AZ16-03zi-B AZ16-12zi-B AZ16-03zi-B Description Standard unit Standard unit with built-in key actuator magnet latch Standard unit with built-in slot rubber seals on key actuator Standard unit with built-in ball-latched key actuator MS AZ 15/16 ADJUSTABLE MOUNTING KIT (Eases installation and facilitates adjustments due to guard misalignment) Contacts (with actuator key inserted) 1 NO & 2 NC 3 NC 1 NO & 2 NC 3 NC 1 NO & 2 NC 3 NC 1 NO & 2 NC 3 NC Part Number M20-CG M20-1 2"P M20-1 2"M AZ15/16-CAP (3 per kit) #6-3/8 SPH (package of 6) # " OWOH (package of 6) AZ-SZ PL-M20-24V PL-M20-120V MS AZ 15/16-P MS AZ 15/16-R/P Suffix AVAILABLE ACCESSORIES Description Cord grip (cable gland) Spare Plastic 1 2" NPT adapter (One supplied with each unit) Metal 1 2" NPT adapter (optional) Key entry closure caps (for unused entry slots) #6-3/8 Spanner Pan Head Tamper-Resistant Sheet Metal Screws (For use on AZ16zi housing terminal cover) #10-32 One-Way Oval Head Tamper-Resistant Machine Screws (For use in mounting actuator key) AZ16zi Lockout Device (accepts up to 6 padlocks) 24VAC/DC LED Pilot Light Kit 110VAC/DC Pilot Light Kit Adjustable mounting kit for parallel mounting Adjustable mounting kit for parallel or perpendicular mounting Funnel entry adapter (Must be ordered with base switch for factory assembly see page 30) TYPICAL INDIVIDUALLY-CODED KEYS 1 MS AZ 15/16-R/P (for parallel or perpendicular mounting) EXAMPLE OF INDIVIDUALLY-CODED KEYS 15,000 codes provide extra security in high-risk applications New! MS AZ 15/16-P (for parallel mounting) 29

30 AZ16zi TECHNICAL DATA Housing Actuator Key Degree of Protection Travel for Positive-Break Key Ejection Force Insertion Force Operating Temperature Mechanical Life Conformity to Standards Key Withdrawal Speed Minimum Closing Radius Glass-fibre reinforced, selfextinguishing plastic Stainless steel IP inches (8 mm) 3 N (0.7 pounds) Approx. 15N (3.3 pounds) 22 F to +175 F 1 million operations UL & CSA, BG A600, P300 2 meters/second (maximum) 9.8" (250mm) SWITCHING DIAGRAMS & CONTACT SCHEMATICS AZ16-12zi 0 5,5 5, Contacts Contact Configuration Contact Gap Switching Action Contact Rating Rated Insulation Voltage Thermal Current Rating Current Rating Rated Impulse Withstand Voltage Short Circuit Protection Type Terminals* Fine silver Double-pole, double-break with electrically-separated contact bridges 2 2 mm Slow-action, positive-break NC contacts A VAC 10A (300VAC) 120VAC 230VAC 2.5V/230VAC (with M12x1 quickconnect) 6kV Fuse 6A (slow-blow) Screw terminals with self-lifting clamps for up to 2.5 mm 2 (AWG13) wire *Optional plug-in M12x1 quick-connect available. Please consult factory. AZ16-03zi ,5 5, Funnel Entry Adapter (Order as part of base switch e.g. AZ16-02z1-B1-2177) DIMENSIONS 5, , mm inch , ,

31 AZ16zi INDIVIDUALLY-CODED ACTUATOR KEY SPECIFICATIONS 1 Applications: harsh environments (coarse dirt, chips, flour ) For holding light to medium-weight guards closed 31

32 SERIES AZ 200 Pulse-Echo Based Non-Contact Safety Interlock Switch Features & Benefits Tamper resistant frequency-matched switch and actuator required for operation. Non-contact sensing for long term reliability. Dual purpose handle modern, ergonomic design no additional door handles are needed. Integral LED diagnostics indicates operating states Integral self-monitoring and door detection sensors satisfy requirements of Safety Control Category 4. *See Note Below. One-hand emergency release hazardous area can be left quickly and safely. Switch and actuator do not protrude into door opening no risk of injury or damage from a protruding actuator. Dual PNP 250 ma safety outputs for application versatility. Description The AZ 200 pulse-echo based non-contact safety interlock is designed for use with movable machine guards/access gates which must be closed for operator safety. The AZ 200 consists of an interlock switch and actuator unit with door handle and optional emergency exit handle. The actuator is always inserted into its housing, protecting the actuator and the operator against damage and injury. Utilizing pulse-echo sensor technology, the actuator and interlock can have an offset of ±5 mm and the actuator still engages the interlock. A sensor stimulates a coil in the actuator, which in turns sends a signal back to the sensor. The pulse-echo technology provides diagnostic information and detects and indicates any misalignment at an early stage. Two different actuator designs accommodate both sliding or hinged guards. The AZ 200 interlock is a dual channel design with two shortcircuit proof, safe PNP outputs, each of which can switch up to 250 ma. It features a choice of one or three electronic diagnostic outputs. These diagnostic outputs signal errors before the safety outputs are switched off, thus enabling a controlled shutdown of the machine. With continuous internal function tests, the monitoring of the safety outputs and the use of door detection sensors, AZ 200 safety interlocks with one diagnostic output can be wired in series without detriment to the control category. Series wired AZ 200s continue to fulfill the requirements of Control Category 4 according to EN with door detection sensors (without the need of a second switch). Typical Applications The AZ 200 is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access panels and other movable guards. The AZ 200 is suitable for both sliding guards and hinged guards. 32 New! AVAILABLE AZ 200 MODELS (Actuator ordered separately below) Model Number Description AZ200SK-1P2P 2-PNP safety outputs, without door detection sensors, one diagnostic output AZ200SK-T1P2P 2-PNP safety outputs, with door detection sensors, one diagnostic output AZ200SK-3P2P 2-PNP safety outputs, without door detection sensors, three diagnostic outputs AZ200SK-T3P2P 2-PNP safety outputs, with door detection sensors, three diagnostic outputs Sensors available with M23 quick disconnect Replace SK with ST in catalog number. Part number: SZ200 Description: Lockout tag, up to 5 padlocks Safety Control Module Requirements Dual-channel safety inputs, suitable for PNP semiconductor outputs. The internal function tests of the sensor cause the outputs to periodically switch off for a millisecond. This must be tolerated by the control module. The following SCHMERSAL safety control modules are recommended for this application: SRB 301 LCB, SRB 324 ST *Note: A safety control module may be required for reset function and/or feedback monitoring functions, as well as increased output current requirements.

33 SERIES AZ 200 AVAILABLE KEYS AND DIMENSIONS AZ 200-B1 ACTUATOR FOR SLIDING DOORS AZ 200-B30 ACTUATOR FOR HINGED DOORS AZ/AZM 200-B1- AZ/AZM 200-B30- A G1 Leave blank (without door detection sensor) L (Door hinge on left side) R (Door hinge on right side) Leave blank (without emergency exit handle) P0 (with emergency exit handle) T (with door detection sensor) Ordering example: To order an AZ 200 actuator handle assembly for a left hand door, with door detection sensor and emergency exit handle, order p/n AZ/AZM200-B1-LTP0 Leave blank (without door detection sensor) T (with door detection sensor) L (Door hinge on left side) R (Door hinge on right side) Leave blank (without emergency exit handle) P1 (with emergency exit handle) Ordering example: To order an AZ 200 actuator handle assembly for a left hand door, with door detection sensor and emergency exit handle, order p/n AZ/AZM200-B30-LTAG1P1 DIMENSIONS OF AZ 200 & AZ/AZM 200-B1 HANDLE AZ/AZM 200-B1 for sliding doors 33

34 SERIES AZ 200 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Degree of Protection IP67 Unlocked Holding Force 30N (7 pounds) Operating Temperature 25 C to +60 C Storage Temperature 25 C to +85 C Response Time 60ms Vibration Resistance 10-55Hz, amplitude 1mm Shock Resistance 30g/11ms Mechanical Life 1 million operations Mounting 40-45mm profiles Conformity to Standards CE BG EN UL/CSA Pending EN IEC DIMENSIONS OF AZ 200 & AZ/AZM 200-B30 HANDLE Door hinge on left-hand side A ELECTRICAL SPECIFICATIONS Mode of Operation Inductive Rated Operating Voltage 24 VDC -15%/+10% Rated Operating Current 0.6A No Load Current 0.1A Residual Current 0.5mA Rated Impulse 0.8kV Withstand Voltage Rated Insulation Voltage 32 VDC Safety Outputs (2) PNP, short-circuit proof Safety Output 0.25A per output Operating Current Safety Output Max. 4V below rated Operating Voltage operating voltage Signaling Output PNP, short-circuit proof Signaling Output Max. 0.05A Operating Current Signaling Output Max. 4V below rated Operating Voltage operating voltage Type Terminals Screw Terminals for up to 15 AWG flexible stranded wire (1.5 mm 2 ) Door hinge on right-hand side AZ/AZM 200-B30 for hinged doors B Legend A = Front and rear manual release B=Cable entry M20 x 1,5 C = Emergency exit P1 D = Door handle G1 C C D D 34

35 SERIES AZ 200 DIAGNOSTICS Function table of visual diagnostic LED, electronic diagnostic output and safety outputs LED State AZ 200 Safety Outputs Diagnostic Outputs AZ P2P AZ P2P OUT OUT2 OUT3 OUT Green Door open 0 V 0 V 0 V 0 V 0 V Green Door closed 0 V 0 V 0 V 24 V 0 V Yellow & Green Door closed and actuator inserted 24 V 24 V 0 V 24 V 24 V Blinking red (1 9 impulses) Error: see blinking codes 24 V 24 V 24 V 24 V 0 V Diagnostic LED error codes The blinking sequence of the red LED of the AZ 200 identifies the active error. The following errors are indicated: Indication (red) Meaning 1 blinking impulse Error output Y1 2 blinking impulses Error output Y2 3 blinking impulses Cross-wire 4 blinking impulses Temperature too high 5 blinking impulses Target error 6 blinking impulses Error target combination 7 blinking impulses Error AD values 8 blinking impulses Error transmission voltage 9 blinking impulses Channel error Continuous red Error Blinking Codes (red) Meaning Autonomous switch-off after Cause 1 blinking impulse Error output Y1 30 min. Error in output test or voltage at output Y1, although the output is switched off 2 blinking impulses Error output Y2 30 min. Error in output test or voltage at output Y2, although the output is switched off 3 blinking impulses Cross-wire 30 min. Cross-wire between the output cables or error at both outputs 4 blinking impulses Temperature too high 30 min. Temperature measurement indicates too high an inner temperature 5 blinking impulses Target error 0 min. The difference between the code (frequency) of the detected target and the set value is too large, false target 6 blinking impulses Error target combination 0 min. An invalid combination of targets was detected at the 4 coils of the AZ200 T. (Current setting: latching bolt detected & door target not detected => latch breakage or tampering attempt) 7 blinking impulses Error AD values 30 min. Internal hardware error 8 blinking impulses Error transmission voltage 0 min. Supply voltage too low or defective internal voltage control 9 blinking impulses Channel error 0 min. Data comparison between the channels leads to differences in the signal evaluation because of an internal hardware error 35

36 SERIES AZ 200 WIRING EXAMPLES WIRING EXAMPLE: SINGLE DEVICE WIRING WIRING COMPARTMENT Meaning Supply Voltage Supply Voltage Safety Input 1 Safety Input 2 Ground Ground Safety Output 1 Safety Output 2 Diagnostic Output 24 V 24 V X1 X2 GND GND Y1 Y2 Terminal OUT Note: In case of single device wiring, the bridge between the 24 V terminal and the X1 and X2 terminals must be established; for series wiring, this bridge must only be established in the first device of the series. WIRING EXAMPLE: SERIES WIRING OF 3 AZ Only interlocks with one diagnostic output can be wired in series.

37 COMPATIBLE AZ 200 SAFETY CONTROLLER SRB 301 LCB TECHNICAL FEATURES Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual channel) Monitored Monitored Contact N.C. (Dry Contacts) or Configuration PNP-switching Number & Type Safety 3 N.O. (Dry Contacts) Outputs Number & Type Auxilliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Manual (24 V Leading Edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 4 Rating Per EN ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 1.7 W (max.), 1.9 VA Fuse (Input Power) Internal glass fuse F1: T 0.25 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable supressor circuit) Switching Capacity 24 VDC, 2 A (Auxilliary Contacts) Application Category AC 15 / DC 13, EN Pick-up Delay 30 ms Drop-out Delay 50 ms Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Cleaner & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN MECHANICAL SPECIFICATIONS Dimensions (W x H x D) 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") Ambient Operating -25 C to +45 C Temperature Range (-13 F to +113 F) Mechanical Life >10 7 switching cycles Expectancy Weight 230 gm (0.5 lbs.) Mounting DIN rail (35mm) Terminal Connections For Use With AZ 200 Supply Voltage Monitored Input #1 (N.C.) Monitored Input #2 (N.C.) Safety Output #1 (N.O.) A1 A2 S12 S Safety Output #2 (N.O.) Safety Output #3 (N.O.) Feedback Monitoring with Automatic or Manual (Leading Edge) Reset Auxiliary Output (N.C.) X1 X

38 COMPATIBLE AZ 200 SAFETY CONTROLLER SRB 324 ST TECHNICAL FEATURES Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual channel) Monitored Monitored Contact N.C. (Dry Contacts) or Configuration PNP-switching Number & Type Safety 5 N.O. (2 delayed: 1-30 sec.) Outputs (dry contacts) Number & Type Auxilliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling 3-PNP Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Monitored-manual (trailing edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1-K4 (safety relays 1-4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 (3 safety outputs) 1 (2 safety outputs) Safety Control Category 4 Rating Per EN ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 4.8 W, 7.8 VA max. (Plus signalling contacts Y1-Y3) Fuse (Input Power) Internal glass fuse F1, tripping current > 2.5 A (reset approx. 1 second) Internal hybrid fuse F2, tripping current > 1.0 A (reset after interruption of supply voltage) Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs Stop 0) (inductive with suitable supressor circuit) Switching Capacity Y1-Y3: 24 VDC, 100mA (PNP) (Auxilliary Contacts) 61/62: 24 VDC, 2A max. (Dry) Application Category AC-15 / DC 13, EN Pick-up Delay 30 ms Drop-out Delay 30 ms (13/14, 23/24, 33/34) Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Cleaner & Creepage Distance Cable Connections DIN VDE (04.97), 4 kv/2 Plug-in, self-lifting, screw terminals 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN MECHANICAL SPECIFICATIONS Dimensions (W x H x D) 45mm x 100mm x 121mm (1.8" x 3.9" x 4.75") Ambient Operating -25 C to +45 C Temperature Range (-13 F to +113 F) Mechanical Life >10 7 switching cycles Expectancy Weight 480 gm Mounting DIN rail Terminal Connections For Use With AZ 200 Supply Voltage Monitored Input #1 Monitored Input #2 Safety Output #1 (NO) A1 A2 S12 S Safety Output #2 (NO) Safety Output #3 (NO) Safety Output #4 Stop Category 1 (NO) Safety Output #5 Stop Category 1 (NO) Feedback Monitoring Monitored-Manual Reset Automatic Reset Jumper Auxiliary PNP Output X1 X2 X3 X4 X4 X5 S31 S32 Y1 Y2 Y3 38

39 Safer by Design 39

40 SERIES TZG Description The Series TZG is designed for use with movable machine guards/access gates which must be closed for operator safety. Their positive-opening NC contacts provide a significantly higher level of safety than conventional springdriven switches whose contacts can weld or stick shut. And their tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Their IP67 rating makes them ideal for interlocking safety guards in hostile environments. Movable Machine Guard Safety Interlock Switch Features & Benefits Highly tamper-resistant actuating mechanism difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Four optional key entry locations rotatable actuator head provides installation versatility. Positive-Break NC contacts assure circuit interruption upon actuator key removal. High key retention force (5 pounds) eliminates inadvertent opening of guard due to shock/vibration. Watertight design meets IP67 washdown requirements. High-strength, galvanized-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates the most hostile environments. Wide selection of actuating keys to meet diverse application requirements. Padlockable key for added security during equipment maintenance. Meets rigid safety agency standards BG, UL, CSA. Funnel-shaped key entry forgiving of key misalignment. Special types for food industry please consult factory. Operation The Series TZG electromechanical safety interlock switch consists of a rugged switch mechanism and a geometricallyunique actuating key. The key is mounted to the movable guard. Upon opening of the guard the NC contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. These positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contact closes upon key removal.) When the guard is closed, the actuating key forces the NC contacts to close and the NO contact to re-open. Typical Applications The Series TZG is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access doors/gates, hinged covers, access panels and other movable guards. 40

41 TZG AVAILABLE MODELS AND ACCESSORIES AVAILABLE STANDARD MODELS (Includes 1 2" NPT Plastic Conduit Adapter. Actuator Keys Sold Separately) Part Number Contacts Description* TZG TZG NO & 1 NC 2 NC *Field-rotatable for key entry from right, left or rear. DIMENSIONS Keyed interlock switch with front* key entry and slow action contacts. Part Number TZ/CO TZ/CW TZ/COR TZ/CK TZ/CWR TZ/COF/HIS.1 TZ/COF/HIS.2 TZ/CORF/HIS.1 TZ/CORF/HIS.2 OPTIONAL ACTUATOR KEYS Description Standard straight actuator key (13" minimum closing radius) Right-angled straight actuator key (11.8" minimum closing radius) Radial entry actuator key (11.8" minimum closing radius) Short straight actuator key (6.3" minimum closing radius) Right-angled bent actuator key (11.8" minimum closing radius) Pivoting straight actuator key (rear-mounted) (13.8" minimum closing radius) Pivoting straight actuator key (top-mounted) (13.8" minimum closing radius) Pivoting straight actuator key (rear-mounted) (7.1" minimum closing radius) Pivoting straight actuator key (top-mounted) (5.9" minimum closing radius) 1 Dimensional base for actuator 41

42 TZG TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Actuator Key Glass-fibre reinforced selfextinguishing thermoplastic Galvanized steel (defeat-resistant design) IP67 20N (4.8 pounds) 12.5mm Approx. 20N (4.8 pounds) Degree of Protection Holding Force Travel for Positive-Break Force to Reach Positive-Break Closing Force Operating Temperature Mechanical Life Shock Resistance Vibration Resistance Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL CSA Minimum Closing Radius Approx. 10 N (2.4 pounds) 13 F to +158 F 1 million operations (minimum) >30g / 18ms >15g / Hz Dependent upon actuator key used. Please see actuator key selection chart. ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically separated contact bridges mm 8A (250VAC) Slow-action, positive-break NC contacts (TZG models) Snap-action, positive-break NC contacts (TZGP models) 10A (slow-blow) TZG models 6A (slow-blow) TZGP models 250VAC 4kV Screw terminals with self-lifting clamps for up to 13 AWG solid wire (2.5mm 2 ) or 13 AWG stranded (1.5mm 2 ) wire 42

43 TZG ACTUATOR KEY SPECIFICATIONS ACTUATOR KEYS TZ/CO TZ/CW TZ/COR 1 TZ/CWR TZ/COF/HIS.1 TZ/COF/HIS.2 TZ/CORF/HIS.1 TZ/CORF/HIS.2 TZ/CK 43

44 SERIES SDG Description The Series SDG is designed for use with movable machine guards/access gates which must be closed for operator safety. Their positive-opening NC contacts provide a significantly higher level of safety than conventional springdriven switches whose contacts can weld or stick shut. And their tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Their IP67 rating makes them ideal for interlocking safety guards in hostile environments. Movable Machine Guard Safety Interlock Switch Features & Benefits Highly tamper-resistant actuating mechanism difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Four optional key entry locations rotatable actuator head provides installation versatility. Positive-Break NC contacts assure circuit interruption upon actuator key removal. Built-in retention force (1.2 pounds) eliminates inadvertent opening of guard due to shock/vibration. Watertight design meets IP67 washdown requirements. High-strength steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant metal housing tolerates the most hostile environments. Wide selection of actuating keys to meet diverse application requirements. Meets rigid safety agency standards BG, UL, CSA. Funnel-shaped key entry forgiving of key misalignment. Other 2-contact configurations available please consult factory. Operation The Series SDG electromechanical safety interlock switch consists of a rugged switch mechanism and a geometricallyunique actuating key. The key is mounted to the movable guard. Upon opening of the guard the NC contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. These positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contact closes upon key removal.) When the guard is closed, the actuating key forces the NC contacts to close and the NO contact to re-open. Typical Applications The Series SDG is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access doors/gates, hinged covers, access panels and other movable guards. 44

45 SDG AVAILABLE MODELS AND ACCESSORIES Part Number Contacts Description* SDG SDG SDG AVAILABLE STANDARD MODELS (Includes 1 2" NPT Conduit Adapter. Actuator Keys Sold Separately) 2 NO & 1 NC 1 NO & 2 NC 3 NC Keyed interlock switch with front* key entry and slow action contacts. *Field-rotatable for key entry from right, left or rear. Units are supplied with tamper-resistant (one-way) screws to replace the standard screws after rotating the actuator head for desired direction of key entry. Part Number BO BOW BOR BOWR BOF/HIS.1 BOF/HIS.2 OPTIONAL ACTUATOR KEYS Description Standard straight actuator key (20" minimum closing radius) Right-angled straight actuator key (20" minimum closing radius) Radial entry actuator key (10" minimum closing radius) Right-angled bent actuator key (10" minimum closing radius) Pivoting straight actuator key (rear-mounted) (13.8" Minimum closing radius) Pivoting straight actuator key (top-mounted) (13.8" Minimum closing radius) 1 DIMENSIONS M20x1 M20x1 5.5mm M20x1 45

46 SDG TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Actuator Key Degree of Protection Cast aluminum with enamel paint Steel (chromated) (defeat-resistant design) IP67 (Switch housing) IP00 (Reversing and locking head) 5N (1.2 pounds) 12.5mm Approx. 5N (1.2 pounds) Holding Force Travel for Positive-Break Force to Reach Positive-Break Closing Force Operating Temperature Mechanical Life Shock Resistance Vibration Resistance Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL CSA Minimum Closing Radius Approx. 5N (1.2 pounds) 13 F to +158 F 1 million operations (minimum) >30g / 18ms >15g / Hz Dependent upon actuator key used. Please see actuator key selection chart. ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically separated contact bridges mm 8A (250VAC) Slow-action, positive-break NC contacts 10A (slow-blow) 250VAC 4kV Screw terminals with self-lifting clamps for up to 13 AWG solid wire (2.5mm 2 ) or 13 AWG stranded (1.5mm 2 ) wire 46

47 SDG ACTUATOR KEY SPECIFICATIONS ACTUATOR KEYS BO BOW 1 BOR BOWR BOF/HIS.1 BOF/HIS.2 47

48 SERIES AZ335 Tamper-Resistant Movable Machine Guard Safety Interlock Switch Features & Benefits Rugged, corrosion-resistant die-cast aluminum housing tolerates the most hostile environments. Positive-break NC contacts assure circuit interruption upon actuator key removal. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Watertight design meets IP67 washdown requirements. Eight optional key entry locations depending upon mounting of rotatable mounting head. High-strength, stainless-steel actuator key tolerant to mechanical abuse without damage. Tapered key entry ports tolerant to key misalignment. Meets rigid safety agency standards IEC, BG, VDE, UL and CSA. Lockout accessory prevents key entry and switch actuation. Optional M12x1 quick-connect please consult factory. Description The AZ335 Series is designed for use with movable machine guards/access gates which must be closed for operator safety. Their positive-opening NC contacts provide a significantly higher level of safety than conventional springdriven switches whose contacts can weld or stick shut. And the switch s tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Their rugged metal housing and IP67 rating make them ideal for interlocking safety guards in industrial and hostile environments. Operation The AZ335 electromechanical safety interlock switch consists of a rugged switch mechanism and a geometrically-unique actuating key. The key is mounted to the movable guard. Upon opening of the guard, the NC contact(s) are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. These positive-break NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contacts close upon key removal.) When the guard is closed, the actuating key forces the NC contact(s) to close, and the NO contacts to re-open. Typical Applications The AZ335 is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access doors/panels, perimeter access gates, hinged covers and other movable guards on textile machinery, packaging equipment, machine tools, assembly machinery, robot work cells and food/chemical processing equipment. AVAILABLE STANDARD MODELS (Includes 1 2" NPT Adapter. Actuator keys sold separately) Part Number Contacts (with key inserted) AZ335-12ZRK 1 NO & 2 NC AZ335-03ZRK 3 NC Note: Available with optional M12x1 quick-connect. Please consult factory. OPTIONAL ACTUATOR KEYS Part Number Description AZ335/355-B1 Straight actuator key. AZ335/355-B Standard actuator key with rubber grommeted mounting holes. AZ335/355-B5 Right angle actuator key. AZ335/355-B6 Adjustable short-radius actuator key. AZ335/355-B5-Flex AZ335/355-B6-Flex Part Number AZ335/ SZ16/335 Floating standard actuator key (tolerant to x and y axis misalignment of ±5mm). Floating standard short-radius actuator key (tolerant to x and y axis misalignment of ±5mm). ACCESSORIES Description Key entry port covers (two-part package). Lockout device (prevents key entry and switch actuation). Accepts up to six padlocks. 48 is a trademark of SCHMERSAL

49 AZ335 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Diecast aluminum with baked enamel finish Actuator Key Stainless steel (defeat-resistant design) Degree of Protection IP67 Travel for Positive-Break 10.7 mm (0.4 inches) Closing Force Approx. 15 N (3.4 pounds) Operating Temperature 22 F to +195 F Mechanical Life > 10 7 operations Key Holding Force 30 N (7 pounds) ( R models only) Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL & CSA Minimum Closing Radius B1 & B5 keys: 150mm B6, B5-Flex & B6-Flex keys: 100mm ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically separated contact bridges mm (minimum) 4A (230VAC) 25A/230VAC (with optional M12x1 quick-connect) Slow-action, positive-break NC contacts Fuse 6A (time-delay) 500VAC 6kV Screw terminals with self-lifting clamps for up to 13 AWG flexible stranded wire (2.5mm 2 ) 1 DIMENSIONS & CONTACT SCHEMATICS AZ335-12zrk AZ335-03zrk , , , , M

50 AZ335 INDIVIDUALLY-CODED ACTUATOR KEY SPECIFICATIONS ACTUATOR KEYS AZ335/355-B1 AZ335/355-B AZ335/355-B5 AZ335/355-B5-Flex AZ335/355-B6 AZ335/355-B6-Flex ø 50

51 1 Safer by Design 51

52 SERIES SHGV Cable-less Keyed Mechanical Safety Guard Interlock with Key Transfer System Features & Benefits Highly tamper resistant difficult to defeat with simple tools, thereby reducing liability exposure. Four optional key entry positions provides installation versatility. Three optional locking cylinder locations provides installation versatility. Corrosion resistant tolerates hostile environments. Funnel shaped entry forgiving of mechanical actuator key misalignment Low cost guard locking eliminates wiring at the guard. Meets rigid safety agency standards Selector switch: UL, CSA, IEC, BG, VDE Mechanical key locking device: IEC, BG, VDE Description The SHGV Series consist of a guard-mounted mechanical locking device and a 2-position key operated selector switch for control panel mounting. This unique key transfer system assures the removal of power before allowing the access control guard to be open without the need for electrical wiring at the interlocked machine guard location. Operation When the machine guard is open the transfer key (for operating the 2-position selector switch) cannot be withdrawn from the guard locking mechanism. Upon closing of the guard, the mechanical actuator key permits the transfer-key to be turned (locking the guard) and withdrawn. The transfer-key can now be removed and inserted into the 2-position selector switch, allowing it to be operated (e.g. power to be turned on) trapping the transfer key in the on position. To unlock (open) the guard, the selector switch must be turned to the off position. The transfer-key can now be withdrawn and inserted into the guard-locking mechanism for release of the mechanical actuator key and opening of the guard. The two lock barrel version allows the removal of a second transfer key when the mechanical actuator key has been released. This second transfer key prevents the removal of the power control transfer key from the keyed interlock. Thus it can be removed from the interlock by the operator to protect against the inadvertent start-up of the equipment. Part Number SHGV/L1 (*) ESS21S2/103 SHGV/R1 (*) ESS21S2/103 SHGV/B1 (*) ESS21S2/103 SHGV/LD1 (*) / (*) ESS21S2/103 SHGV/RD1 (*) / (*) ESS21S2/103 AVAILABLE MODELS Lock Barrel Left Description Lock Barrel Right Lock Barrel Rear Lock Barrel Left & Lock Barrel in Front Cover Lock Barrel Right & Lock Barrel in Front Cover Includes guard device SHGV with standard BO actuator element, keyed selector switch ESS21S2, and contact block EF103 ( 1NO/1NC) (*) Individual key identification code stamped on selector switch cylinder. Note: This system is recommended for applications in which there is no residual motion or hazard after the removal of power. For applications in which there is residual motion or the presence of a hazard immediately following the removal of power, a solenoid-locking console ( Model SVE) is recommended. Please consult factory. Typical Applications Recommended for use where wiring directly to the movable guard is cost prohibitive or subject to damage due corrosive chemicals or other harsh environmental conditions. 52 is a trademark of SCHMERSAL

53 SERIES SHGV TECHNICAL DATA MECHANICAL SPECIFICATIONS Protection Class IP 65 (Housing) IEC/EN IP 00 (Control Head) IEC/EN Actuating Forces Insertion of actuating element - 15 N Withdrawal of actuating element - 5 N Ambient temperature - 25 C to + 70 C Storage temperature - 40 C to + 80 C Material ALsi 12 painted signal red (RAL 3000) Housing Steel passivated with SHG Cover Perbunan seals(oil and gasoline resistant) Mechanical life 2 x 10 6 operating cycles Shock resistance > 30 x g / 18ms Vibration resistance > 15 x g/ Hz Climatic resistance 40/91 to DIN FW 24 to DIN ELECTRICAL SPECIFICATIONS Conformity to Standard IEC/EN Protection Class IP 65 to IEC/EN Contacts Fine silver Rated breaking capacity 230Vac/6A - 400VAC/4A Rated operating current 230Vac/6A - 400VAC/4A Rated insulation voltage 400VAC / 450VDC Thermal test current 10 A Utilization Category AC-15; DC-13 Max. fuse rating 10 A (slow blow) Ambient temperature - 25 C to + 80 C Switching frequency 6000 s/h 1 DIMENSIONAL DRAWING FOR SHGV GUARD LOCKING DEVICE 53

54 SERIES AZ415 Description The AZ415 Series is designed for movable machine guards/access gates which must be closed for operator safety. Their positive-opening NC contacts provide a significantly higher level of safety than conventional springdriven switches whose contacts can weld or stick shut. And their tamper-resistant design prevents bypassing with simple tools, bent wires or other readily available means. Operation The AZ415 electromechanical safety interlock switch consists of a rugged switch mechanism and a geometrically-unique actuating key. The key is mounted to the movable guard. Upon opening of the guard, the NC contacts are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. These NC contacts assure circuit interruption (and machine stoppage) upon removal of the actuator key. (The NO contacts close upon key removal.) In the closed position, the guard is held shut by an adjustable ball catch integral to the AZ415 housing. Tamper-Resistant Movable Machine Guard Safety Interlock Switch Features & Benefits Highly tamper-resistant difficult to defeat. Positive-break NC contacts assure circuit interruption upon key removal. Watertight design meets IP67 washdown requirements. High-strength, metal actuator key tolerates mechanical abuse without damage. Rugged, enamel-coated metal housing tolerates the most hostile environments. Adjustable actuator key holding force up to 110 pounds permits use of switch as door latch. Meets rigid safety agency standards UL, CSA, IEC, BG and VDE. ACTUATING KEYS & ACCESSORIES Part Number Description AZM415-B1 AZM415-B2 AZM415-B3 AVAILABLE STANDARD MODELS (Actuator key sold separately see below) Part Number (AZ415 - Switch Block S1*/ Switch Block S2) AZ415-11/11zpk (formerly p/n AZ415-22zpk) AZ415-11/02zpk AZ415-02/11zpk AZ415-02/02zpk AZ/AZM415-B4PS Contact Configuration with actuator key inserted (Switch Block S1*/Switch Block S2) Linear entry actuator key Small radius x-axis entry actuator key (9.8" minimum closing radius) Small radius y-radius entry actuator key (9.8" minimum closing radius) Slide bolt actuator key 2 NO / 2 NC 1 NO & 1 NC / 2 NC 2 NC / 1 NO & 1 NC 2 NC / 2 NC *Only Switch Block S1 has positive-break contacts. Typical Applications The AZ415 is intended for use as a safety interlock switch on movable machine guards which, when open, expose the operator/maintenance personnel to machine hazards. Typical applications are the interlocking of protective gratings, access doors/gates, hinged covers, access panels and other movable guards. Optional Safety Controller. See Page is a trademark of SCHMERSAL

55 AZ415 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Actuator Key Degree of Protection Travel for Positive-Break Force to Reach Positive-Break Actuator Key Holding Force Operating Temperature Mechanical Life Conformity to Standards IEC BG-GS-ET-19 VDE Minimum Closing Radius Die-cast aluminum with blue enamel finish Die-cast aluminum IP inches (5mm) Depending upon ball catch setting (3.5 pounds minimum) Adjustable, 2.2 to 110 pounds -13 F to +175 F 1 million operations 9.8" (250 mm) with B2 or B3 actuating key ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Type Terminals Fine silver Double-pole, double-break with electrically separated contact bridges 2mm x 2mm 4A (230VAC) Slow-action, positive-break NC contacts Fuse 6A (slow-blow) 250VAC 4kV Screw terminals with self-lifting clamps for up to 1.5mm 2 (15AWG) flexible stranded wire 1 DIMENSIONS (mm) , ø6,5.26 8,6.34 8, , M20 ø11.43 mm inch WIRING DIAGRAM (AZ415-11/11 shown) 55

56 AZ415 TECHNICAL DATA ACTUATOR KEY DIMENSIONS B2 Actuating radii For hinged doors over the wide edge of the actuator B3 Actuating radii For hinged doors over the small edge of the actuator Dowel holes are also provided in the actuator body. With the use of dowel pins the removal of the actuator can be prevented. By turning the adjusting screw a, the actuator can be brought into any desired position. Both actuators can also be used on sliding doors. Recommended key clearance greater than 3 mm > 3mm 56

57 AZ415 TECHNICAL DATA ACTUATOR KEY DIMENSIONS , ,5 6, < mm inch B1 Actuator ,4.25 B4pS actuator for hand operated locking Hand operated locking actuator The hand operated lock bolt has the following advantages: 1. No further mechanical expenditures such as handles or levers are necessary. 2. The shearing forces on the actuator is 25,000 N (5,500 lbs.). 3. Simple installation of the unit. 4. Observing the actuating radius is not necessary. 5. An open guard door cannot fall shut and lock, causing the switch to be actuated. The door must be manually closed and locked. 6. To insure personal safety when hazardous conditions are present, three holes are provided for padlocking which prevents the door from being locked. 57

58 58 Safer by Design

59 KEYED INTERLOCK SWITCHES WITH SOLENOID LATCHING New! 2 New! Switch Series SELECTION GUIDE Housing Material Envelope Dimensions Contact Configurations Catalog Page AZM170 Glass-fiber, reinforced thermoplastic 1 1 4" 2 1 2" 5" 1 NO & 1 NC 2 NC 60 AZM161 Glass-fiber, reinforced thermoplastic 1 1 4" 3 1 2" 5 1 8" 2 NO & 4 NC 3 NO & 3 NC 66 New! AZM200 Glass-fiber, reinforced thermoplastic 1 3 4" 9" 2" 2 PNP 70 New! MZM100 Glass-fiber, reinforced thermoplastic 1 3 4" 7 1 4" 1 3 4" 2 PNP Safety Outputs 1 Diagnostic Output 76 TZF/TZM Glass-fiber, reinforced thermoplastic 1 1 2" 4" 5" 2 NO & 1 NC 82 TKF/TKM Die-cast aluminum 2 1 2" 3 1 2" 8" 2 NO & 2 NC 86 TZK AZM415 Glass-fiber, reinforced thermoplastic Die-cast aluminum 2" 5" 5 1 2" AZS 2305 Fail-to-Safe Timer & FWS Fail-to-Safe Standstill Monitors 1 3 4" 2" 7" 1 NO & 2 NC 90 2 NO & 2 NC 3 NO & 3 NC

60 SERIES AZM170 Description The AZM170 Series is designed for machines/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time delay, motion detector, position sensor or other suitable component. The unit features independent actuator key (guard) position and solenoid-latching pin position contacts. These permit the prevention of machine restart until the guard is closed and the solenoid-latching pin is in the locked position. The AZM170 consists of an electromechanical safety interlock switch joined to a solenoid-latching mechanism. Both the safety switch and solenoid mechanism feature positive-break contacts. In addition the actuator key features a built-in latch (unlocked key holding force of 7 pounds), and an auxiliary manual unlocking device the latter provided to aid in installation and for use in the event of a power failure (when using the unlocking by solenoid model). Each unit is supplied with a cord grip and a cap to seal the unused key entry port in the solenoid-latching mechanism. Typical Applications The AZM170 is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, which may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping presses, articulating robot arms, mixing machines, metal working equipment, printing presses and packaging machinery. Solenoid-Latching Machine Guard Safety Interlock Switch Features & Benefits Compact design only 1 1 4" 3" 4 1 4". Ideal where space is limited. Watertight design meets IP67 washdown requirements. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Positive-break NC contacts assure interruption of safety circuit upon actuator key removal. Two key entry locations provide mounting flexibility. Rugged, corrosion-resistant, high-impact glass-fibre reinforced housing tolerates the most hostile environments. High-strength stainless steel actuator key tolerant to mechanical abuse without damage. Three styles of actuator key accommodate a wide variety of movable guards. Easy-to-wire screw terminals facilitates fast installation. Power-on or Power-off latching option for application versatility. Built-in manual unlatching release (via special triangular key) for easier installation. Padlockable key for added security during maintenance. Meets rigid IEC, UL, CSA, BG, VDE standards. Units available with M12x1 quick-connect. (Please consult factory). Two optional key entrances 60 is a trademark of SCHMERSAL

61 AZM170 AVAILABLE MODELS AND ACCESSORIES AVAILABLE STANDARD MODELS (Order desired actuator key separately) Part Number Locking via spring. Unlocking via energizing of solenoid. AZM170SK-11zrk-2197-* 1 NO & 1 NC AZM170SK-02zrk-2197-* 2 NC AZM170SK-12/00zrk-2197-* 1 NO & 2 NC AZM170SK-11/11zrk-2197-* 2 NO & 2 NC AZM170SK-02/01zrk-2197-* 3 NC AZM170SK-02/10zrk-2197-* 1 NO & 2 NC Locking via energizing of solenoid. Unlocking via spring. (See Note 1 below) AZM170SK-11zrka-* AZM170SK-02zrka-* AZM170SK-12/00zrka-* AZM170SK-11/11zrka-* AZM170SK-02/01zrka-* AZM170SK-02/10zrka-* Available Contacts (with actuator key inserted) 1 NO & 1 NC 2 NC 1 NO & 2 NC 2 NO & 2 NC 3 NC 1 NO & 2 NC Individually-coded key models available. (Model AZM170zi). (For extra security in high-risk applications.) *Please specify solenoid operating voltage via the addition of one of the following suffix codes: Voltage Add Suffix 24VAC/DC -24VAC/DC 115VAC -115VAC 230VAC -230VAC Note: AZM170SK-xx/yy versions are available as 24VAC/DC only. Example: AZM170sk-11zrk-24VAC/DC designates a switch with a 24VAC/DC solenoid which unlocks upon energizing of solenoid. AZ17/170-B1 AZ17/170-B5 ACTUATOR KEYS & ACCESSORIES Part Number AZM170-B6 AZ17/170-B11 AZ17/170-B15 AZ17/170-B AZM-KEY MS AZM 170-P MS AZM 170-R/P Description Standard key (7.87" minimum closing radius) Right-angle key (7.87" minimum closing radius) Flexible, close-radius key (1.97" minimum closing radius) Elongated standard straight key (7.87" minimum closing radius) Elongated right-angle key (7.87" minimum closing radius) Standard straight key with vibration-resistant mounting (7.87" minimum closing radius) Solenoid latch bypass/override key (for locking via spring models only) Adjustable mounting kit for parallel mounting Adjustable mounting kit for parallel or perpendicular mounting AZS2305 Fail-to-Safe Timer (Please see page 98) FWS1205B Fail-to-Safe Standstill Monitor (Page 100) MS mounting kits require the use of -B6 keys MS AZM 170 ADJUSTABLE MOUNTING KIT (Eases installation and facilitates adjustments due to guard misalignment) MS AZM 170-P (for parallel mounting) 2 Note 1: Use of this model permits the guard to be opened in the event of a power failure. Generally accepted safety standards/practices suggest this model only be used after conducting a thorough risk evaluation in the context of the application. MS AZM 170-R/P (for parallel or perpendicular mounting) Solenoid-latch bypass/override key (for locking via spring models only) 61

62 AZM170 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Stainless steel IP67 30N (7 pounds) Actuator Key Degree of Protection Unlocked Key Holding Force Travel for Positive-Break Closing Force Locking Force Operating Temperature Solenoid Operating Temperature Mechanical Life > 10 6 operations Conformity to Standards IEC EN DIN VDE BG-GS-ET, EN 1088 UL & CSA Minimum Closing Radius 11 mm (0.440 inches) Approx. 12N (2.7 pounds) Approx. 1000N (225 pounds) 22 F to +175 F 7 F to +140 F 1.97" (with B6 actuating key) 7.87" (with B1, B5, B11 and B15 actuating key) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Isolation Voltage Type Terminals* Solenoid Supply Voltages Fine silver Double-pole, double-break with electrically separated contact bridges 4A/230VAC Slow-action, positive-break NC contacts 6A (time-delay) 250V Screw terminals 24VDC/AC 110VAC Hz 230VAC Hz Max. 10 Watts *Optional insulation displacement connection (IDC) or M12x1 quick-connect terminations available. Please consult factory. SWITCHING DIAGRAMS & CONTACT SCHEMATICS (Power-to-unlock) AZM 170SK-11 SWITCHING DIAGRAMS & CONTACT SCHEMATICS (Power-to-lock) AZM 170SK-11 A1 A AZM 170SK-02 AZM 170SK-02 A1 A Note: Above diagrams are with actuator key inserted and solenoid de-energized. Note: Above diagrams are with actuator key inserted and solenoid de-energized. 62

63 AZM170 TECHNICAL DATA SWITCHING DIAGRAMS & CONTACT SCHEMATICS (Power-to-unlock) AZM 170SK-12/00zrk SWITCHING DIAGRAMS & CONTACT SCHEMATICS (Power-to-lock) AZM 170SK-12/00zrka 2 AZM 170SK-11/11zrk AZM 170SK-11/11zrka AZM 170SK-02/01zrk AZM 170SK-02/01zrka AZM 170SK-02/10zrk AZM 170SK-02/10zrka Note: Above diagrams are with actuator key inserted and solenoid de-energized. 63

64 64 AZM170 TECHNICAL DATA DIMENSIONS ,2.32 ca , ø 4,2.17 ø M ACTUATOR KEYS ,3.17 5,5.27 AZ17/170-B , AZ17/170-B , ,3.17 AZ17/170-B b a a b AZM170-B , , ,3.17 AZ17/170-B11 ø ø4, AZ17/170-B mm inch M20

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66 AZM161 Solenoid-Latching Safety Interlock Switch Description The AZM161 Series is designed for machines/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time delay, motion detector, position sensor or other suitable component. The unit features independent actuator key (guard) position and solenoid-latching monitoring contacts. There is a mechanical linkage preventing the solenoid position contacts from changing unless the key is inserted (guard closed). The AZM161 consists of an electromechanical safety interlock switch section with positive-break NC contacts and an actuator key. In addition, the solenoid mechanism features 1 NO and 2 NC solenoid-latching monitoring contacts, and an auxiliary manual unlocking device the latter provided to aid in installation and for use in the event of a power failure (when using the unlocking by solenoid model). Operation The AZM161 electromechanical safety interlock switch assembly consists of a rugged switch-solenoid-latching mechanism and a geometrically-unique locking actuator key. The switch actuating key is typically mounted to a movable machine guard. When the guard is closed, the actuating key is held in position by the solenoid-latching mechanism. The guard may only be opened by energizing or de-energizing (depending upon model) the solenoid-latching mechanism. Upon opening of the guard, the switch s positive-break NC contacts are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The NO contacts close upon key removal. The machine is prevented from starting until the actuating key is inserted (guard is closed) and the solenoid has locked it in the closed position. Features & Benefits Solenoid-locking design controls access to hazardous areas until safe conditions exist. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Positive-break NC contacts assure circuit interruption upon actuator key removal. Conditional safe outputs actuating key must be fully inserted and solenoid must be actuated to lock key before closed safety signal is provided. Watertight design meets IP67 environmental requirements. High-strength, stainless-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates hostile environments. Four optional key entry locations provide installation flexibility. Independent actuator key position and locking pin position monitoring contacts provide a higher degree of safety. Available in solenoid-locking and solenoidunlocking models for application versatility. Meets rigid safety agency standards IEC, BG, UL and CSA. Wide selection of accessories to meet diverse application requirements. Typical Applications The AZM161 is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, which may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping presses, articulating robot arms, mixing machines, metal working equipment, printing presses and packaging machinery. Optional Safety Controller (see page 328) and Standstill Monitor (see pages 100 & 102). 66

67 AZM161 AVAILABLE MODELS AND ACCESSORIES AVAILABLE STANDARD MODELS (Includes 1 2" NPT Plastic Adapter. Actuator key sold separately) Part Number Contacts Description AZM161SK-12/12rk- 2NO & 4 NC Actuating key locked by spring and unlocked by energizing solenoid. AZM161SK-12/12rka- 2NO & 4 NC Actuating key locked by energizing solenoid and unlocked by spring. (See Note 1 below) Please specify solenoid operating voltage via addition of one of the following suffix codes: Voltage Add Suffix 24VAC/DC -24VAC/DC 110/230VAC -110/230VAC Example: AZM161SK-12/12rk-24VAC/DC Add suffix T after the k for Manual Emergency Release Note 1: Use of this model permits the guard to be opened in the event of a power failure. Generally accepted safety standards/practices suggest this model only be used after conducting a thorough risk evaluation in the context of the application. is a trademark of SCHMERSAL AVAILABLE KEYS & ACCESSORIES for AZM161 Keyed-Interlock Switches Part Number Description AZM161-B1 AZM161-B1E AZM161-B6 AZM161-B AZM-Key M16-CG Standard actuating key Standard actuating key with heavy-duty mounting bracket Small radius actuating key Funnel entry adapter with elongated flexible-movement actuating key Solenoid-latch bypass key Cord grip (cable gland) M16-1 2"P Plastic 1 2" NPT adapter M16-1 2"M Metal 1 2" NPT adapter PL-M16-24V PL-M16-120V Add suffix to basic part number MS AZM 161-P MS AZM 161-R/P 24VAC/DC pilot light kit 120VAC/DC pilot light kit Gold contacts Adjustable mounting kit for parallel mounting Adjustable mounting kit for parallel or perpendicular mounting AZS2305 Fail-to-Safe Timer (Please see page 98) FWS1205B Fail-to-Safe Standstill Monitor (Page 100) MS mounting kits require the use of -B6 keys 2 MS AZM 161 ADJUSTABLE MOUNTING KIT (Eases installation and facilitates adjustments due to guard misalignment) Solenoid-latch bypass key (for locking via spring models) MS AZM 161-R/P (for parallel or perpendicular mounting) MS AZM 161-P (for parallel mounting) 67

68 AZM161 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced selfextinguishing thermoplastic Actuator Key Stainless steel (defeat-resistant design) Degree of Protection IP67 Unlocked Holding Force 30N (7 pounds) Travel for Positive-Break 8mm (0.315 inches) Force to Reach 10N (Approx. 2.4 pounds) Positive-Break Closing Force Approx. 15 N (3.4 pounds) Operating Temperature 13 F to +104 F Mechanical Life 1 million operations Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL CSA Solenoid Locking Force Key Return Force Minimum Closing Radius 2,000N (440 pounds) 0N 5.9" (150mm) with B1 and B1E actuating key 3.7" (95mm) with B6 actuating key ELECTRICAL SPECIFICATIONS Contacts Fine silver Contact Configuration Double-pole, double-break with electrically separated contact bridges Contact Gap 2 2 mm (minimum) Contact Rating 4A (230VAC) Switching Action Slow-action, positive-break NC contacts Short Circuit Protection Fuse 6A (time-delay) Rated Insulation Voltage 250VAC Rated Impulse 6kV Withstand Voltage Type Terminals* Screw terminals with self-lifting clamps for up to 13 AWG flexible stranded wire (2.5mm 2 ) Available Solenoid 24VDC, 110VDC, 230VDC Supply Voltages (Vs) 24VAC/50Hz 115VAC/60Hz 230VAC/50Hz Solenoid Power 10W (maximum) Consumption Solenoid Duty Cycle 100% Solenoid Pull-in Voltage (0.85 to 1.1) Vs Solenoid Drop-out Voltage (0.2 to 0.75) Vs *Optional cage clamp terminations available. Please consult factory. SWITCHING DIAGRAMS & CONTACT SCHEMATICS (Solenoid-mechanism not energized) AZM 161SK-12/12rk AZM 161SK-12/12rka 68 Note: Above diagrams are with actuator key inserted and solenoid de-energized.

69 AZM161 TECHNICAL DATA DIMENSIONS (Switch & Actuator Keys) Ø ,5.22 M16 (AZM161SK-12/12 only) M16 M ø 5, , , mm inch AZM161-B1 AZM161-B1E AZM161-B6 b ø5,5.22 ø10,5.41 a ø5, a b 69

70 SERIES AZM 200 Pulse-Echo Based Non-Contact Solenoid Interlock Features & Benefits Solenoid locking design controls access to hazardous areas until safe conditions exist. Non-contact sensing for long term reliability. Dual purpose handle unlatches and opens guard no additional door handles are needed. Integral LED diagnostics indicates operating states Integral self-monitoring and door detection sensors satisfy requirements of Safety Control Category 4. *See Note Below. One-hand emergency release hazardous area can be left quickly and safely even during a power failure. Switch and actuator do not protrude into door opening no risk of injury or damage from a protruding actuator. Dual PNP 250 ma safety outputs for application versatility. Description The AZM 200 Series is designed for machine/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time delay, motion detector, position sensor or other suitable component. The AZM 200 consists of a solenoid-latching interlock and actuator unit with door handle and optional emergency exit handle. The actuator is always inserted into its housing, protecting the actuator and the operator against damage and injury. Utilizing pulse-echo sensor technology, the actuator and interlock can have an offset of ±5 mm and the actuator still engages the interlock. Due to the one-hand operation of the emergency exit handle, the hazardous area can be left quickly and safely even during a power failure (when using the unlock by power model). The solenoid interlock is a dual channel design with two short-circuit proof, safe PNP outputs, each of which can switch up to 250 ma. With continuous internal function tests, the monitoring of the safety outputs and the use of door detection sensors, AZM 200 solenoid interlocks with one diagnostic output can be wired in series without detriment to the control category. Series wired AZM 200s continue to fulfill the requirements of Control Category 4 according to EN with door detection sensors (without the need of a second switch). Typical Applications The AZM 200 is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, which may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping machines, metal working equipment, printing presses and packaging machines. 70 AVAILABLE AZM 200 MODELS (Actuator ordered separately below) Model Number Description Lock by Spring, Power to unlock AZM200SK-1P2P 2-PNP safety outputs, without door detection sensors, one signaling output AZM200SK-T1P2P 2-PNP safety outputs, with door detection sensors, one signaling output AZM200SK-3P2P 2-PNP safety outputs, without door detection sensors, three signaling outputs AZM200SK-T3P2P 2-PNP safety outputs, with door detection sensors, three signaling outputs Power to lock AZM200SK-1P2Pa 2-PNP safety outputs, without door detection sensors, one signaling output AZM200SK-T1P2Pa 2-PNP safety outputs, with door detection sensors, one signaling output AZM200SK-3P2Pa 2-PNP safety outputs, without door detection sensors, three signaling outputs AZM200SK-T3P2Pa 2-PNP safety outputs, with door detection sensors, three signaling outputs Sensors available with M23 quick disconnect Replace SK with ST in catalog number. Note: If switch is ordered with door detection sensor (T) the actuator must also be ordered as the T version. Part number: SZ200 Description: Lockout tag, up to 5 padlocks Safety Control Module Requirements Dual-channel safety inputs, suitable for PNP semiconductor outputs. The internal function tests of the sensor cause the outputs to periodically switch off for a millisecond. This must be tolerated by the control module. The following SCHMERSAL safety control modules are recommended for this application: SRB 301 LCB, SRB 324 ST *Note: A safety control module may be required for reset function and/or feedback monitoring functions, as well as increased output current requirements.

71 SERIES AZM 200 AVAILABLE KEYS AND DIMENSIONS AZM 200-B1 ACTUATOR FOR SLIDING DOORS AZM 200-B30 ACTUATOR FOR HINGED DOORS AZ/AZM 200-B1- AZ/AZM 200-B30- A G1 Leave blank (without door detection sensor) L (Door hinge on left side) R (Door hinge on right side) Leave blank (without emergency exit handle) P0 (with emergency exit handle) T (with door detection sensor) Ordering example: To order an AZM 200 actuator handle assembly for a left hand door, with door detection sensor and emergency exit handle, order p/n AZ/AZM200-B1-LTP0 Leave blank (without door detection sensor) T (with door detection sensor) L (Door hinge on left side) R (Door hinge on right side) Leave blank (without emergency exit handle) P1 (with emergency exit handle) Ordering example: To order an AZM 200 actuator handle assembly for a left hand door, with door detection sensor and emergency exit handle, order p/n AZ/AZM200-B30-LTAG1P1 2 DIMENSIONS OF AZM 200 & AZ/AZM 200-B1 HANDLE AZ/AZM 200-B1 for sliding doors 71

72 SERIES AZM 200 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Degree of Protection IP67 Unlocked Holding Force 30N (7 pounds) Solenoid Holding Force 2300N (506 pounds) Operating Temperature 25 C to +60 C Storage Temperature 25 C to +85 C Response Time 30ms Vibration Resistance 10-55Hz, amplitude 1mm Shock Resistance 30g/11ms Mechanical Life 1 million operations Mounting 40-45mm profiles Conformity to Standards CE BG EN UL/CSA EN IEC DIMENSIONS OF AZM 200 & AZ/AZM 200-B30 HANDLE ELECTRICAL SPECIFICATIONS Mode of Operation Inductive Rated Operating Voltage 24 VDC -15%/+10% Rated Operating Current 1.0A No Load Current 0.5A Residual Current 0.5mA Rated Impulse 0.8kV Withstand Voltage Rated Insulation Voltage 32 VDC Safety Outputs (2) PNP, short-circuit proof Safety Output 0.25A per output Operating Current Safety Output Max. 4V below rated Operating Voltage operating voltage Signaling Output PNP, short-circuit proof Signaling Output Max. 0.05A Operating Current Signaling Output Max. 4V below rated Operating Voltage operating voltage Type Terminals Screw Terminals for up to 15 AWG flexible stranded wire (1.5 mm 2 ) Door hinge on left-hand side A Door hinge on right-hand side AZ/AZM 200-B30 for hinged doors B Legend A = Front and rear manual release B=Cable entry M20 x 1,5 C = Emergency exit P1 D = Door handle G1 C C D D 72

73 SERIES AZM 200 DIAGNOSTICS Function table of visual diagnostic LED, electronic diagnostic output and safety outputs Diagnostic Outputs LED State AZM 200 Safety Outputs AZM P2P AZM P2P OUT OUT2 OUT3 OUT Green Supply voltage 0 V or 24 V 0 V 0 V 0 V 0 V Yellow Actuator inserted and locked 24 V (if X1=X2=24 V) 0 V 0 V 24 V 0 V Blinking yellow Blinking red (1 9 impulses) Actuator inserted and not locked Error: see blinking codes 0 V See table below 24 V 0 V 24 V 24 V 24 V 24 V 24 V 0 V 2 Diagnostic LED error codes The blinking sequence of the red LED of the AZM 200 identifies the active error. The following errors are indicated: Indication (red) Meaning 1 blinking impulse Error output Y1 2 blinking impulses Error output Y2 3 blinking impulses Cross-wire 4 blinking impulses Temperature too high 5 blinking impulses Target error 6 blinking impulses Error target combination 7 blinking impulses Error AD values 8 blinking impulses Error transmission voltage 9 blinking impulses Channel error Continuous red Error Blinking Codes (red) Meaning Autonomous switch-off after Cause 1 blinking impulse Error output Y1 30 min. Error in output test or voltage at output Y1, although the output is switched off 2 blinking impulses Error output Y2 30 min. Error in output test or voltage at output Y2, although the output is switched off 3 blinking impulses Cross-wire 30 min. Cross-wire between the output cables or error at both outputs 4 blinking impulses Temperature too high 30 min. Temperature measurement indicates too high an inner temperature 5 blinking impulses Target error 0 min. The difference between the code (frequency) of the detected target and the set value is too large, false target 6 blinking impulses Error target combination 0 min. An invalid combination of targets was detected at the 4 coils of the AZM. (Current setting: latching bolt detected & door target not detected => latch breakage or tampering attempt) 7 blinking impulses Error AD values 30 min. Internal hardware error 8 blinking impulses Error transmission voltage 0 min. Supply voltage too low or defective internal voltage control 9 blinking impulses Channel error 30 min. Data comparison between the channels leads to differences in the signal evaluation because of an internal hardware error 73

74 SERIES AZM 200 WIRING EXAMPLES WIRING EXAMPLE: SINGLE DEVICE WIRING WIRING COMPARTMENT Meaning Supply Voltage Supply Voltage Safety Input 1 Safety Input 2 Solenoid Input Ground Ground Safety Output 1 Safety Output 2 Diagnostic Output Terminal 24 V 24 V X1 X2 IN GND GND Y1 Y2 OUT Note: In case of single device wiring, the bridge between the 24 V terminal and the X1 and X2 terminals must be established; for series wiring, this bridge must only be established in the first device of the series. WIRING EXAMPLE: SERIES WIRING OF 3 AZM VDC 24V 24V X1 X2 IN AZM V 24V X1 X2 IN AZM V 24V X1 X2 IN AZM 200 GND GND Y1 Y2 OUT GND GND Y1 Y2 OUT GND GND Y1 Y2 OUT 0V Reset I1 I2 PLC I3 +24VDC K B K A Q1 Q2 Q3 A1 S12 S22 X1 X SRB 301 LC/B A Only interlocks with one diagnostic output can be wired in series. 0V K A K B N

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76 SERIES MZM 100 Non-Contact Magnetic-Latching Interlock Features & Benefits Magnetic-latching design controls access to hazardous areas until safe conditions exist (100 lbs. locked holding force). Forced-closed operating principle no mechanical wear due to non-contact design. Integral LED diagnostics indicates operating states Integral self-monitoring and door detection sensors satisfy requirements of Safety Control Category 4. *See Note Below. Designed for daisy chaining up to 200 m. Automatic magnetic latch (35 N) no mechanical latching required ( r version only). Smooth surfaces allow for easy cleaning ideal where high hygienic standards need to be maintained. Dual PNP 250 ma safety outputs for application versatility. Description The MZM 100 Series is designed for machine/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their magnetic-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. The MZM 100 consists of a magnetic-latching interlock and actuator unit. An electromagnet is utilized to generate a 500 N holding force. An integrated pulse-echo based sensor detects and monitors the position of the safety guard. This sensor technology permits an offset between the actuator and interlock of ±5 mm vertical and ±3 mm horizontal. The MZM100 magnetic-latching interlock is a dual channel design with two short-circuit proof, safe PNP outputs, each of which can switch up to 250 ma. The holding force is permanently electronically measured and monitored. If the holding force drops below 500 N, the safety outputs are not enabled, recognizing a dirty interlock. With continuous internal function tests, the monitoring of the safety outputs and the use of door detection sensors, MZM 100 magnetic-latching interlocks can be wired in series without detriment to the control category. Series wired MZM 100s continue to fulfill the requirements of Control Category 4 according to EN (without the need of a second switch). Typical Applications The MZM 100 is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, which may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping machines, food processing equipment, metal working equipment, wood working and packaging machines. AVAILABLE MZM 100 MODELS & ACCESSORIES (Accessories ordered separately) Model Number Power to lock MZM100ST-1P2Pa MZM100ST-1P2Pra Accessories MZM100-B1 MS MZM 100-W M23-9P M23-9P-5m 2-PNP safety outputs, 1 diagnostic output 2-PNP safety outputs, 1 diagnostic output, with latching Actuator Mounting Set Description M23x1, 9 pin female connector M23x1, 9 pin female connector, 5 m cable Safety Control Module Requirements Dual-channel safety inputs, suitable for PNP semiconductor outputs. The internal function tests of the sensor cause the outputs to periodically switch off for a millisecond. This must be tolerated by the control module. The following SCHMERSAL safety control modules are recommended for this application: SRB 301 LCB, SRB 324 ST *Note: A safety control module may be required for reset function and/or feedback monitoring functions, as well as increased output current requirements. 76

77 SERIES MZM 100 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Degree of Protection IP67 Unlocked Holding Force 35N (7 pounds) ( r version only) Solenoid Holding Force 500N Operating Temperature 25 C to +55 C Storage Temperature 25 C to +85 C Response Time 100ms Vibration Resistance 10-55Hz, amplitude 1mm Shock Resistance 30g/11ms Mechanical Life 1 million operations Mounting 40mm profiles Conformity to Standards CE BG EN UL/CSA EN IEC DIMENSIONS Switch ELECTRICAL SPECIFICATIONS Mode of Operation Magentic & Inductive Rated Operating Voltage 24 VDC -15%/+10% Rated Operating Current 1.0A No Load Current 0.5A Residual Current 0.5mA Rated Impulse 0.8kV Withstand Voltage Rated Insulation Voltage 32 VDC Safety Outputs (2) PNP, short-circuit proof Safety Output 0.25A per output Operating Current Safety Output Max. 4V below rated Operating Voltage operating voltage Signaling Output PNP, short-circuit proof Signaling Output Max. 0.05A Operating Current Signaling Output Max. 4V below rated Operating Voltage operating voltage Termination Connector M23x1 Actuator 2 Mounting Set Exploded View 77

78 SERIES MZM 100 DIAGNOSTICS Function table of visual diagnostic LED, electronic diagnostic output and safety outputs State MZM 100 LED Safety outputs Diagnostic output green yellow red Y1, Y2 OUT Guard open on off off 0 V 0 V Guard closed, unlocked on blinks off 0 V 24 V Guard closed and locked on on off 24 V 24 V Warning, door locked on on blinks** 24 V* 0 V Error, door locked on off blinks** 0 V 0 V * after 30 min. 0V ** see blinking code Diagnostic LED error codes The blinking sequence of the red LED of the MZM 100 identifies the active error. The following errors are indicated: Indication (red) Meaning 1 blinking impulse Error output Y1 2 blinking impulses Error output Y2 3 blinking impulses Cross-wire 4 blinking impulses Temperature too high 5 blinking impulses Target error 6 blinking impulses Error holding force 7 blinking impulses Error AD values 8 blinking impulses Error transmission voltage 9 blinking impulses Channel error 10 blinking impulses Magnet is too hot Blinking Codes (red) Meaning Autonomous switch-off after Cause 1 blinking impulse Error output Y1 30 min. Error in output test or voltage at output Y1, although the output is switched off 2 blinking impulses Error output Y2 30 min. Error in output test or voltage at output Y2, although the output is switched off 3 blinking impulses Cross-wire 30 min. Cross-wire between the output cables or error at both outputs 4 blinking impulses Temperature too high 30 min. Temperature measurement indicates too high an inner temperature 5 blinking impulses Target error 0 min. The difference between the code (frequency) of the detected target and the set value is too large, false target 6 blinking impulses Holding force error 0 min. The required holding force is not obtained (misalignment/soiling). The holding force is < 500 N. 7 blinking impulses Error AD values 30 min. Internal hardware error 8 blinking impulses Error transmission voltage 0 min. Supply voltage too low or defective internal voltage control 9 blinking impulses Channel error 30 min. Data comparison between the channels leads to differences in the signal evaluation because of an internal hardware error 10 blinking impulses Magnet temperature 0 min. The magnet is too hot: Temperature is too high T>70 C 78

79 SERIES MZM 100 WIRING EXAMPLE Safety Sensors in large systems The sensors have separate input and output cables. The output of one sensor can be directly wired into the input of the next sensor. The sensor chain can be built up over a length of two hundred meters. The supply voltage is wired in both safety inputs of the last solenoid interlock of the chain (starting from the control relay). The safety outputs of the first interlock are wired to the control relay. SERIES CONNECTION OF MZM Safety outputs -> Control relay WIRING OF THE INTEGRATED CONNECTOR MZM 100 Solenoid interlock with diagnostic output Pin configuration A1 Supply Voltage Pin 1 A2 Ground Pin 3 X1 safety input Pin 2 X2 safety input Pin 6 Y1 safety output Pin 4 Y2 safety output Pin 7 OUT diagnostic output pin 5 IN magnet control pin 8 79

80 COMPATIBLE AZM 200 & MZM 100 SAFETY CONTROLLER SRB 301 LCB TECHNICAL FEATURES Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual channel) Monitored Monitored Contact N.C. (Dry Contacts) or Configuration PNP-switching Number & Type Safety 3 N.O. (Dry Contacts) Outputs Number & Type Auxilliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Manual (24 V Leading Edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 4 Rating Per EN ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 1.7 W (max.), 1.9 VA Fuse (Input Power) Internal glass fuse F1: T 0.25 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable supressor circuit) Switching Capacity 24 VDC, 2 A (Auxilliary Contacts) Application Category AC 15 / DC 13, EN Pick-up Delay 30 ms Drop-out Delay 50 ms Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Cleaner & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN MECHANICAL SPECIFICATIONS Dimensions (W x H x D) 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") Ambient Operating -25 C to +45 C Temperature Range (-13 F to +113 F) Mechanical Life >10 7 switching cycles Expectancy Weight 230 gm (0.5 lbs.) Mounting DIN rail (35mm) Terminal Connections For Use With AZM 200 Supply Voltage Monitored Input #1 (N.C.) Monitored Input #2 (N.C.) Safety Output #1 (N.O.) A1 A2 S12 S Safety Output #2 (N.O.) Safety Output #3 (N.O.) Feedback Monitoring with Automatic or Manual (Leading Edge) Reset Auxiliary Output (N.C.) X1 X

81 COMPATIBLE AZM 200 & MZM 100 SAFETY CONTROLLER SRB 324 ST TECHNICAL FEATURES Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual channel) Monitored Monitored Contact N.C. (Dry Contacts) or Configuration PNP-switching Number & Type Safety 5 N.O. (2 delayed: 1-30 sec.) Outputs (dry contacts) Number & Type Auxilliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling 3-PNP Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Monitored-manual (trailing edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1-K4 (safety relays 1-4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 (3 safety outputs) 1 (2 safety outputs) Safety Control Category 4 Rating Per EN ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 4.8 W, 7.8 VA max. (Plus signalling contacts Y1-Y3) Fuse (Input Power) Internal glass fuse F1, tripping current > 2.5 A (reset approx. 1 second) Internal hybrid fuse F2, tripping current > 1.0 A (reset after interruption of supply voltage) Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs Stop 0) (inductive with suitable supressor circuit) Switching Capacity Y1-Y3: 24 VDC, 100mA (PNP) (Auxilliary Contacts) 61/62: 24 VDC, 2A max. (Dry) Application Category AC-15 / DC 13, EN Pick-up Delay 30 ms Drop-out Delay 30 ms (13/14, 23/24, 33/34) Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Cleaner & Creepage Distance Cable Connections DIN VDE (04.97), 4 kv/2 Plug-in, self-lifting, screw terminals 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN MECHANICAL SPECIFICATIONS Dimensions (W x H x D) 45mm x 100mm x 121mm (1.8" x 3.9" x 4.75") Ambient Operating -25 C to +45 C Temperature Range (-13 F to +113 F) Mechanical Life >10 7 switching cycles Expectancy Weight 480 gm Mounting DIN rail 2 Terminal Connections For Use With AZM 200 Supply Voltage Monitored Input #1 Monitored Input #2 Safety Output #1 (NO) A1 A2 S12 S Safety Output #2 (NO) Safety Output #3 (NO) Safety Output #4 Stop Category 1 (NO) Safety Output #5 Stop Category 1 (NO) Feedback Monitoring Monitored-Manual Reset Automatic Reset Jumper Auxiliary PNP Output X1 X2 X3 X4 X4 X5 S31 S32 Y1 Y2 Y3 81

82 SERIES TZF/TZM Description The TZF/TZM Series is designed for machines/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time delay, motion detector, position sensor or other suitable component. The unit features independent actuator key (guard) position and solenoid-latching monitoring contacts. These permit the prevention of machine restart until the guard is closed and the solenoid-latching pin is in the locked position. The TZF/TZM Series consists of an electromechanical safety interlock switch with positive-break contacts and a locking actuator key. In addition, the TZFS model features an auxiliary manual unlocking device the latter provided to aid in installation and for use in the event of a power failure (when using the unlocking by solenoid model). Operation The TZF/TZM Series of electromechanical safety interlock switch assembly consists of a rugged switch, a solenoidoperated latching mechanism, and a geometrically-unique actuator key. The switch actuating key is typically mounted to a movable machine guard. When the guard is closed, the actuating key is held in position by the latching mechanism. The guard may only be opened by energizing or de-energizing (depending upon model) the latching mechanism. Upon opening of the guard, the switch s positive-break NC contacts are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The NO contacts close upon key removal. The solenoid-latching mechanism circuit features a NO and a NC contact which permit monitoring its status. This NC contact is wired in series with the NC contact in the safety switch circuit. Thus the machine is prevented from starting until the actuating key is inserted (guard is closed) and the solenoid has locked it in the closed position. Heavy-Duty Solenoid-Latching Safety Interlock Switch Features & Benefits Solenoid-locking & spring-locking designs controls access to hazardous areas until safe conditions exist. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Positive-break NC contacts assure circuit interruption upon actuator key removal. Conditional safe outputs actuating key must be fully inserted and solenoid must be actuated to lock key before closed safety signal is provided. Watertight design meets IP67 environmental requirements. High-strength, galvanized-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates hostile environments. Three optional key entry locations rotatable actuator head provides installation versatility. Independent actuator key position and locking pin position monitoring contacts provide a higher degree of safety. Padlockable key for added security during equipment maintenance. Meets rigid safety agency standards BG, UL, CSA. Wide selection of actuating keys to meet diverse application requirements. Special types for food industry please consult factory. Typical Applications The TZF/TZM Series is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, which may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping presses, articulating robot arms, mixing machines, metal working equipment, printing presses and packaging machinery. 82 is a trademark of SCHMERSAL

83 SERIES TZF/TZM AVAILABLE MODELS AND ACCESSORIES AVAILABLE STANDARD MODELS (Includes 1 2" NPT Plastic Conduit Adapter and TZ/CO Standard Actuator key) Part Number Contacts Description TZFCS/96-* TZMC/96-* 2NC & 2 NO (NC contacts in series) 2NC & 2 NO (NC contacts in series) *Please specify solenoid operating voltage via addition of one of the following suffix codes: Voltage Add Suffix 24VDC No Suffix 115VAC VAC -230 Example: TZMC/ Actuating key locked by spring and unlocked by energizing solenoid with right-side key entry. (Field-rotatable for entry from front or rear). Actuating key locked by energizing solenoid and unlocked by spring with right-side key entry. (Field-rotatable for entry from front or rear). (See Note 1 below) Note 1: Use of this model permits the guard to be opened in the event of a power failure. Generally accepted safety standards/practices suggest this model only be used after conducting a thorough risk evaluation in the context of the application. 2 OPTIONAL ACTUATOR KEYS & ACCESSORIES Part Number Description TZ/CO TZ/CW TZ/COR TZ/CK TZ/CWR TZ/COF/HIS.1 TZ/COF/HIS.2 TZ/CORF/HIS.1 TZ/CORF/HIS.2 TZ-69 TZ-75 AZS2305 FWS1205B Standard straight actuator key (13" minimum closing radius) Right-angled straight actuator key (11.8" minimum closing radius) Radial entry actuator key (11.8" minimum closing radius) Short straight actuator key (6.3" minimum closing radius) Right-angled bent actuator key (11.8" minimum closing radius) Pivoting straight actuator key (rear-mounted) (13.8" minimum closing radius) Pivoting straight actuator key (top-mounted) (13.8" minimum closing radius) Pivoting straight actuator key (rear-mounted) (7.1" minimum closing radius) Pivoting straight actuator key (top-mounted) (5.9" minimum closing radius) Straight safety interlock auxiliary release key (for TZFCS/96 models only) Right-angled safety interlock auxiliary release key (for TZFCS/96 models only) Fail-to-Safe Timer (Please see page 98) Fail-to-Safe Standstill Monitor (Page 100) 83

84 SERIES TZF/TZM TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Actuator Key Glass-fibre reinforced selfextinguishing thermoplastic Galvanized steel (defeat-resistant design) IP67 20N (4.8 pounds) 14.5 mm 20N (Approx. 4.8 pounds) Degree of Protection Unlocked Holding Force Travel for Positive-Break Force to Reach Positive-Break Closing Force Operating Temperature Mechanical Life Shock Resistance Vibration Resistance Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL CSA Solenoid Locking Force Minimum Closing Radius Approx. 10 N (2.4 pounds) 13 F to +104 F 2 million operations (minimum) 30g / 11ms 20g / 10 55Hz 1,700N (380 pounds) Dependent upon actuator key used. Please see actuator key selection chart. ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Available Solenoid Voltages Fine silver Double-pole, double-break with electrically separated contact bridges Guard monitoring: mm Solenoid monitoring: 2 3 mm 8A (250VAC) Slow-action, positive-break NC contacts 10A (slow-blow) 250VAC 4kV Screw terminals with self-lifting clamps for up to 13 AWG solid wire (2.5mm 2 ) or 13 AWG stranded (1.5mm 2 ) wire 24VDC 115VAC 230VAC Solenoid Power 8.8W (maximum) Consumption Solenoid Duty Cycle 100% WIRING DIAGRAM* DIMENSIONS E2 (-) 24VDC E1 (+) * Actuating key not inserted and solenoid unlocked. M20x1 TZ/69 Three-square socket wrench for versions TZFCS (supplied) 84

85 SERIES TZF/TZM ACTUATOR KEY SPECIFICATIONS ACTUATOR KEYS TZ/CO TZ/CW TZ/COR 2 TZ/CWR TZ/COF/HIS.1 TZ/COF/HIS.2 TZ/CORF/HIS.1 TZ/CORF/HIS.2 TZ/CK 85

86 SERIES TKF/TKM Description The TKF/TKM Series is designed for machines/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time delay, motion detector, position sensor or other suitable component. The unit features independent actuator key (guard) position and solenoid-latching monitoring contacts. These permit the prevention of machine restart until the guard is closed and the solenoid-latching pin is in the locked position. The TKF/TKM Series consists of an electromechanical safety interlock switch with positive-break contacts and a locking actuator key. In addition, the TKFS model features an auxiliary manual unlocking device the latter provided to aid in installation and for use in the event of a power failure (when using the unlocking by solenoid model). Heavy-Duty Solenoid-Latching Safety Interlock Switch Features & Benefits Solenoid-locking & spring-locking designs controls access to hazardous areas until safe conditions exist. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Positive-break NC contacts assure circuit interruption upon actuator key removal. Conditional safe outputs actuating key must be fully inserted and solenoid must be actuated to lock key before closed safety signal is provided (Series TKM). Watertight design meets IP67 environmental requirements. High-strength, galvanized-steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant metal housing tolerates hostile environments. Three optional key entry locations rotatable actuator head provides installation versatility. Independent actuator key position and locking pin position monitoring contacts provide a higher degree of safety. Padlockable key for added security during equipment maintenance. Meets rigid safety agency standards BG, UL, CSA. Wide selection of actuating keys to meet diverse application requirements. Special types available for concealed installation please consult factory. Typical Applications The TKF/TKM Series is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, which may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping presses, articulating robot arms, mixing machines, metal working equipment, printing presses and packaging machinery. Operation The TKF/TKM Series of electromechanical safety interlock switch assembly consists of a rugged switch, a solenoidoperated latching mechanism, and a geometrically-unique actuator key. The switch actuating key is typically mounted to a movable machine guard. When the guard is closed, the actuating key is held in position by the latching mechanism. The guard may only be opened by energizing or de-energizing (depending upon model) the latching mechanism. Upon opening of the guard, the switch s positive-break NC contacts are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The NO contacts close upon key removal. The solenoid-latching mechanism circuit features a NO and a NC contact which permit monitoring its status. This NC contact is wired in series with the NC contact in the safety switch circuit. Thus the machine is prevented from starting until the actuating key is inserted (guard is closed) and the solenoid has locked it in the closed position. 86 is a trademark of SCHMERSAL

87 SERIES TKF/TKM AVAILABLE MODELS AND ACCESSORIES AVAILABLE STANDARD MODELS (Includes 1 2" NPT Conduit Adapter. Actuator key sold separately) Part Number Solenoid Operating Voltage Contacts Description TKF/90 TKF/*/90 24VDC 115/230VAC (50/60Hz) 2NC & 2 NO (NC contacts in series) Series actuating key locked by spring and unlocked by energizing solenoid TKM/90 TKM/*/90 24VDC 115/230VAC (50/60Hz) 2NC & 2 NO (NC contacts in series) Series actuating key locked by energizing solenoid and unlocked by spring (See Note 1 below) TKF/R/90 TKF/R*/90 24VDC 115/230VAC (50/60Hz) 2NC & 2 NO (NC contacts in series) Parallel actuating key (for right-hand insertion) locked by spring and unlocked by energizing solenoid 2 TKM/R/90 TKM/R*/90 24VDC 115/230VAC (50/60Hz) 2NC & 2 NO (NC contacts in series) Parallel actuating key (for right-hand insertion) locked by energizing solenoid and unlocked by spring (See Note 1 below) TKF/L/90 TKF/L*/90 24VDC 115/230VAC (50/60Hz) 2NC & 2 NO (NC contacts in series) Parallel actuating key (for left-hand insertion) locked by spring and unlocked by energizing solenoid TKM/L/90 TKM/L*/90 24VDC 115/230VAC (50/60Hz) 2NC & 2 NO (NC contacts in series) Parallel actuating key (for left-hand insertion) locked by energizing solenoid and unlocked by spring (See Note 1 below) * Insert 115 for 115VAC model Insert 230 for 230VAC model Note 1: Use of this model permits the guard to be opened in the event of a power failure. Generally accepted safety standards/ practices suggest this model only be used after conducting a thorough risk evaluation in the context of the application. Part Number ACTUATOR KEYS & ACCESSORIES Description TK/R/90 TK/RF/90 TK/P/90 TK/PF/90 AZS2305 FWS1205B Standard Series actuator key (For sliding guards only) Series actuator key with telescopic section (For sliding guards only) Parallel actuator key for right- or left-hand insertion (10 minimum closing radius) Parallel actuator key (with telescopic section) for right- or left-hand insertion (10 minimum closing radius) Fail-to-Safe Timer (Please see page 98) Fail-to-Safe Standstill Monitor (Page 100) 87

88 SERIES TKF/TKM TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Cast aluminum, enamel finish Actuator Key & Steel, chromated Locking Bolt (defeat-resistant design) Degree of Protection IP67 Unlocked Holding Force 5N (1.2 pounds) Travel for Positive-Break 72 mm ( Series actuator) 38 mm ( Parallel actuator) Force to Reach 5N (Approx. 1.2 pounds) Positive-Break Closing Force Approx. 10 N (2.4 pounds) Operating Temperature 32 F to 120 F Mechanical Life 1 million operations (minimum) Shock Resistance 30g / 18ms Vibration Resistance 20g / 2 100Hz Conformity to Standards IEC EN DIN VDE BG-GS-ET-15 UL CSA Solenoid Locking Force 2,000N (450 pounds) Minimum Closing Radius 250mm ( Parallel actuator) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Available Solenoid Voltages Fine silver Double-pole, double-break with electrically separated contact bridges Guard monitoring: 2 3 mm Solenoid monitoring: 2 2 mm 8A (250VAC) Slow-action, positive-break NC contacts 10A (slow-blow) 250VAC 4kV Screw terminals with self-lifting clamps for up to 13 AWG solid wire (2.5mm 2 ) or 13 AWG stranded (1.5mm 2 ) wire 24VDC 115VAC/230VAC Solenoid Power 12.0W (maximum) Consumption Solenoid Duty Cycle 100% DIMENSIONS 88

89 SERIES TKF/TKM ACTUATOR KEY SPECIFICATIONS ACTUATOR KEYS Series TK/R/90 (For sliding guards only) Series TK/RF/90 (With telescopic section) (For sliding guards only) 2 (For sliding guards only) Parallel Actuator Key TK/P/90 Parallel Actuator Key TK/PF/90 (With telescopic section) 89

90 SERIES TZK Description The TZK Series is designed for machines/work cells where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time delay, motion detector, position sensor or other suitable component. The unit s contact arrangement permits the prevention of a machine restart until the guard is closed and in the locked position. Each unit is supplied with a 1 2" NPT conduit adapter. Operation The TZK Series electromechanical safety interlock switch consists of a rugged switch with a solenoid-latching mechanism and a geometrically-unique actuating key. The switch actuating key is typically mounted to a movable machine guard. When the guard is closed, the actuating key is held in position by the solenoid-latching mechanism. The guard may only be opened by energizing or de-energizing (depending upon model) the solenoid-latching mechanism. Upon opening of the guard, the switch s positive-break NC contacts are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The NO contacts close upon key removal. Heavy-Duty Solenoid-Latching Safety Interlock Switch Features & Benefits Solenoid-locking design controls access to hazardous areas until safe conditions exist. Highly tamper-resistant difficult to defeat with simple tools, tape, bent wires, etc. Reduces liability exposure. Positive-break NC contacts ensure circuit interruption upon key removal. Watertight design meets IP67 environmental sealing requirements. Positive locking integral mechanical interlock prevents solenoid latching until actuating key is fully inserted. High-strength steel actuator key tolerates mechanical abuse without damage. Rugged, corrosion-resistant housing tolerates the most hostile environments. Available in solenoid-locking and solenoidunlocking models for application versatility. Optional floating actuator key tolerates up to 5mm of guard misalignment without damage. Meets rigid safety agency standards IEC, BG (UL and CSA pending) Rotatable actuating head four user-selectable 90 positions for installation flexibility. Funnel entry forgiving of minor guard misalignment. Optional spring-loaded actuator keys tolerates axial misalignment of guard. Built-in key entry dust cover prevents ingress of dirt and dust when key is removed. Typical Applications The TZK Series is intended for use as a safety interlock switch on movable machine guards which must not be opened until dangerous conditions, that may exist after the removal of power, have abated. Such conditions are flywheel overrun, spindle momentum, unstable rest positions, etc. Typical applications are textile machines, stamping presses, articulating robot arms, mixing machines, heavy working equipment, printing presses and packaging machinery. 90 is a trademark of SCHMERSAL

91 SERIES TZK AVAILABLE MODELS AND ACCESSORIES AVAILABLE STANDARD MODELS (Includes 1 2" NPT Adapter. Order desired actuator key separately) Part Number* Contacts (Guard Closed) Description TZKF/CS* 1 NO & 2 NC Actuating key locked by spring and unlocked by energizing solenoid TZKM/C* 1 NO & 2 NC Actuating key locked by energizing solenoid and unlocked by deenergizing solenoid (See Note 1 below) *Please specify solenoid operating voltage via addition of one of the following suffix codes: Voltage Add Suffix 24VDC No Suffix 115VAC -115VAC 230VAC -230VAC Example: TZKF/CS-115VAC Part Number TZK/CO TZK/CW TZK/COF TZK/CORF/7.5 TZK/CORF/15 TZK/APL TZ-69 TZ-75 ACTUATOR KEYS & ACCESSORIES Description Standard straight actuating key Standard right-angle actuating key Spring-loaded actuator key tolerates axial movement of +7.5 /-15 or -7.5 /+15 depending upon mounting orientation Pre-tensioned, spring-loaded actuator key tolerates axial movement of +7.5 or -7.5 depending upon mounting orientation Pre-tensioned, spring-loaded actuator key tolerates axial movement of +15 or -15 depending upon mounting orientation Mounting adapter plate facilitates easy alignment between actuating key and interlock Standard straight auxiliary release key Right-angle auxiliary release key 2 Note 1: Use of this model permits the guard to be opened in the event of a power failure. Generally accepted safety standards/practices suggest this model only be used after conducting a thorough risk evaluation in the context of the application. AZS2305 FWS1205B Fail-to-Safe Timer (Please see page 98) Fail-to-Safe Standstill Monitor (Page 100) TZ-75 TZ-69 Auxiliary release keys (for locking via spring models) 91

92 SERIES TZK TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Galvanized steel IP67 2.3mm 10 N (2.2 pounds) 20 N (4.4 pounds) Actuator Key Degree of Protection Travel for Positive-Break Key Insertion Force Key Holding Force (without solenoid-latching) Solenoid Locking Force Operating Temperature Mechanical Life Mounting Orientation Solenoid Override Slack Resistance Vibration Resistance Switching Frequency Conformity to Standards IEC 947 EN DIN VDE 0660 EN 1088 UL & CSA Minimum Closing Radius 2,000N (440 pounds) +32 F to +122 F (0 C to +50 C) 2 x 10 6 Operations (minimum) Any position Manual release from front surface 30g / 11ms 20g / 10-55Hz 120 cycles/hour (maximum) 6.9" (175mm) for CO and CORF actuating key 9.8" (250mm) for CW actuating key 5.9" (150mm) for COF actuating key ELECTRICAL SPECIFICATIONS Contacts Silver-plated, gold Contact Configuration Double-pole, double-break, electrically-separated contact bridges Contact Rating 8A/115VAC, 15A/250VAC (AC 15) 13A/24VDC (DC13) Switching Action Slow-action, positive-break NC contacts Short Circuit Protection 10A Rated Insulation Voltage 250VAC Rated Impulse Withstand 2.5 KV Voltage Type Terminals Screw terminals with self-lifting cable clamps for up to 13AWG flexible stranded wire (1.5mm 2 ) Available Solenoid Voltages 24VDC 115VAC/50-60 Hz 230VAC/50-60 Hz Solenoid Power 10W (maximum) Consumption Solenoid Duty Cycle 100% SWITCHING DIAGRAMS & CONTACT SCHEMATICS (Actuator key inserted and no power to solenoid) TZKF/CS TZKM/C , , E1 E2 0 2,3 3, E1 E2 0 2,3 3,

93 7,5 SERIES TZK TECHNICAL DATA DIMENSIONS (Basic Switch & Optional Mounting Adapter Plate) , TZK/APL Mounting Adapter Plate ,5 5.7 M , ,5.89 ACTUATOR KEY DIMENSIONS TZK/CO Straight Actuating Key TZK/CW Right-Angle Actuating Key , , , , ,5.26 8, , , TZK/CORF/15 Flexibly-Mounted Floating Actuator Key ,5.26 8, , ,5.26 4, M20x , mm inch TZK/CORF/7.5 Pre-Tensioned Flexibly-Mounted Actuator Key , , , ,

94 SERIES AZM415 Description The AZM415 Series is designed for movable machine guards where access to a hazardous work area must be controlled until safe conditions exist. Their solenoid-latching feature permits locking a machine guard until dangerous conditions, which may exist immediately after removal of power, have abated. Solenoid-latching may be controlled by a time-delay, motion detector, position sensor or other suitable component. Latching may occur upon energizing or de-energizing the solenoid depending upon model. In addition the AZM415 features positive-break NC contacts, and an adjustable-force ball latch which maintains a holding force on the guard when the key is in the unlocked state. A two-key model is also available for guards which may be open in two directions (Model AZM415-33zpdk). Operation The AZM415 two-piece electromechanical safety interlock switch consists of a rugged switch and solenoid-latching mechanism and a geometrically-unique actuating key. The switch actuating key is typically mounted to a movable machine guard. When the guard is closed, the actuator key is locked in position by a toggle-lever system. The guard may only be opened by energizing or de-energizing (depending upon model) the solenoid-latching mechanism. Upon opening of the guard the switch s positive-break NC contacts are forced to open through a direct (non-resilient) mechanical linkage with the actuating key. The NO contacts close upon key removal. Optional Safety Controller. See Pages 84, 86, 88 and 328. Heavy-Duty Solenoid-Latching Safety Interlock Switch Features & Benefits Solenoid-locking design controls access to hazardous areas until safe conditions exist. Highly tamper-resistant difficult to defeat. Positive-break NC contacts assure circuit interruption upon actuator key removal. Watertight design meets IP67 washdown requirements. High-strength, metal actuator key tolerates mechanical abuse without damage. Rugged, enamel-coated metal housing tolerates the most hostile environments. Adjustable actuator key holding force up to 110 pounds permits use of switch as door latch. Available in solenoid-locking and solenoidunlocking models for application versatility. Meets rigid safety agency standards UL, CSA, IEC, BG and VDE. Industrial-strength locking force up to 560 pounds. Patented toggle-lever locking system facilitates easy unlocking of (even heavily misaligned) guards. Two-key model for double-sided guards (AZM415-33zpdk). Optional B4 Actuator Key prevents unintentional guard closure. AVAILABLE STANDARD MODELS (Actuator key sold separately see chart below) AZM415 Switch insert S1 solenoid position *Please specify solenoid operating voltage via addition of one of the following suffix codes: Voltage Add Suffix 24VAC/DC -24VAC/DC 120VAC -120VAC ACTUATING KEYS & ACCESSORIES Description Part Number Linear entry actuator key (For sliding lift-off guards) Small radius (250mm) x-axis entry actuator key (For hinged guards) Small radius (250mm) y-radius entry actuator key (For hinged guards) Slide bolt actuator key (For sliding guards) Fail-to-Safe Timer XX / YY ZPK Switch insert S2 key position 11 (1 NO/1 NC) 02 (2 NC) Fail-to-Safe Standstill Monitor 11 (1 NO/1 NC) 02 (2 NC) 20 (2 NO) AZM415-B1 AZM415-B2 AZM415-B3 T (manual override) Leave blank (power to unlock) A (power to lock) AZ/AZM415-B4pS AZS2305 (Page 98) FWS1205B (Page 100) 94 is a trademark of SCHMERSAL

95 AZM415 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Actuator Key Degree of Protection Travel for Positive-Break Force to Reach Positive-Break Solenoid Locking Force Actuator Key Holding Force Operating Temperature Mechanical Life Conformity to Standards IEC BG-GS-ET-19 VDE 0660 UL CSA Minimum Closing Radius DIMENSIONS Die-cast aluminum with blue enamel finish Die-cast aluminum IP67 5mm (0.2 inches) Depending upon ball catch setting (3.5 pounds minimum) 560 pounds Adjustable, 2.2 to 110 pounds -13 F to +175 F 1 million operations 9.8" (250mm) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Type Terminals Available Solenoid Supply Voltages (Vs) Fine silver Double-pole, double-break with electrically separated contact bridges 2mm x 2mm 4A (230VAC) Slow-action, positive-break NC contacts Fuse 6A (slow-blow) 250VAC 4kV Screw terminals with self-lifting clamps for up to 13AWG flexible stranded wire (1.5 mm 2 ) 24VAC/DC 115VAC/60Hz 230VAC/50Hz Solenoid Power 10W (maximum) Consumption Solenoid Duty Cycle 100% 2 M20 95

96 AZM415 TECHNICAL DATA WIRING SCHEMATICS AZM415xx/yyZPK (Power-to-unlock) 11/11 WIRING SCHEMATICS AZM415xx/yyZPKA (Power-to-lock) 11/11 11/02 11/02 11/20 11/20 02/11 02/11 02/02 02/02 02/20 02/20 96 Contacts shown with actuator key inserted and solenoid de-energized.

97 AZM415 TECHNICAL DATA ACTUATOR KEY DIMENSIONS B1 Actuator , , B4pS Actuator for Hand Operated Locking < , , B2 Actuating radii For hinged doors over the wide edge of the actuator B3 Actuating radii For hinged doors over the small edge of the actuator Dowel holes are also provided in the actuator body. With the use of dowel pins the removal of the actuator can be prevented. By turning the adjusting screw a, the actuator can be brought into any desired position. Both actuators can also be used on sliding doors. 97

98 AZS 2305 Fail-To-Safe Timer Safety Category (EN954-1): Features Time can be set between 0.1s and 99min. To EN 1088 Control Category 3 to EN enabling circuits Recognition of short-circuit between connections 2 short-circuit proof additional transistor outputs Integral System Diagnostics (ISD) 2 channel microprocessor control Dimensions 55 x 75 x 110 mm ISD The following faults are recognized by the safety controller and indicated by means of ISD Failure of the unit s internal safety relay to pull-in or drop-out Short-circuits between the input connections Interruption of the input connections Difference in time setting between channel I and channel II Faults on input or relay control circuits of the timer Model Designation AZS VDC AZS VAC AZS VAC Function Table Additional semiconductor output Y Function of output Y AZS 2305 Y1 Enable, enabling circuits closed Y2 No Enable, enabling circuits open Approvals BG UL CSA 98

99 AZS 2305 Typical Applications Typical Wiring Diagram A1 S13 S14 S21 AZM VDC 0 0V +24 VDC S22 H1 N 0V L1 X1 X2 Y1 Y S A1 Y1 Y H2 L1 E 2 max. 100mA max. 100mA K1 K1 K2 K2 0V A2 X3 X4 X5 X6 X7 X A2 S13 S14 S21 S V AES 3335/3336 AZS 2305 N K3 SK1 K4 3 M Application Notes The arrangement in the wiring diagram fulfills Control Category 1 to EN Control Category 3 can be achieved. Exclusion of faults due to Breakage or release of the actuator, fault in the solenoid interlock is to be substantiated and documented. Monitoring of a sliding, hinged or removable guard device using an AZM range solenoid interlock (A). The solenoid interlock releases the guard device only when the set time has elapsed. The time begins to run when the power contactors have dropped out. The AES range guard door controller checks the position of the guard device. The coil of the solenoid interlock is energized by operation of the pushbutton E After release has taken place, the guard device must be opened if H1 is not connected. The wiring diagram is with the guard device closed and shows the de-energized condition. 99

100 FWS 1205 Fail-To-Safe Standstill Monitors Safety Category (EN954-1): Features Confirmation of standstill using 2 impulse sensors Control Category 3 to EN Operational voltage 24 VDC Reset input 2 short-circuit proof semiconductor outputs Integral System Diagnostics (ISD) 2 channel microprocessor control Customer-specific standstill frequencies possible 2 enabling paths Dimensions 22.5 x 75 x 110 mm ISD The following faults are recognized by the safety controller and indicated by means of ISD Interruption of the connections to one of the inductive proximity switches Failure of the proximity switches Failure of one channel being evaluated Failure of the unit s internal safety relay to pull-in or drop-out Faults on input or relay control circuits of the safety controller Model Designation FWS 1205A-24VDC (Execution A) FWS 1205B-24VDC (Execution B) FWS 1205C-24VDC (Execution C) Standstill Frequencies Execution A Execution B Execution C Function Table Additional transistor output Y Function of output Y Input X1 1Hz 2Hz 1Hz Input X2 2Hz 2Hz 1Hz Y1 Enable, Enabling circuits closed Y2 Fault Approvals BG UL CSA 100

101 FWS 1205 Typical Applications Typical Wiring Diagram 2 FWS 1205 Application Notes The solenoid interlock can be opened when the FWS 1205 has registered standstill of the motor by means of the two PNP inductive proximity switches. The coil of the solenoid interlock is then energized by operation of the pushbutton E The AES controller checks the position of the guard device. Monitoring of the guard device using a solenoid interlock and a safety switch with separate actuator. Control Category 3 can also be achieved without using the safety switch by connecting the NO and NC contacts of solenoid interlock to the guard door monitor. Exclusion of faults due to Breakage or release of the actuator, fault in the solenoid interlock is to be substantiated and documented. Release is only possible when the run-down movement has come to an end. After release has taken place, the guard device must be opened. The wiring diagram is with the guard device closed and shows the de-energized condition. 101

102 FWS 2505 Fail-To-Safe Standstill Monitors Safety Category (EN954-1): Features Confirmation of standstill using 2 impulse sensors Control Category 3 to EN enabling circuits Available for various operational voltages Reset input 2 short-circuit proof semiconductor outputs 1 N/C auxiliary contact Integral System Diagnostics (ISD) 2 channel microprocessor control Customer-specific standstill frequencies possible VAC/DC Dimensions 45 x 100 x 121 mm ISD The following faults are recognized by the safety controller and indicated by means of ISD Interruption of the connections to the inductive proximity switches Short-circuit between connections Failure of the proximity switches Failure of one channel being evaluated Failure of the unit s internal safety relay to pull-in or drop-out Faults on input or relay control circuits of the safety control unit Model Designation FWS 2505A V AC/DC (Execution A) FWS 2505C V AC/DC (Execution C) Standstill Frequencies Execution A Execution C Function Table Additional transistor output Y Function of output Y High (24V) Input X2 1Hz 1Hz Input X4 2Hz 1Hz Y1 Y2 Enable, Enabling circuits closed Fault condition Other frequencies on request. Approvals BG UL CSA 102

103 FWS 2505 Typical Applications 2 Typical Wiring Diagram Application Notes The solenoid interlock can be opened when the FWS 2505 has registered standstill of the motor by means of the two PNP inductive proximity switches. The coil of the solenoid interlock is then energized by operation of the pushbutton E The AES guard door controller checks the position of the guard device. Monitoring of the guard device using a solenoid interlock. To achieve Control Category 3 the exclusion of faults due to Breakage or release of the actuator, fault in the solenoid interlock is to be substantiated and documented. Release is only possible when the run-down movement has come to an end. After release has taken place, the guard device must be opened. The wiring diagram is with the guard device closed and shows the de-energized condition. 103

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105 APPLICATION ACCESSORIES New! New! STS Safety Handle Assembly Page 106 B25 Safety Door Handle Page 112 TG-1 Safety Door Handle Page 114 New! 3 ZSD Enabling Device GFS Safety Foot Control SEPK(G) Two-Hand Control Consoles New! Page 116 Page 118 Page 122 TFA/TFI Guard Alignment Aid Page

106 SERIES STS Safety Guard Door-Handle System (with Emergency Release Option) Features & Benefits Suited for all types of guards... for application versatility. Dual-purpose handle... unlatches and opens guard. No additional door handles are needed. Optional inside emergency release handle available... heightens system safety level. Interlock switch mountable from inside or outside guard for application flexibility. Rugged, durable design... actuator designed for 15,000 N (3,400 pounds) of shear force. Mechanical design facilitates easy actuator key withdrawal... without sticking or binding. Meets ANSI/RIA R15.06 safety standards... provides for emergency egress. Description The STS door handle system consists of one safety interlock switch (ordered separately), an actuator key and handle assembly (with or without emergency release handle), mounting plates, and an optional lockout/tagout device. An optional red interior release handle is available which opens the guard from the inside in case of an emergency. Operation New! Should someone find themselves in a hazardous area and the guard is accidentally closed, the guard can be opened from the inside by turning the optional emergency handle (2). Locking of the guard from the inside is not possible. When using the optional emergency handle with a solenoidlatching keyed interlock switch, always order the version with an emergency unlocking feature. In this case the emergency latching release button or knob (1) provided with this model must be actuated before operating the emergency release handle (2). AVAILABLE ACCESSORIES Part Number Description MP TG-01 TFA-010 TFI-010 TFA-020 TFI-020 SZ SZ AVAILABLE STANDARD MODELS Please see page 93 Handle mounting plate for inside mounted actuators Alignment aid for outside mounting (for hinged guards) Alignment aid for inside mounting (for hinged guards) Alignment aid for outside mounting (AZ 16 & AZM 161 ONLY) Alignment aid for inside mounting (AZ 16 & AZM 161 ONLY) Lockout tag for STS30-02/-04/-06/-08 Lockout tag for STS30-01/-03/-05/

107 SERIES STS SELECTION TABLE & ORDERING GUIDE: SAFETY DOOR-HANDLE SYSTEM Actuator Mounting Position Actuator Door Hinge With emergency handle Inside Right XX-STS30-01* Left XX-STS30-02* Outside Right XX-STS Left XX-STS30-06 Without emergency handle Inside Right Left XX-STS30-03* XX-STS30-04* Outside Right XX-STS30-07 Left XX-STS30-08 *For actuators mounted on the inside, mounting plate MP TG-01 (ordered separately) must be used to mount the door handle when the door frame width is smaller than the handle. View from outside the hazardous area View from inside the hazardous area 107

108 SERIES STS TO ORDER COMPLETE STS DOOR HANDLE SYSTEM 1. Complete catalog number by replacing XX with the desired safety interlock switch. Please see Catalog GK-1. AZ 16 AZ 3350 (See below) AZ 415 AZM 161 AZM Order Safety Switch separately (see Catalog GK-1). NOTE: AZ3350 is an AZ335 switch with an actuator head with a funnel shaped key entry (SDG head, see Catalog GK-1). Available only with STS Door Handle System. Model AZ zuek-U90 AZ zuek-U270 AZ zk-U90 AZ zk-U270 AVAILABLE MODELS Description Actuated head rotated 90 for door hinge left Actuated head rotated 270 for door hinge right Actuated head rotated 90 for door hinge left Actuated head rotated 270 for door hinge right Example: To order a safety door handle system with a right-hand door hinge, an emergency release handle, for inside mounting and equipped with an AZM XPKT-24 VAC/DC safety inerlock switch, order SCHMERSAL part numbers: AZM 415-STS30-01 AZM-22XPKT-24 VAC/DC Note: If door frame is smaller than the handle assembly, also order the MP TG-01 Mounting Plate Example: To order a safety door handle system with a left-hand door hinge, an emergency release handle, for inside mounting and equipped with an AZM 161SK-24rkT safety inerlock switch, order SCHMERSAL part numbers: AZM 161-STS30-02 AZM 161SK-24rkT 108

109 SERIES STS DIMENSIONS AZ 16-STS30- AZ 3350-STS30- AZ 415-STS30- AZ 16 STS30-01/-03/-05/-07 AZ 3350 STS30-01/-03/-05/-07 AZ 415 STS30-01/-03/-05/-07 AZ 16 STS30-02/-04/-06/-08 AZ 3350 STS30-02/-04/-06/-08 AZ 415 STS30-02/-04/-06/-08 3 AZM 161-STS30- AZM 415-STS30- AZM 161 STS30-01/-03/-05/-07 AZM 415 STS30-01/-03/-05/-07 AZM 161 STS30-02/-04/-06/-08 AZM 415 STS30-02/-04/-06/-08 AZ 16 Handle Dimensions 109

110 SERIES STS ACCESSORIES Lockout Accessory MP TG-01 Handle Mounting Plate ORDERING DETAILS Lockout Tag for STS30-02/-04/-06/-08 SZ for STS30-01/-03/-05/-07 SZ TFA Hinged Guard Alignment Aid (for outside mounting) Mounting outside Self-centering of the guard door End stop Suitable for all types of actuators Actuator can be easily inserted or extracted TFI Hinged Guard Alignment Aid (for inside mounting) Mounting inside Self-centering of the guard door End stop Suitable for all types of actuators Actuator can be easily inserted or extracted 110

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112 SERIES B25 Safety Door Handle System for AZ17 and AZM170 Interlock Switches Features & Benefits Ergonomically-designed door handles for easy operation. Pre-machined mounting plates for easy installation. Dual-purpose handle releases interlock acutator key and opens guard. Low-profile design minimizes protruding handle. No protruding actuator recessed actuator key when guard is open makes for safer installation. User flexibility actuator can be supplied without handle. Users can mount their own handle design on the integral, pre-tapped (M6) 8mm square shaft. New! AZ17 zrk Installation AZM170 zrk Installation Description The Series BN25 is designed to allow easy realization of a combination door handle and safety interlock for use on light to medium weight hinged and sliding machine guards. Each unit consists of a door handle assembly with integral handle and safety interlock actuator key for operating a Series AZ17 zrk or AZM170 zrk interlock switch. Operation Upon manual turning of the star-grip or T-grip handle, the safety interlock switch actuator key is withdrawn from the switch body opening the positive-break, normally-closed switch contacts (and, if so equipped, closing the normally-open switch contact). Opening the normally-closed safety contact(s) removes power to the machine hazard. Upon operation, the actuator key is withdrawn into the door handle housing thus eliminating the potential hazard represented by a protruding key. Typical Applications The low-profile ergonomically-designed door handle is ideal for use on light- to medium-weight movable machine guards. 112

113 SERIES B25 AVAILABLE STANDARD MODELS & ACCESSORIES Compatible Safety Interlock* (order separately) Series AZ17 zrk Series AZM170 zrk Series AZ17 zrk Series AZM170 zrk Part Number AZ17-B25-L-G1 AZ17-B25-L-G2 AZ17-B25-R-G1 AZ17-B25-R-G2 AZM170-B25-L-G1 AZM170-B25-L-G2 AZM170-B25-R-G1 AZM170-B25-R-G2 MP-B25* Description Star-grip for left-hand hinged guard T-grip for left-hand hinged guard Star-grip for right-hand hinged guard T-grip for right-hand hinged guard Star-grip for left-hand hinged guard T-grip for left-hand hinged guard Star-grip for right-hand hinged guard T-grip for right-hand hinged guard Mounting plates for switch & handle assembly *Note: The AZ17 or AZM170 Safety Interlock Switch and the mounting plates are not included in the delivery and must be ordered separately. Please note the assembly requires the interlock with the latching ( r ) option. See Catalog GK-1. To order unit without Star-grip or T-grip handle, please change suffix to G0. For example AZ17-B25-L-G0. 3 Mounting Plates MP-B25 Order separately DIMENSIONS Star-Grip T-Grip AZ17 zrk Installation AZM170 zrk Installation 113

114 SERIES TG-1 Door Handle For Use With Solenoid Locking Switches Features & Benefits Integrated door release eliminates wiring to a console push-button. LED status indicators door status is known at a glance. Optional integrated push-button Optional integrated Emergency-Stop eliminates wiring to a remote console. Longer solenoid life solenoid energized only while release button is pushed. Tapered key entry ports tolerant to key misalignment. Meets rigid safety agency standards IEC, BG, VDE. Lockout accessory prevents key entry and switch actuation. Description The TG-1 handle has an integrated button for unlocking spring-to-lock solenoid switches. There are two LEDs indicating if the door is locked (green) or unlocked (red). Operation Pushing the button will energize the solenoid, allowing the door to be opened using the same hand. Releasing the handle and button will de-energize the solenoid, allowing the door to lock when closed. AVAILABLE STANDARD MODELS Part Number Description TG-WGR No top button TG-WGR10 With top-mounted emergency-stop TG-WGRS With top-mounted push button Note: Other variations are available. Please consult factory. Part Number M12-8P-5M ACCESSORY Description Matching cable set. 114

115 SERIES TG-1 TECHNICAL DATA MECHANICAL SPECIFICATIONS WIRING DIAGRAMS Housing Degree of Protection Termination Switching Voltage for Enabling Switch and Emergency Stop Button Switching System Rated Operating Voltage LED PA and POM IP65 Plug-in connector M 12 x 1, 8 pole 24VDC; max 30VAC/36VDC Slow action, positive-break NC contacts 24VDC LEDs LED red 5 / (GY) 4 / (YE) 3 / (GN) LED green Enabling Switch (BN) / 2 (WH) / 1 8 / (RD) View of Plug-in Connector 8 / (RD) Emergency Stop Button or Push Button (BN) / 2 1 / (WH) (GN) / 3 (YE) / 4 5 / (GY) 7 / (BU) 6 / (PK) (BU) / 7 6 / (PK) 3 DIMENSIONS red LED green LED Switch ,5 150 Plug-in connector M12x

116 SERIES ZSD 3-Position Hand-Held Enabling Device Features & Benefits Redundant contacts... allows use in up to safety control category 4 systems. Auxiliary contact... for status signalling. Positive-break contacts from position 2 to position 3... enhances safety. 3-position (OFF-ON-OFF) design... provides for machine stop control when operator squeezes or releases actuator from center on position. Rugged IP65 rating... withstands harsh industrial environments. Optional normally-open top-mounted pushbutton... enables machine jog/start control. Meets ANSI/RIA R15.06 safety standards... to satisfy enabling device requirements. Description The ZSD is a hand-held dead man switch with 3 operating positions OFF-ON-OFF. The machine/robot can be operated in the on position. It provides safety based on normal human behavior of either releasing or squeezing the actuator in an emergency situation. Operation Machine/robot operation is only allowed when the enabling device is held in the middle ( on ) position. Releasing the switch (position 1) or squeezing the switch (position 3) shuts down the equipment. Typical Applications Used in robotic cells and automated manufacturing systems to provide operator safety during set-up, maintenance, or troubleshooting. SWITCHING DIAGRAM FOR ZSD5 Operating Characteristics Position Normally open contact 1 2* Normally open contact 3 4* Auxiliary contact 5 6 Open:, Closed: * Positive-break contacts from position 2 to position 3 Part Number ZSD5 ZSD6 ZSD-H AVAILABLE STANDARD MODELS (INCLUDES M20 STRAIN RELIEF) Description 3-Position Enabling Switch (OFF-ON-OFF) 3-Position Enabling Switch (but with top-mounted pushbutton - 1NO contact) Metal Holding Bracket Note: For factory installed cable, add length in meters, e.g. ZSD5-5m. Use of a SCHMERSAL safety controller with cross short monitoring is required (SCHMERSAL models SRB301ST-24 or SRB301SQ). 116

117 ZSD TECHNICAL DATA MECHANICAL SPECIFICATIONS Operating Temperature Operating Humidity Storage Temperature Operating Frequency Mechanical Life 25 C to +60 C (no freezing) 45% to 85% RH maximum (no condensation) 40 C to +80 C (no freezing) 1,200 operations/hour Position 1 2 1: 1,000,000 minimum Position : 100,000 minimum Shock Operating Extremes 100m/s 2 Resistance Damage Limits 1000m/s 2 Vibration Operating Extremes 5 to 55Hz, amplitude 0.5mm minimum Resistance Damage Limits 16.7Hz, amplitude 1.5mm minimum Terminal Pulling Strength 20N minimum Terminal Screw Torque 0.5 to 0.6Nm Degree of Protection IP65 Weight Approx. 240g (ZSD6) Approx. 210g (ZSD5) Conforming to Standards IEC , EN , JIS C , ANSI/RIA R15.6 Approvals UL, CSA, BG ELECTRICAL SPECIFICATIONS Contact Resistance 100mΩ maximum Between live & dead metal parts: Insulation Resistance 100MΩ maximum (at 500VDC) Between positive & negative live parts: 100MΩ minimum (at 500VDC) Impulse Withstand Voltage 2.5kV Electrical Life 100,000 cycles load Recommended Wire Size AWG Recommended Cable inch diameter Conditional Short Circuit Current 50A (250V) Recommended Short 250V/10A fast-blow fuse (IEC ) Circuit Protection Contact Rating 30V, 125V 3 ACCESSORIES Part Number ZSD-H Description Metal holding bracket (for mounting/holding a ZSD enabling device) DIMENSIONS (mm) ZSD5/6 x 1.5 Note: Model with top-mounted pushbutton shown. 117

118 SERIES GFS Safety Foot Switch Features & Benefits Positive-Break Contacts... assure circuit interruption upon complete foot pedal actuation. Automatic latching following an emergency stop signal... meets EN 418 standard for E-Stop switches. Unique design with protective shield... avoids unintentional actuation due to falling debris or dropped items. Release modes... only manually by pushing the button on the top of the pedal. Heavy duty aluminum shield... tolerates mechanical abuse without damage. Meets rigid safety agency standards... UL, CSA, IEC, BG, VDE. Description Extensive accident prevention research has shown that in the event of pain/distress, the foot is frequently not removed from the foot pedal that is enabling equipment operation. Paradoxically, weight is often shifted forward and pressure on the foot pedal is increased (rather than removed). Recognizing this, the series GFS safety foot switch features 3-stage operation. It is designed to stop hazardous movements in machinery whether released or fully-depressed in an emergency situation. It s positive-break, normally-closed contacts provide a significantly higher level of safety than conventional springdriven contacts which can weld/stick shut. Their glass-fiber reinforced pedal and aluminum protective shield make them ideal for heavy-duty applications in hostile environments. Operation The results of accident prevention research has been translated into a specific product according to the research. In the event of pain, the foot is frequently not removed from the switching pedal, but paradoxically pressure is increased, and the weight shifted forward. The solution to this problem is provided by a 3-stage safety foot switch. Position 1. The pedal is not actuated in the upper position. Machine OFF Typical Applications The GFS foot switch is intended for use in machines or areas where operation using the hands is not possible. Typical applications are profile and tube bending machines, bar turning machines, thread cutting, and wire drawing machines. AVAILABLE MODELS Part Number GFS 1 S D 1 O VD GFS 2 S D 2 O VD Contacts 1 NC 2 NC All Enclosures include PG to 1/2" NPT metal conduit adapter Signal Output 0ff Position 1 (Pedal not actuated) Position 2. The operation circuit contact closes after actuating the foot pedal (the pedal is in contact with the tangible pressure-point stop). Machine ON On Position 2 (Pedal depressed to pressure point) Position 3. The pressure point is overcome in the event of danger or sensing pain, the circuit contact opens and is automatically latched. Machine Emergency Stop Operation to position 3 requires manual reset using the integral push button actuator Optional safety controllers for E-Stop applications are available. Please consult factory. 0ff Position 3 (Pedal fully depressed) 118 is a trademark of SCHMERSAL

119 GFS SERIES TECHNICAL DATA 3 CONTACT DIAGRAMS GFS 1SD/1OVD 1 NO 1 NC GFS 2SD/2OVD 2 NO 2 NC Position 1 Position 2 Position 3 Each contact (Same as GFS 1SD/10VD) Latched (Release via topmounted pushbutton 119

120 GFS SERIES TECHNICAL DATA MECHANICAL SPECIFICATIONS Enclosure Aluminum (die casting) Protecting Hood (shield) Aluminum (die casting) Pedal Glass-fiber reinforced thermoplastic ( nylon 66) Degree of Protection IP 65 to IEC/EN Ambient temperature 25 C to + 80 C Mechanical life > 1 million operations Conformity to Standards IEC/EN , EN 418 BG-GS-ET-15 ELECTRICAL SPECIFICATIONS Contact Rating 16 A / 400VAC Switching Action Slow-action NC Positive break contacts Rated Insulation Voltage 500 V Type Terminals Screw terminals,2.5 mm 2 max. (including conductor ferrules) Withstand Voltage 6 kv Thermal test current 10 A Max. fuse rating 16 A (slow-blow) GFS SERIES DIMENSIONS (mm) 72 14, ø 33 82,

121 3 Safer by Design 121

122 SERIES SEPK(G) New! 2-Hand Control Consoles (with light force actuators) Features & Benefits Choice of console material rugged Lexan or die-cast aluminum. Optional control functions consoles designed to accept up to 8 additional control and signalling devices. Hinged console covers facilitate easy wiring and assembly. Ergonomically-designed shelf to support hands during actuation (SEPG model) minimizes stress. Protective safety hoods protect against accidental actuation of pushbuttons. Integral E-stop mushroom pushbutton for easy emergency stop control IP65 ingress protection rating tolerates hostile, wet environments. Meets EN574 standard (SEPG model) safety of machinery for two-hand control consoles. Available adjustable stands (optional) to optimize user comfort. Available optional accessories e.g., safety controllers, foot pedals, rollers, special paint finishes for application flexibility. Custom units available please consult factory. AVAILABLE STANDARD MODELS Description Schmersal s family of two-hand control consoles have an ergonomic design that require the operator to use both hands to initiate a control action. Thus they insure that the operator s hands are kept away from the hazardous area of a machine during operation. The units are designed such that simultaneous operation (within 0.5 seconds) of both control buttons is required to initiate the machine cycle. The control buttons must remain actuated to complete the machine cycle. Each is equipped with an integral E-stop mushroom pushbutton to facilitate emergency stoppage. Units are available with a wide choice of options and accessories, such as adjustable stands, auxiliary control buttons, foot pedals, special colors, etc. for optimizing safety and functionality. Typical Applications Two-hand control consoles are used as protective devices in setting up and operating single-stroke equipment, and other applications where it is desired to keep both of the operator s hands safe from a hazardous area during machine operation. Applications are typically found in the metal working, rubber, plastics and chemical industries as well as in semi-automatic assembly equipment. Model Number SEPK /95 SEPK02.0.L.22 SEPG /95.E1 SEPG05.3.L.22 Description Plastic (Lexan), hooded console with one red, 38.5mm E-stop mushroom button (1NO & 1NC contact) and two light force (2.3 lbs.) black, 55mm mushroom pushbutton actuators (each with 1NO & 1NC contact) Empty plastic (Lexan) hooded console (gray) with 3 bore holes for actuators Powder-coated (gray) aluminum hooded console with one red, 38.5mm E-stop mushroom button (1NO & 1NC contacts) and two light force (2.3 lbs.) black, 55mm mushroom pushbutton actuators (each with 1NO & 1NC contact) Empty powder-coated (gray) aluminum hooded console with 3 bore holes for actuators Note: Also available as custom control panels with up to 8 control and/or signalling devices in the central portion of the console (in addition to the E-stop actuator) and adjustable height floor stands (with or without rollers). Please consult factory. AVAILABLE ACCESSORIES Part Number Description SRB201ZH-24VDC EDRR40RT Two-hand control safety controller (Please see page 268 for details) E-stop actuator 122 EFR EF303.1 AF02 AF10 Spring element for E-stop E-stop actuator contact block with 1NO & 1NC contact Control actuator contact block with 1NO contact Control actuator contact block with 1NC contact

123 SERIES SEPK(G) MECHANICAL SPECIFICATIONS Console Material Console Color Ingress Protection Lexan (SEPK02 ) Die-cast aluminum (SEPG05 ) RAL 7035, light gray (SEPK02 ) RAL 7004, signal gray (SEPG05 ) IP65 ELECTRICAL SPECIFICATIONS (Contact Blocks) Specification Rated Operating Current (Ie) Type AF (Operating Pushbuttons) 6A, 250VAC (AC15) 3A, 24VDC (DC13) Contact Type Type EF (E-stop Button) 8A, 250VAC (AC15) 5A, 24VDC (DC13) Mechanical Life Expectancy of Contact Blocks Temperature Range Mushroom Button Actuating Force Type A Contacts: 5 million cycles (minimum) Type B Contacts: 10 million cycles (minimum) Type AF Contacts: -25 C to +60 C Type EF Contacts: -25 C to +80 C 2.3 lbs. (SEPK02 ) 2.3 lbs. (SEPG05 EI) Insulation Voltage (Ui) 500V@Test Voltage of 2,500V Short Circuit Protection Wire Size 2 x 0.5 to 2.5mm 2 (2 x 20AWG to 13AWG) 440V@Test Voltage of 2,500V 10A, Slow-blow 10A, Slow-blow 2 x 0.5 to 1.5mm 2 (2 x 20AWG to 15AWG) DIMENSIONS SEPK 3 DIMENSIONS SEPG 123

124 Series TFA/TFI Guard Alignment Aid New! Features & Benefits Self-aligning self-centering design helps align guard. End-stop functions as end-stop to protect guard from excessive shock on closing. Easy-to-install on inside or outside of guard. Reduces maintenance minimizes risk of downtime due to misaligned guard. Suitable for retrofit on existing guards. TFA Guard Alignment Aid (for outside mounting) Mounting outside Self-centering of the guard door End stop Suitable for all types of actuators Actuator can be easily inserted or extracted TFI Guard Alignment Aid (for inside mounting) Mounting inside Self-centering of the guard door End stop Suitable for all types of actuators Actuator can be easily inserted or extracted 124

125 EMERGENCY CABLE-PULL SWITCHES New! SELECTION GUIDE 4 Switch Series Housing Material Maximum Span Contact Configurations Rated Catalog Page ZS71 Die-cast aluminum 65 feet 1 NO & 1 NC 2 NC (Optional) 126 ZS73 Die-cast aluminum 165 feet 1 NO & 1 NC 2 NC (Optional) 130 ZS75 Die-cast aluminum 165 feet 1 NO & 1 NC 2 NC 2 NO & 2 NC 4 NC (Optional) 134 ZS441 Die-cast aluminum 80 feet 1 NO & 1 NC 2 NC No 138 Bidirectional ZS75S Die-cast aluminum 165 feet (Each Direction) 2 NO & 2 NC 4 NC (Optional) 142 New! ZS80 Die-cast aluminum 165 feet (50m) 2 NO & 2 NC 1 NO & 3 NC 4 NC No 146 New! S900 Cable-Pull Switch Wire Tensioner

126 ZS71 Emergency Cable-Pull Switch (Meets EN418) Description The ZS71 is designed to provide continuous emergency stop along exposed areas of machinery and conveyors which present hazards to operators/maintenance personnel. Unlike E-stop pushbuttons, emergency-stop cable-pull systems can be actuated at any point along the trip-wire. The unit features a positive-opening NC contact which is forced open when the trip-wire is pulled. This design also assures actuation if the operator falls into, leans on, or is pushed against the trip-wire. In addition, the switch is designed to operate if the trip wire is cut or goes slack. Their rugged metal housing, small size and watertight design (IP65) make them ideal for use in hostile environments where space is limited. Features & Benefits Rugged, corrosion-resistant, die-cast aluminum housing tolerates the most hostile environments. Positive-break NC contact assures circuit interruption upon pulling of trip wire. Visual position indicator for ease of installation. Push/pull operation actuates if trip-wire is pulled or goes slack. Watertight design meets IP65 requirements, equipped with watertight collar. Continuous E-stop protection for supported trip-wire spans up to 65 feet (20m). Meets rigid safety standards UL, CSA. Low actuating force operates with only 13.5 lbs of force. Ideal for short-run applications. Explosion protected optional IEC-rated explosion-proof models available. Mounting accessories ease and extend installation. Optional integrated emergency-stop button for easy actuation when in proximity to switch. Operation The ZS71 features an axial actuating shaft and a double-pole contact block with either 1 NO & 1 NC or 2 NC contacts (with trip-wire pre-tensioned). When the trip-wire is pulled, the positive-break NC contact is forced open via a direct mechanical linkage with the actuating shaft. If the trip-wire goes slack (e.g. breaks or is cut) the NC contact opens resulting in equipment stoppage. Manual (key or pushbutton) reset mechanisms assure the equipment cannot be restarted until the reset is actuated. Optional integrated emergency-stop button on face of switch assures complete emergency stop. Typical Applications The ZS71 is ideal for replacing multiple, discrete E-stop pushbuttons or achieving a continuous immediately accessible emergency stop especially where space is limited. Typical applications include conveyor lines, textile machinery, packaging machinery, turret lathes, and transfer lines. 126 is a trademark of SCHMERSAL

127 ZS71 AVAILABLE MODELS AND ACCESSORIES Part Number AVAILABLE STANDARD MODELS Contact Configuration Type Reset Pre-Tensioned Force Typical Actuating Force (F) Maximum Cable Length ZS71-10/1S WVDA-55N* 1 NO & 1 NC Pushbutton 12.5 lbs (55N) 1.4 lbs (6N) 32.5 ft (10m) ZS71-10/1S WVDA* 1 NO & 1 NC Pushbutton 45.5 lbs (200N) 6 lbs (25N) 65 ft (20m) ZS71-10/1S WVSA-55N* 1 NO & 1 NC Key 12.5 lbs (55N) 1.4 lbs (6N) 32.5 ft (10m) ZS71-10/1S WVSA* 1 NO & 1 NC Key 45.5 lbs (200N) 6 lbs (25N) 65 ft (20m) ZS71-20 WVDA-55N 2 NC Pushbutton 12.5 lbs (55N) 1.4 lbs (6N) 32.5 ft (10m) ZS71-20 WVDA 2 NC Pushbutton 45.5 lbs (200N) 6 lbs (25N) 65 ft (20m) ZS71-20 WVSA-55N 2 NC Key 12.5 lbs (55N) 1.4 lbs (6N) 32.5 ft (10m) ZS71-20 WVSA 2 NC Key 45.5 lbs (200N) 6 lbs (25N) 65 ft (20m) ZS71-10/1S WVD-NA-55N 1 NO & 1 NC Pushbutton 12.5 lbs (55N) 1.4 lbs (6N) 32.5 ft (10m) ZS71-10/1S WVD-NA 1 NO & 1 NC Pushbutton 45.5 lbs (200N) 6 lbs (25N) 65 ft (20m) ZS71-20WVD-NA-55N 2 NC Pushbutton 12.5 lbs (55N) 1.4 lbs (6N) 32.5 ft (10m) ZS71-20WVD-NA 2 NC Pushbutton 45.5 lbs (200N) 6 lbs (25N) 65 ft (20m) *Available in an IEC-rated explosion-proof design. To order, add prefix EEX to part number. Equipped with integral emergency stop button. AVAILABLE ACCESSORIES Part Number Description PL-M20-24V 24V Pilot light kit PL-M20-120V 120V Pilot light kit 4 STQ441-SC STQ441-EB STQ441-CC STQ441-TB STQ441-TH STQ441-PU New! S900 5mm diameter steel cable, PVC coated M10 eye bolt & hex nut Cable clamp Turnbuckle Thimble Pulley assembly (for cable "cornering") Cable-Pull Switch Wire Tensioner (see page 150) For recommended installation instructions, please see page 141. ZS71-10/1S WVD-NA Emergency pushbutton option 127

128 ZS71 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Die-cast aluminum with fiberglassreinforced thermoplastic cover Degree of Protection IP65 (pushbutton reset) IP54 (key reset) Maximum Supported 65 feet (20m) Span Operating Temperature 13 F to +158 F ( 25 C to +70 C) Mechanical Life 1 million operations Conformity to Standards EN418, UL, CSA Minimum Cable Tension 6.7 lbs. (30N) Typical Deflection (S) 4.4" (11cm) Required for Operation ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Type Terminals Fine silver 1 NO & 1 NC or 2 NC doublepole, double-break with electrically-separated contact bridges 6A/400VAC Snap-action, positive-break NC contacts (with wire pulling). Snapaction NO contact. 6A (external) Screw terminals with clamping washers T( C) l (m) Cable length vs. temperature range At 3m distance, intermediate wire supports are required, see accessories. DIMENSIONS 128

129 ZS71 TECHNICAL DATA DIMENSIONS ø , ø M , mm inch SWITCHING DIAGRAMS & CONTACT SCHEMATICS 4 129

130 ZS73 Heavy-Duty Emergency Cable-Pull Switches Meet EN 418 Description The ZS73 is designed to provide a continuous emergency stop along exposed areas of machinery and conveyors which present hazards to operators/maintenance personnel. Unlike E-stop pushbuttons, emergency stop cable-pull systems can be actuated at any point along the trip-wire. The units feature positive-opening NC contacts which are forced open when the trip-wire is pulled. This design also assures machine stoppage if an operator falls into, leans on, or is pulled against the trip wire. In addition the switch is designed to operate if the trip wire is cut or goes slack. To comply with OSHA and other safety regulations, the ZS73 features a manual mechanical reset which must be actuated before the controlled equipment can be restarted. Their rugged metal housing and watertight design (IP65) make them ideal for achieving a higher degree of E-stop safety in industrial and hostile environments. Features & Benefits Rugged, corrosion-resistant, die-cast aluminum housing tolerates the most hostile environments. Positive-break NC contacts assure circuit interruption upon pulling of trip wire. Watertight design meets IP65 requirements. Continuous E-stop protection for supported trip-wire spans up to 164 feet (50m). Meets rigid safety agency standards EN 418 Available in two operating force models for application compatibility. Mounting accessories ease and extend installation. Satisfies OSHA push/pull operating requirements trips if cable is pulled or goes slack. Explosion protected optional IEC-rated explosion-proof models available. Signal lamp optional lamp signals tripped and latched condition. Operation The ZS73 features an axial actuating shaft and a double-pole contact block with 1 NO and 1 NC contact or 2 NC contacts (with trip-wire attached). When installed, the trip-wire is pretensioned until the actuating shaft is pulled out 6 mm, closing the NO contact(s). When the trip-wire is pulled, the positive-break NC contact(s) are forced open via a direct mechanical linkage with the actuating shaft. If the trip-wire goes slack (e.g. breaks or is cut) the NO contact, closed during pre-tensioning, opens resulting in equipment stoppage. Manual pushbutton reset assures the equipment cannot be restarted until the reset is actuated. Typical Applications The ZS73 emergency cable-pull switches are ideal for replacing multiple, discrete E-stop pushbuttons or achieving a continuous, immediately accessible emergency stop. Typical applications include conveyor lines, textile machinery, packaging machinery, turret lathes, power plants, gravel processing and transfer lines. 130 is a trademark of SCHMERSAL

131 ZS73 AVAILABLE MODELS AND ACCESSORIES Part Number Contact Configuration AVAILABLE STANDARD MODELS Type Reset Pre-Tensioned Force ZS73-10/1S WVD-98N* ZS73-10/1S WVD-177N* ZS73-10/1S WVD-275N* ZS73-10/1S WVD* 1 NO & 1 NC 1 NO & 1 NC 1 NO & 1 NC 1 NO & 1 NC Pushbutton Pushbutton Pushbutton Pushbutton lbs (79-98N) lbs ( N) lbs ( N) lbs ( N) ZS73-10/1S WVS-98N* 1 NO & 1 NC Key lbs (79-98N) ZS73-10/1S WVS-177N* 1 NO & 1 NC Key lbs ( N) ZS73-10/1S WVS-275N* 1 NO & 1 NC Key lbs ( N) ZS73-10/1S WVS* 1 NO & 1 NC Key lbs ( N) ZS73-20 WVD-98N 2 NC Pushbutton lbs (79-98N) ZS73-20 WVD-177N 2 NC Pushbutton lbs ( N) ZS73-20 WVD-275N 2 NC Pushbutton lbs ( N) ZS73-20 WVD 2 NC Pushbutton lbs ( N) ZS73-20 WVS-98N 2 NC Key lbs (79-98N) ZS73-20 WVS-177N 2 NC Key lbs ( N) ZS73-20 WVS-275N 2 NC Key lbs ( N) ZS73-20 WVS 2 NC Key lbs ( N) Typical Actuating Force (F) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) Recommended Cable Length (Minimum & Maximum) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) *Available in an IEC-rated explosion-proof design. To order, add prefix EEX to part number. 4 AVAILABLE ACCESSORIES Part Number Description PL-M20-24V 24V Pilot light kit PL-M20-120V STQ441-SC STQ441-EB STQ441-CC STQ441-TB STQ441-TH STQ441-PU New! S V Pilot light kit 5mm diameter steel cable, PVC coated M10 eye bolt & hex nut Cable clamp Turnbuckle Thimble Pulley assembly (for cable "cornering") Cable-Pull Switch Wire Tensioner (see page 150) Explosion-proof option For recommended installation instructions, please see page 141. Pilot light option 131

132 ZS73 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Die-cast aluminum, color-painted Thermoplastic cover Degree of Protection IP65 (pushbutton reset) IP54 (key reset) Maximum Supported 164 feet (50m) Span Typical Deflection (S) 5.1" (13cm) Required for Operation Mechanical Life 1 million operations Operating Temperature 13 F to +158 F ( 25 C to +70 C) Conformity to Standards CE UL BG CSA EN 418 IEC EN Explosion Protection E Ex dll CT6 ( Ex models only) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges 6A/400VAC Snap-action, positive-break NC contacts (with wire pulling) 6A (Slow blow) 400VAC Screw terminals with clamping washers Note: Hard-coated housing available with stainless steel accessories. Please consult factory. Note: Bi-directional unit available, up to 50m each direction. Please consult factory. DIMENSIONS Pushbutton Reset Key Reset M , , M mm inch SWITCHING DIAGRAMS & CONTACT SCHEMATICS T( C) l (m) Cable length vs. temperature range At 5m distance, intermediate wire supports are required. See accessories.

133 ZS73 INSTALLATION DETAILS PRE-TENSIONING ADJUSTMENT To ensure positive-break operation, the switch should be pinned through the holes shown (1). The trip-wire should be pre-tensioned to the point where the linear switch actuating cam is in the middle position (3). The standard 395N axial pulling force required for pre-tensioning can be reduced by adjusting the grooved nut (2). For trip-wire spans of less than 30m, the unit can be supplied with lighter force pre-tensioning springs. PRE-TENSIONING FORCE VS. ACTUATION FORCE The actuating force is a function of the: trip-wire span pre-tensioning spring set pre-tensioning force as shown. Units are available with lighter springs for trip-wire spans of less than 30m. Please see ordering details under AVAILABLE OPTIONS

134 ZS75 Heavy-Duty Emergency Cable-Pull Switches Meet EN 418 Features & Benefits Rugged, corrosion-resistant, die-cast aluminum housing tolerates the most hostile environments. Positive-break NC contacts assure circuit interruption upon pulling of trip wire. Watertight design meets IP65 requirements. Continuous E-stop protection for supported trip-wire spans up to 164 feet (50m). Meets rigid safety agency standards EN 418 Available in four operating force models for application compatibility. Mounting accessories ease and extend installation. Satisfies OSHA push/pull operating requirements trips if cable is pulled or goes slack. Explosion protected optional IEC-rated explosion-proof models available. Signal lamp optional lamp signals tripped and latched condition. Description The ZS75 is designed to provide a continuous emergency stop along exposed areas of machinery and conveyors which present hazards to operators/maintenance personnel. Unlike E-stop pushbuttons, emergency stop cable-pull systems can be actuated at any point along the trip-wire. The units feature positive-opening NC contacts which are forced open when the trip-wire is pulled. This design also assures machine stoppage if an operator falls into, leans on, or is pulled against the trip wire. In addition the switch is designed to operate if the trip wire is cut or goes slack. To comply with OSHA and other safety regulations, the ZS75 features a manual mechanical reset which must be actuated before the controlled equipment can be restarted. Their rugged metal housing and watertight design (IP65) make them ideal for achieving a higher degree of E-stop safety in industrial and hostile environments. Operation The ZS75 features an axial actuating shaft and up to two double-pole contact blocks. When installed, the trip-wire is pre-tensioned until the actuating shaft is pulled out 6 mm, closing the NO contact(s). When the trip-wire is pulled, the positive-break NC contact(s) are forced open via a direct mechanical linkage with the actuating shaft. If the trip-wire goes slack (e.g. breaks or is cut) the NO contacts, closed during pre-tensioning, open resulting in equipment stoppage. Manual pushbutton reset assures the equipment cannot be restarted until the reset is actuated. Typical Applications The ZS75 emergency cable-pull switches are ideal for replacing multiple, discrete E-stop pushbuttons or achieving a continuous, immediately accessible emergency stop. Typical applications include conveyor lines, textile machinery, packaging machinery, turret lathes, power plants, gravel processing and transfer lines. 134 is a trademark of SCHMERSAL

135 ZS75 AVAILABLE MODELS AND ACCESSORIES Part Number ZS75-20/2S WVD-98N* ZS75-20/2S WVD-177N* ZS75-20/2S WVD-275N* ZS75-20/2S WVD* ZS75-20/2S WVS-98N* ZS75-20/2S WVS-177N* ZS75-20/2S WVS-275N* ZS75-20/2S WVS* ZS75-40 WVD-98N ZS75-40 WVD-177N ZS75-40 WVD-275N ZS75-40 WVD ZS75-40 WVS-98N ZS75-40 WVS-177N ZS75-40 WVS-275N ZS75-40 WVS Contact Configuration 2 NO & 2 NC 2 NO & 2 NC 2 NO & 2 NC 2 NO & 2 NC 2 NO & 2 NC 2 NO & 2 NC 2 NO & 2 NC 2 NO & 2 NC 4 NC 4 NC 4 NC 4 NC 4 NC 4 NC 4 NC 4 NC AVAILABLE STANDARD MODELS Type Reset Pushbutton Pushbutton Pushbutton Pushbutton Key Key Key Key Pushbutton Pushbutton Pushbutton Pushbutton Key Key Key Key Pre-Tensioned Force lbs (79-98N) lbs ( N) lbs ( N) lbs ( N) lbs (79-98N) lbs ( N) lbs ( N) lbs ( N) lbs (79-98N) lbs ( N) lbs ( N) lbs ( N) lbs (79-98N) lbs ( N) lbs ( N) lbs ( N) Typical Actuating Force (F) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) lbs (5-8N) lbs (19-25N) lbs (33-41N) lbs (38-60N) Recommended Cable Length (Minimum & Maximum) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) <33 ft (<10m) ft (10-20m) ft (20-30m) ft (30-50m) *Available in an IEC-rated explosion-proof design. To order, add prefix EEX to part number. 4 AVAILABLE ACCESSORIES Part Number Description PL-M25-24V 24V Pilot light kit PL-M25-120V STQ441-SC STQ441-EB STQ441-CC STQ441-TB STQ441-TH STQ441-PU New! S V Pilot light kit 5mm diameter steel cable, PVC coated M10 eye bolt & hex nut Cable clamp Turnbuckle Thimble Pulley assembly (for cable "cornering") Cable-Pull Switch Wire Tensioner (see page 150) For recommended installation instructions, please see page

136 ZS75 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Degree of Protection Die-cast aluminum, color-painted IP65 (pushbutton reset) IP54 (key reset) 164 feet (50m) Maximum Supported Span Typical Deflection (S) 5.1" (13cm) Required for Operation Mechanical Life Operating Temperature Conformity to Standards UL CSA BG EN 418 IEC EN Explosion Protection 1 million operations 13 F to +158 F ( 25 C to +70 C) E Ex dll CT6 ( Ex models only) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges 6A/400VAC Snap-action, positive-break NC contacts (with wire pulling) 6A (Slow blow) 400VAC Screw terminals with clamping washers DIMENSIONS Pushbutton Reset Key Reset , , M mm inch SWITCHING DIAGRAMS & CONTACT SCHEMATICS T( C) ZS75-20/2S l (m) Cable length vs. temperature range ZS75-40 At 5m distance, intermediate wire supports are required. See accessories. 136

137 ZS75 INSTALLATION DETAILS PRE-TENSIONING ADJUSTMENT To ensure positive-break operation, the switch should be pinned through the holes shown (1). The trip-wire should be pre-tensioned to the point where the linear switch actuating cam is in the middle position (3). The standard 395N axial pulling force required for pre-tensioning can be reduced by adjusting the grooved nut (2). For trip-wire spans of less than 30m, the unit can be supplied with lighter force pre-tensioning springs. PRE-TENSIONING FORCE VS. ACTUATION FORCE The actuating force is a function of the: trip-wire span pre-tensioning spring set pre-tensioning force as shown. Units are available with lighter springs for trip-wire spans of less than 30m. Please see ordering details under AVAILABLE OPTIONS

138 Series ZS441 Heavy-Duty Emergency Cable-Pull Switch Meets EN 418 Typical Applications ZS441 emergency cable-pull switches are ideal for replacing multiple, discrete E-stop pushbuttons or achieving a continuous, immediately accessible emergency stop. Typical applications include conveyor lines, textile machinery, packaging machinery, turret lathes, power plants, gravel processing and transfer lines. Features & Benefits Rugged, corrosion-resistant, die-cast aluminum housing tolerates the most hostile environments. Positive-break NC contacts assure circuit interruption upon pulling of trip wire. Watertight design meets IP65 requirements. Continuous E-stop protection for trip-wire spans up to 82 feet (25m). Meets rigid safety agency standards EN 418 Available in three reset styles pushbutton, key and non-reset. Available in three operating force models for application compatibility. Mounting accessories ease and extend installation. Built-in vibration tolerance eliminates nuisance tripping. Push/pull operation actuates if trip-wire is pulled or goes slack. Description The ZS441 Series is designed to provide a continuous emergency stop along exposed areas of machinery and conveyors which present hazards to operators/maintenance personnel. Unlike E-stop pushbuttons, emergency stop cablepull systems can be actuated at any point along the trip-wire. The units feature positive-opening NC contacts which are forced open when the trip-wire is pulled. This design also assures machine stoppage if an operator falls into, leans on, or is pulled against the trip wire. In addition the switch is designed to operate if the trip wire is cut or goes slack. To comply with OSHA and other safety regulations, the ZS441 features a manual mechanical reset which must be actuated before the controlled equipment can be restarted. Their rugged metal housing and watertight design (IP65) make them ideal for achieving a higher degree of E-stop safety in industrial and hostile environments. Operation The ZS441 features an axial actuating shaft and a doublepole contact block with 1 NO/1 NC or 2 NC contacts (with tripwire attached). When installed, the trip-wire is pre-tensioned until the actuating shaft is pulled out 6 mm, closing the open contact. When the trip-wire is pulled, the positive-break NC contact is forced open via a direct mechanical linkage with the actuating shaft. If the trip-wire goes slack (e.g. breaks or is cut) the NO contact, closed during pre-tensioning, opens resulting in equipment stoppage. Manual (key or pushbutton) reset mechanisms assure the equipment cannot be restarted until the reset is actuated. 138 Part Number PL-M20-24V PL-M20-120V STQ441-SC STQ441-EB STQ441-CC STQ441-TB STQ441-TH STQ441-PU New! S900 AVAILABLE ACCESSORIES 24V Pilot light kit 120V Pilot light kit Description 5mm diameter steel cable, PVC coated M10 eye bolt & hex nut Cable clamp Turnbuckle Thimble Pulley assembly (for cable "cornering") Cable-Pull Switch Wire Tensioner (see page 150) For recommended installation instructions, please see page 141. is a trademark of SCHMERSAL

139 ZS441 AVAILABLE MODELS AND ACCESSORIES Part Number Contact Configuration AVAILABLE STANDARD MODELS Type Reset Pre-Tensioned Force Typical Actuating Force (F) Recommended Cable Length (Minimum & Maximum) ZS441-10/1S-60N 1 NO & 1 NC Non-Reset 13.5 lbs (60N) 1.3 lbs (6N) ft (0-5m) ZS441-10/1S-150N 1 NO & 1 NC Non-Reset 34 lbs (150N) 3.1 lbs (14N) ft (5-15m) ZS441-10/1S 1 NO & 1 NC Non-Reset 50 lbs (220N) 5.2 lbs (23N) ft (15-25m) ZS441-10/1SVD-60N 1 NO & 1 NC Pushbutton 13.5 lbs (60N) 1.3 lbs (6N) ft (0-5m) ZS441-10/1SVD-150N 1 NO & 1 NC Pushbutton 34 lbs (150N) 3.1 lbs (14N) ft (5-15m) ZS441-10/1SVD 1 NO & 1 NC Pushbutton 50 lbs (220N) 5.2 lbs (23N) ft (15-25m) ZS441-10/1SVS-60N 1 NO & 1 NC Key 13.5 lbs (60N) 1.3 lbs (6N) ft (0-5m) ZS441-10/1SVS-150N 1 NO & 1 NC Key 34 lbs (150N) 3.1 lbs (14N) ft (5-15m) ZS441-10/1SVS 1 NO & 1 NC Key 50 lbs (220N) 5.2 lbs (23N) ft (15-25m) ZS N 2 NC Non-Reset 13.5 lbs (60N) 1.3 lbs (6N) ft (0-5m) ZS N 2 NC Non-Reset 34 lbs (150N) 3.1 lbs (14N) ft (5-15m) ZS NC Non-Reset 50 lbs (220N) 5.2 lbs (23N) ft (15-25m) ZS441-20VD-60N 2 NC Pushbutton 13.5 lbs (60N) 1.3 lbs (6N) ft (0-5m) ZS441-20VD-150N 2 NC Pushbutton 34 lbs (150N) 3.1 lbs (14N) ft (5-15m) ZS441-20VD 2 NC Pushbutton 50 lbs (220N) 5.2 lbs (23N) ft (15-25m) ZS441-20VS-60N 2 NC Key 13.5 lbs (60N) 1.3 lbs (6N) ft (0-5m) ZS441-20VS-150N 2 NC Key 34 lbs (150N) 3.1 lbs (14N) ft (5-15m) ZS441-20VS 2 NC Key 50 lbs (220N) 5.2 lbs (23N) ft (15-25m) T( C) l (m) Cable length vs. temperature range 139

140 ZS441 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing (Standard) Die-cast aluminum with baked enamel finish Housing (Optional) Cast iron Degree of Protection IP65 (pushbutton reset) IP54 (key reset) Maximum Supported 80 feet (25m) Span Typical Deflection (S) 4" (10cm) Required for Operation Operating Temperature 22 F to +195 F Mechanical Life operations Conformity to Standards IEC UL EN CSA EN418 DIN VDE ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges 6A (Slow-blow) Snap-action, positive-break NC contacts (with wire pulling) Fuse 25A (time-delay) 400VAC Screw terminals with self-lifting clamps for up to 13 AWG flexible stranded wire (2.5 mm 2 ) SWITCHING DIAGRAMS & CONTACT SCHEMATICS DIMENSIONS Non-Reset Pushbutton Reset ø ø Key Reset SW SW M M mm inch 140

141 ZS441 TECHNICAL DATA Recommended Emergency Cable-Pull Switch Installation Instructions (For ZS71, ZS73, ZS75 and ZS441 models) See page 150 for new S900 Cable-Pull Switch Wire Tensioner (not shown above) 4 Part # S900 - Tensioner Replaces turnbuckle & cable clamps New! 141

142 ZS75S Bidirectional Heavy-Duty Bidirectional Emergency Cable-Pull Switch Typical Applications ZS75S emergency rope-pull switches are ideal for replacing multiple, discrete E-stop pushbuttons or achieving a continuous, immediately accessible emergency stop. Typical applications include conveyor lines, textile machinery, packaging machinery, turret lathes, power plants, gravel processing and transfer lines. Description ZS75S is designed to provide a continuous emergency stop along exposed areas of machinery and conveyors which present hazards to operators/maintenance personnel. Unlike E-stop pushbuttons, emergency stop cable-pull systems can be actuated at any point along the trip-wire. The units feature positive-opening NC contact(s) which are forced open when the trip-wire is pulled. This design also assures machine stoppage if an operator falls into, leans on, or is pulled against the trip-wire. To comply with OSHA and other safety regulations, the ZS75S features a manual mechanical reset which must be actuated before the controlled equipment can be restarted. In addition the switch is designed to fail-to-safe if the trip wire is cut or goes slack. Their rugged metal housing and watertight design (IP65) make them ideal for achieving a higher degree of E-stop safety in industrial and hostile environments. An optional signal lamp enables distance viewing of switch status. Operation Available with 2 NO & 2 NC or 4 NC contacts, the ZS75S is designed to mount between two trip-wires. When either trip-wire is pulled, the positive-break NC contact(s) are forced open via a direct mechanical linkage with the actuating lever. If either trip-wire goes slack (e.g. breaks or is cut), the tension spring of the other trip wire pulls the actuating lever also forcing the NC contacts to open. When actuated, the switch remains latched until manually reset via a pushbutton or key. (An optional signal lamp is also available.) Manual reset assures the equipment cannot be restarted until actuated. Features & Benefits Rugged, corrosion-resistant, die-cast aluminum housing tolerates the most hostile environments. Positive-break NC contacts assure circuit interruption upon pulling of trip wire. Watertight design meets IP65 requirements. Continuous E-stop protection for trip-wire spans up to 164 feet (50m). Meets rigid safety agency standards EN418 Available in two operating force models for application compatibility. Mounting accessories ease and extend installation. Satisfies OSHA push-pull operating requirements trips if cable is pulled or goes slack. Signal lamp optional lamp signals tripped and latched condition. Part Number ZS75S-20/2S VD ZS75S-40 VD ZS75S-20/2S VS AVAILABLE STANDARD MODELS 2 NO & 2 NC 4 NC 2 NO & 2 NC ZS75S-40 VS 4 NC Note: Pilot lamp option available for all above models. Add suffix G24 (24VDC) Part Number PL-M25-24V PL-M25-120V STQ441-SC STQ441-EB STQ441-CC STQ441-TB STQ441-TH STQ441-PU Contact Configuration AVAILABLE ACCESSORIES 24V Pilot light kit 120V Pilot light kit Type Reset Pushbutton Key 5mm diameter steel cable, PVC coated M10 eye bolt & hex nut Cable clamp Turnbuckle Thimble Description Pulley assembly (for cable cornering ) 142 is a trademark of SCHMERSAL STQ441-SS Stainless spring New! S900 Cable-pull switch wire tensioner (see page 150) For recommended installation instructions, please see page 144.

143 ZS75S BIDIRECTIONAL TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Degree of Protection Actuating Force Die-cast aluminum, color-painted IP65 (pushbutton reset) IP54 (key reset) Depends upon wire span and model 165 feet (50m) in each direction Maximum Supported Span Mechanical Life Operating Temperature Conformity to Standards UL CSA BG EN 418 IEC EN million operations 13 F to +158 F ( 25 C to +70 C) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges 6A/400VAC Snap-action, positive-break NC contacts (with wire pulling) 6A (Slow blow) 400VAC Screw terminals with clamping washers DIMENSIONS 4 SWITCHING DIAGRAMS & CONTACT SCHEMATICS ZS75-20/2S ZS

144 ZS75S BIDIRECTIONAL TECHNICAL DATA RECOMMENDED INSTALLATION DETAILS Mounting Instructions Cable Pull Switches Series ZS75S Bidirectional Part # S900 - Tensioner Replaces turnbuckle & cable clamps New! See page 150 for new S900 Cable-Pull Switch Wire Tensioner (not shown above) 144

145 4 Safer by Design 145

146 ZS80 Emergency Cable-Pull Switch (Meets EN 418) New! Features & Benefits Rugged, corrosion-resistant housing tolerates hostile environments. Positive-break NC contacts assures circuit interruption upon pulling of trip-wire. Push/pull operation operates if trip-wire is pulled or goes slack. Integrated emergency-stop button assures complete emergency stop. Watertight design meets IP67 environmental requirements. Continuous E-stop protection for supported spans up to 164 feet (50m). Visual position indicator for ease of installation. Lever for reset and position indication. Four contacts in a compact housing available in three contact configurations. Meets rigid safety standards EN 418, UL/CSA & BG pending. Mounting accessories ease and extend installation. Description The ZS80 is designed to provide continuous emergency stop control along exposed areas of machinery and conveyors which present hazards to operator/maintenance personnel. Unlike E-Stop pushbuttons, emergency cable-pull systems can be actuated at any point along the trip wire. The unit features a double-break contact block offering a choice of two positive-opening NC contacts and two NO contacts, three positive-opening NC contacts and one NO contact, or four positive-opening NC contacts which change state when the cable is pulled or goes slack. Thus the switch can be actuated if an operator falls into, is pulled into, or leans on the trip wire. In addition the unit features an integrated E-Stop pushbutton, a position indicator for easier installation, a lever-actuated reset, three cable entries, and an optional signaling lamp. The unit is capable of spanning lengths of up to 50 meters. Its rugged, metal housing and watertight design (IP 67) make them ideal in hostile environments. The units meet EN 418, IEC/EN , and IEC/EN , with UL and CSA pending. Operation The ZS80 features an axial actuating shaft and double-break 2A-rated contacts with either 2 NC and 2 NO contacts, 3 NC and 1 NO contacts, or 4 NC contacts (with trip-wire pre-tensioned). When the trip-wire is pulled, the positive-opening NC contact(s) are forced to open via a direct mechanical linkage with the actuating shaft resulting in machine stoppage. If the trip-wire goes slack (e.g. breaks or is cut) the NC contact(s) opens also resulting in equipment stoppage. The integral lever-actuated reset mechanism assures that the equipment cannot be restarted until the cable-pull switch reset has been actuated. Typical Applications The ZS80 is ideal for replacing multiple, discrete E-stop pushbuttons or achieving a continuous, immediately accessible emergency stop especially where space is limited. Typical applications include conveyor lines, textile machinery, packaging machinery, and transfer lines. 146 is a trademark of SCHMERSAL

147 ZS80 AVAILABLE MODELS AND ACCESSORIES Part Number ZS80-2O/2S WVD ZS80-3O/1S WVD ZS80-40 WVD Contact Configuration 2 NO & 2 NC 1 NO & 3 NC 4 NC AVAILABLE STANDARD MODELS Pre-Tensioned Force Typical Actuating Force (F) Recommended Cable Length (Maximum) 22 lbs (100N) 9.2 lbs (41N) 165 ft (50m) 22 lbs (100N) 9.2 lbs (41N) 165 ft (50m) 22 lbs (100N) 9.2 lbs (41N) 165 ft (50m) AVAILABLE ACCESSORIES Part Number Description PL-M20-24V 24V Pilot light kit PL-M20-120V STQ441-SC STQ441-EB STQ441-CC STQ441-TB 120V Pilot light kit 5mm diameter steel cable, PVC coated M10 eye bolt & hex nut Cable clamp Turnbuckle STQ441-TH Thimble STQ441-PU Pulley assembly (for cable cornering ) New! S900 Cable-pull switch wire tensioner (see page 150) 4 147

148 ZS80 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Cover Degree of Protection Maximum Supported Span Operating Temperature Mechanical Life Conformity to Standards Die-cast aluminum, enamel finish Fiberglass reinforced thermoplastic cover (ULTRAMID A3X2G5, Black) IP feet (50m) 4 F to +158 F ( 20 C to +70 C) 1 million operations CE EN 418 BG/UL/CSA Pending ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges 2A/250VAC Slow-action, positive-break NC contacts with wire pull 6A (Slow blow) 250VAC Screw terminals with self-lifting clamps for up to 13 AWG flexible stranded wire (2.5mm 2 ) T( C) DIMENSIONS l (m) Cable length vs. temperature range SWITCHING DIAGRAMS & CONTACT SCHEMATICS ZS80 2O/2S ZS80 3O/1S ZS80 4O 148

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150 S900 Cable-Pull Switch Wire Tensioner Features & Benefits Smooth adjustment reduces adjustment effort. Only one tool required simplifies installation. Anti-slip design reduces need for readjustment. Ergonomic risk of injury is reduced. Time-saving cost of ownership is reduced. AVAILABLE MODEL Model Number S900 Description Cable Pull Wire Tensioner Description The S900 is a unique wire tensioning device which simplifies the installation and adjustment of cable pull switches. Conventional systems are usually time consuming and difficult to install and adjust. The S900 eliminates the need for a turnbuckle and at least 3 cable clamps. Note: The S900 wire tensioner works with any emergency cable-pull switch. The cable-pull switch is purchased separately. DIMENSIONS 150

151 4 Safer by Design 151

152 152 Safer by Design

153 NON-CONTACT SAFETY SENSORS These rugged presence-sensing devices feature a sealed (IP67) housing, making them ideal interlocks in hostile environments. Their tamper-resistant design and small size make them attractive alternatives to conventional proximity sensors, magnetic switches, and limit switches. Used with SCHMERSAL s matched safety circuit monitors, they allow achieving the highest levels of machine safety. New! New! Sensor Series SELECTION GUIDE Approximate Envelope Dimensions Operating Voltage Contact Configuration(s) BNS " 1.4" 0.5" 24VDC 1 NO & 1 NC 1 NO & 2 NC BNS " 1.4" 0.5" 24VDC 1 NO & 1 NC 1 NO & 2 NC 3NC Catalog Page No. BNS33 3.5" 1.0" 0.5" 24VAC/DC 1 NO & 1 NC 120VAC/DC 1 NO & 2 NC 1 NO NC 2 NC New! BNS33S.625" 3.5" 1" 24VDC 100VAC/DC 1 NO & 2 NC 162 BNS " 0 100VAC/DC 1 NO & 1 NC 1 NO & 2 NC 164 BNS30 & BNS " 0 24VDC 1 NC 166 BNS " 1.7" 1.7" 24VDC 1 NC 168 BNS " 2" 3" 100VAC/DC 2 NC 1 NO & 2 NC 170 BZ " 2" 3" 24VDC 1 NO & I NC 172 New! BNS-B20 NA 24VDC 2 PNP 174 New! CSS " 3.6" 24VDC 1 NO & I NC 176 New! CSS 34 1" 4" 1" 24VDC 2 PNP 184 Coded-Magnet Sensor Compatible AES Safety Controllers

154 SERIES BNS250 Coded-Magnet Sensors Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Integral LED status indicators facilitate easy installation and provide visual indication of switch status. Shock and vibration tolerant designed to withstand mechanical abuse. Satisfy CE & fail-to-safe requirements when used with Series AES safety controllers. Description The Series BNS250 coded-magnet sensors are designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. Both switch and magnet assemblies are sealed to IP67 (submersible) standards. Their tamper-resistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features a 1- meter long prewired pigtail. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. Typical Applications The sealed, compact BNS250 is ideal for use on movable machine guards in hostile environments. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. Part Number BNS250-11z BNS250-12z BNS250-11zG BNS250-12zG BNS250-11zG-2205 (side entry cable) AVAILABLE STANDARD MODELS (Please order BPS250 magnet separately) Contact Configuration* 1 NO & 1 NC 1 NO & 2 NC 1 NO & 1 NC 1 NO & 2 NC 1 NO & 1 NC Description Multiple reed switch (100VAC/DC) assembly with 1-meter prewired pigtail Multiple reed switch (24VDC/10mA) assembly with 1 meter prewired pigtail and built-in LED display Multiple reed switch (24VDC/10mA) assembly with 5 meter pigtail (side entry) and built-in LED display BPS250 N/A Coded-magnet actuator *Contact configuration in presence of BPS250 coded-magnet actuator. *Important Note: Series BNS Coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series AES safety controller. (Please see selection chart on Page 189.)! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY. 154

155 BNS250 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Switching Distance S * On : 4mm (0.16") Off : 14mm (0.55") Degree of Protection IP67 Operating Temperature 13 F to +158 F Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE, UL, CSA VDE 0660 Part 209 *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS Maximum Operating Voltage 100VAC/DC 24VDC for -11zG or -12zG versions Maximum Continuous 100 ma (BNS250-11z/12z) Current Rating 10 ma (BNS250-11zG/12zG) Maximum Switching 1W (BNS250-11z/12z) Capacity (Power Rating) 240mW (BNS250-11zG/12zG) Type Connection* 1 meter long LiYY4* 0.25mm 2 (23AWG) pre-wired pigtail *Longer prewired cables (3M, 5M, or 10M lengths) available on request. Please consult factory. DIMENSIONS ø4, , , ø4,5.18 mm inch Note: BNS250 reed switch assemblies should be mounted at least 50mm (2") apart. WIRING DETAILS BNS250-11z BNS250-12z BNS250-11zG BNS250-12zG 13 (black) 21 (white) 14 (blue) 22 (brown) 13 (black) 21 (white) 14 (blue) C (brown) 13 (black) 21 (white) 14 (blue) 22 (brown) 13 (black) 21 (white) 14 (blue) C (brown) 5 Contacts shown with gate closed MISALIGNMENT ALLOWANCE 155

156 SERIES BNS260 Coded-Magnet Sensors Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Integral LED status indicators facilitate easy installation and provide visual indication of switch status. Shock and vibration tolerant designed to withstand mechanical abuse. Satisfy CE & fail-to-safe requirements when used with Series AES safety controllers. Description The Series BNS260 coded-magnet sensors are designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. Both switch and magnet assemblies are sealed to IP67 (submersible) standards. Their tamper-resistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features a 1-meter long prewired pigtail or an available connector. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. AVAILABLE BNS260 CODED-MAGNET SENSORS Ordering Details (Order BPS260 Actuator below) BNS260- Z - - Safety Contacts Signalling Contacts 11 (1 NO/1 NC) 02 (2 NC) Leave blank (no signalling contact) /01 (1 NC) Leave blank (without LED) G (with LED) L (Left hand hinge) R (Right hand hinge) Leave blank (Cable) ST (Connector) Ordering example: To order a BNS260 with 1NO/1NC safety contacts, a NC signaling contact, LED left hand hinge and cable order p/n BNS260-11/01ZGL CODED MAGNET ACTUATORS & ACCESSORIES Typical Applications The sealed, compact BNS260 is ideal for use on movable machine guards in hostile environments. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. Note: 4 pole models accept either a screw-on or snap-on connector. 6 pole models accept only a snap-on connector. Model Number BPS260-1 BPS260-2 BNS260 M8S-4P-XX M8S-6P-XX M8SRA-4P-XX M8SRA-6P-XX Description Standard Actuator Actuator for 90 operation Spacer for mounting reed switch or magnet on ferrous material Straight snap-on connector. Available -2m, -5m and -10m lengths Right angle snap-on connector. Available -2m, -5m and -10m lengths *Important Note: Series BNS Coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series AES safety controller. (Please see selection chart on Page 189.) 156! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY.

157 BNS260 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Switching Distance S * On : 5mm (0.2") Off : 15mm (0.6") Degree of Protection IP67 Operating Temperature 13 F to +158 F Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE, VDE 0660 Part 209 *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS Maximum Operating Voltage 75VAC/DC 24VDC for LED versions Maximum Continuous 400 ma without LED Current Rating 10 ma with LED Maximum Switching 10va without LED 240mW with LED Type Connection* 1 meter long LiYY4* 0.25mm 2 (23AWG) pre-wired pigtail or M8 4 or 6 pin connector (ST) *Longer prewired cables (3M, 5M, or 10M lengths) available on request. Please consult factory. DIMENSIONS BNS260 BPS260 mm Note: BNS260 reed switch assemblies should be mounted at least 50mm (2") apart. WIRING DETAILS (Contact configuration shown in presence of BPS260 Coded-magnet actuator) BNS260-02z(G) Contacts shown with gate closed BNS260-02/01z(G) BNS260-11z(G) BNS260-11/01z(G) 5 QUICK-CONNECT DIAGRAMS BNS260 4-Pole MISALIGNMENT ALLOWANCE BNS260 6-Pole 157

158 SERIES BNS33 Coded-Magnet Sensors Description The Series BNS33 coded-magnet sensors are designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. Both switch and magnet assemblies are sealed to IP67 (submersible) standards (IP69K for BNS33S). Their tamperresistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features an optional built-in LED display of switch status, and a 1-meter long prewired pigtail to assure sealing integrity. Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Integral LED status indicators facilitate easy installations and provide visual indication of switch status. Shock and vibration tolerant designed to withstand mechanical abuse. Satisfy EN954, Category 1, 3, or 4 when used with appropriate Series AES safety controllers. Optional high-strength field coded-magnets extends sensing range to 10mm. Units available with M8 quick-connect. (Please consult factory). Available stainless steel housing (BNS33S) ideal for the food industry. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. Typical Applications The sealed, compact BNS33 is ideal for use on movable machine guards in hostile environments or where space is limited. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. Required Safety Controller. *Important Note: Series BNS coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series AES safety controller. (Please see selection chart on Page 189.)! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY. 158

159 BNS33 AVAILABLE MODELS AND ACCESSORIES Part Number BNS33-11z** BNS33-12z*** BNS33-11zG** BNS33-12zG*** BNS33-12z-2187** AVAILABLE STANDARD MODELS (Please order BPS33 or BPS magnet separately) Contact Configuration* 1 NO & 1 NC 1 NO & 2 NC 1 NO & 1 NC 1 NO & 2 NC 1 NO & 2 NC Maximum Contact Rating 100VAC/DC (400mA) 24VDC (10mA) 120VAC/DC (250mA) Description Multiple reed switch assembly with 1-meter prewired pigtail Multiple reed switch assembly with 1-meter prewired pigtail and built-in LED display Multiple reed switch assembly with 1-meter prewired pigtail AVAILABLE ACCESSORIES Part Number Description BN31/33 M8ST-2M M8ST-5M M8ST-10M M8ST-15M M8ST-RA-2M M8ST-RA-5M BNS-SS-CVR BPS-SS-CVR Shim plate for mounting reed switch assembly on ferrous material Straight quick-connect with 2M cable Straight quick-connect with 5M cable Straight quick-connect with 10M cable Straight quick-connect with 15M cable Right-angle quick-connect with 2M cable Right-angle quick-connect with 5M cable Stainless-steel protective cover for BNS33-xxx Stainless-steel protective cover for BPS33-xxx BNS33S-12z** BNS33S-12zG** New! New! 1 NO & 2 NC 1 NO & 2 NC 100VAC/DC (250mA) 24VDC (10mA) Multiple reed switch assembly with 1-meter prewired pigtail and stainless steel enclosure Coded Magnet Sensor BPS33 N/A N/A Coded-magnet actuator (5mm sensing distance) BPS N/A N/A BPS33S N/A N/A New! BNS33-11z-ST** BNS33-11zG-ST** BNS33-12z-ST*** BNS33-12zG-ST*** 1NO & 1NC 1NO & 1NC 1NO & 2NC 1NO & 2NC 60VAC/DC (400mA) 24VDC (10mA) 60VAC/DC (400mA) 24VDC (10mA) Coded-magnet actuator (10mm sensing distance) Stainless steel coded-magnet actuator Multiple reed switch assembly with M8x1 quick-connect Multiple Reed Switch Assembly Safety Controller Coded-Magnet Sensor and Safety Controller sold separately. 5 *Contact configuration in presence of BPS33 coded-magnet actuator. **These models feature isolated contacts. ***These models feature C-form contacts. Note: Longer prewired cables (3M, 5M, or 10M lengths) available on request. Please consult factory. Note: SPEZ-2237 for sliding doors is available for BNS33-11z and -11zG only. Contact factory for more information. 159

160 BNS33 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Switching Distance S * On : 5mm (0.2") Off : 15mm (0.6") On : 8mm (0.3") (For BNS33S only) Off : 18mm (0.7") (For BNS33S only) Degree of Protection IP67 (BNS33S: IP69k) Operating Temperature 13 F to +158 F (+178 F for BNS33S) Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE, UL, CSA VDE 0470 Part 1 IEC 529/EN60529 *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS For electrical ratings see page 139 Type Connection* 1 meter long LiYY4* 0.25mm 2 (23AWG) pre-wired pigtail. M8x1 quick-connect for versions with ST suffix *Longer prewired cables available on request. Please consult factory. BPS33 MISALIGNMENT ALLOWANCE BNS33S MISALIGNMENT ALLOWANCE 160

161 BNS33 TECHNICAL DATA DIMENSIONS 88 Note: 27mm width and 14.5mm depth for BNS33S/BPS33S M , ,5.02 ø5.02 DIA 18,5.073 BNS33 with Quick- Connect Terminal 4, Note: BNS33 reed switch assemblies should be mounted at least 50mm (2") apart. WIRING DETAILS 5 Quick-Connect for BNS33-11 units Quick-Connect for BNS33-12 units Contacts shown with gate closed Pins 1-2 are Normally-closed Pins 3-4 are Normally-open Pin 1: Common Pins 2 & 4 are Normally-closed Pin 3 is Normally-open 161

162 SERIES BNS33S Stainless Steel Coded-Magnet Sensors New! Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Integral LED status indicators facilitate easy installations and provide visual indication of switch status. Shock and vibration tolerant designed to withstand mechanical abuse. Satisfy EN954, Category 1, 3, or 4 when used with appropriate Series AES safety controllers. Stainless steel housing ideal for the food industry. Description The Series BNS33S coded-magnet sensor is designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. Both switch and magnet assemblies are sealed to IP69K standards. Their tamper-resistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features an optional built-in LED display of switch status, and a 1-meter long prewired pigtail to assure sealing integrity. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. Part Number BNS33S-12z** BNS33S-12zG** AVAILABLE STANDARD MODELS (Please order BPS33S magnet separately) Contact Configuration* 1 NO & 2 NC 1 NO & 2 NC Maximum Contact Rating 100VAC/DC (250mA) 24VDC (10mA) BPS33S N/A N/A Description Multiple reed switch assembly with 1-meter prewired pigtail and stainless steel enclosure Stainless steel coded-magnet actuator *Contact configuration in presence of BPS33S coded-magnet actuator. **These models feature isolated contacts. Note: Longer prewired cables (3M, 5M, or 10M lengths) available on request. Please consult factory. Typical Applications The sealed, compact BNS33S is ideal for use on movable machine guards in hostile environments or where space is limited. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. *Important Note: Series BNS coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series AES safety controller. (Please see selection chart on Page 189.)! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY. 162

163 BNS33S TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Type V4A (316L) stainless steel Switching Distance S * On : 8mm (0.3") Off : 18mm (0.7") Degree of Protection IP69k Operating Temperature 13 F to +178 F Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE, UL, CSA VDE 0470 Part 1 IEC 529/EN60529 *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS For electrical ratings see page Type Connection* 1 meter long LiYY4* 0.25mm 2 (23AWG) pre-wired pigtail. *Longer prewired cables available on request. Please consult factory. DIMENSIONS Note: BNS33 reed switch assemblies should be mounted at least 50mm (2") apart. WIRING DETAILS BNS33S MISALIGNMENT ALLOWANCE 5 Contacts shown with gate closed 163

164 SERIES BNS303 Coded-Magnet Sensors Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Shock and vibration tolerant designed to withstand mechanical abuse. Satisfy EN954, Category 4 when used with appropriate safety controller. Description The Series BNS303 coded-magnet sensors are designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. Both switch and magnet assemblies are sealed to IP67 (submersible) standards. Their tamper-resistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features an integral built-in LED display of switch status, and a 1-meter long prewired pigtail. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. AVAILABLE STANDARD MODELS (Please order BPS300 or BPS303 magnet separately) Part Number BNS303-11z BNS303-12z BNS303-11zG BNS303-12zG BPS300 BPS303** Contact Configuration* 1 NO & 1 NC 1 NO & 2 NC 1 NO & 1 NC 1 NO & 2 NC N/A N/A Description Multiple reed switch (100VAC/DC/400mA) assembly with 1-meter prewired pigtail Multiple reed switch (24VDC/10mA) assembly with 1-meter prewired pigtail and built-in LED display Coded-magnet actuator (front mount) Coded-magnet actuator (rear mount) *Contact configuration in presence of BPS300 or BPS303 codedmagnet actuator. **Available with stainless-steel outer jackets. Please consult factory. Typical Applications The sealed, compact BNS303 is ideal for use on movable machine guards in hostile environments. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. *Important Note: Series BNS coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series AES safety controller. (Please see selection chart on Page 189.) BPS300 Actuator BPS303 Actuator**! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY. 164

165 BNS303 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Switching Distance, S * On : 5mm (0.2") Off : 15mm (0.6") On : 8 mm Off : 18mm Suffix 2211 only Degree of Protection IP67 Operating Temperature 13 F to +158 F Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE, UL, CSA VDE 0660 Part 209 EN1088 *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS Maximum Operating Voltage 24VDC (with LED) 100VAC/DC (without LED) Maximum Continuous 10mA (with LED) Current Rating 400mA (without LED) Maximum Switching 10VA Capacity (Power Rating) Type Connection* 1 meter long LiYY4* 0.25mm 2 (23AWG) pre-wired pigtail *Longer prewired cables (3M, 5M, or 10M lengths) available on request. Please consult factory. DIMENSIONS mm inch ø 4, ø x 1, M ø ø ø BPS 303 (Ideal for use in the food industry) Note: BNS303 reed switch assemblies should be mounted at least 50mm (2") apart WIRING DETAILS MISALIGNMENT ALLOWANCE BNS303-11z 13 (black) 21 (white) 14 (blue) 22 (brown) 13 (black) 21 (white) BNS303-11zG 14 (blue) 22 (brown) 22 (black) 32 (white) BNS303-12z 14 (blue) C (brown) BNS303-12zG 13 (black) 21 (white) 14 (blue) C (brown) Contacts shown with gate closed 165

166 SERIES BNS30 & BNS300 Coded-Magnet Sensor with Integral Safety Control Module Description The Series BNS30 and BNS300 coded-magnet sensors are designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. In addition, the Series features an integral monitoring and control circuit which detects faults in the reed switch array (satisfying EN954, Category 1 without use of an ancillary safety relay module). Both switch and magnet assemblies are sealed to IP67 (submersible) standards. Their tamper-resistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features an integral LED display of switch status and a 1-meter long prewired pigtail. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Integral LED status indicators facilitate easy installations and provide visual indication of switch status. Shock and vibration tolerant designed to withstand mechanical abuse. Integral reed switch monitoring & control module detects faults in reed switch array. Satisfies EN954, Safety Category 1. Available in metal (BNS30) or plastic (BNS300) housings for application versatility. AVAILABLE STANDARD MODELS (Please order BPS300 or BPS303 magnet separately) Part Number BNS30-01ZG** and BNS300-01zG** BPS300 BPS303*** Contact Configuration* 1 NC N/A N/A Description Multiple reed switch (24VDC/30mA) assembly with 1-meter prewired pigtail and built-in LED display Coded-magnet actuator (front mount) Coded-magnet actuator (rear mount) *Contact configuration in presence of BPS300 or BPS 303 coded-magnet actuator. **Important Note: The BNS30 and BNS300 are 4-wire sensors designed to satisfy EN954, Category 1 requirements. They are not designed for use with a separate safety controller. ***Available with stainless-steel outer jacket. Please consult factory Typical Applications The sealed, compact units are ideal for use on movable machine guards in hostile environments. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. BPS300 Actuator BPS303 Actuator*** 166

167 BNS300 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic (BNS300) Brass, nickel-plated (BNS30) Switching Distance S * On : 5mm (0.2") Off : 15mm (0.6") Degree of Protection IP67 Operating Temperature 13 F to +158 F Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE, UL, CSA VDE 0660 Part 209 EN954-1 EN1088 BG-GS-ET-14 *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS Maximum Supply Voltage Maximum Continuous Current Rating Maximum Switching Capacity (Power Rating) Type Connection* 24VDC 30mA Voltage: 250VAC Current: 3A (750VA) 1 meter long LiYY4* 0.25mm2 (23AWG) pre-wired pigtail *Longer prewired cables (3M, 5M, or 10M lengths) available on request. Also available with M12x1 quick-connect. Please consult factory. DIMENSIONS & WIRING DETAILS ø2.08 x M ø 4, ø mm inch BN BK BK BU 24 VDC 30 ma BNS zG Note: BNS300 reed switch assemblies should be mounted at least 50mm (2") apart. L+ L- ø ø BPS 300 (Ideal for use in the food industry) 5 MISALIGNMENT ALLOWANCE 167

168 SERIES BNS333 Coded-Magnet Sensors with Integral Safety Control Module Features & Benefits Compact size ideal for limited space applications. Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Rugged, corrosion-resistant housing tolerates most industrial environments. Integral LED status indicators facilitate easy installation and provide visual indication of switch status. Shock and vibration tolerant designed to withstand mechanical abuse. Integral reed switch monitoring/control module detects faults in reed switch array. Satisfies EN954, Category 1. AVAILABLE STANDARD MODELS (Please order BPS300 or BPS303 magnet separately) Part Number Contact Configuration* Description Description The Series BNS333 coded-magnet sensors are designed for use as a safety interlock switch on movable machine guards/articulating robot arms. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The reed switches, wired in series, will only close in the presence of their matched magnetic field array. In addition, the BNS333 features an integral monitoring and control circuit which detects faults in the reed switch array (satisfying EN954, Category 1 without use of an ancillary safety circuit monitoring module). Their tamper-resistant design prevents bypassing with a simple magnet or improperly coded magnetic field. In addition, the BNS module features an optional built-in LED display of switch status. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. BNS333-01YU** BNS333-01YD** BNS333-01YL** BNS333-01YR** BNS333-01YV** BPS300 1 NC N/A Multiple reed switch(24vac/ DC/40mA) assembly with integral switch monitoring and control module. Actuation from rear ( U ) Same as above but actuation from front ( D ) Same as above but actuation from left ( L ) Same as above but actuation from right ( R ) Same as above but actuation from top ( V ) Coded-magnet actuator (front mount) Coded-magnet actuator BPS303*** N/A (rear mount) *Contact configuration in presence of BPS300 or BPS 303 coded-magnet actuator. **The BNS333 is a 4-wire sensor designed to satisfy EN954, Category 1 requirements. It is not designed for use with a separate safety controller. ***Available with stainless steel outer jacket. Please consult factory Typical Applications The sealed, compact BNS333 is ideal for use on movable machine guards in hostile environments. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. BPS300 Actuator BPS303 Actuator*** 168

169 BNS333 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Switching Distance S * On : 4mm (0.16") Off : 14mm (0.55") Degree of Protection IP65 Operating Temperature 13 F to +158 F Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards CE VDE 0660, Part 209 EN EN 1088 BG-GS-ET-1L *Without ferromagnetic material in vicinity of switch or magnet. The proximity of ferrous material may affect switching distances. ELECTRICAL SPECIFICATIONS Maximum Operating Voltage 24VDC Maximum Continuous 40mA Current Rating Maximum Switching Voltage: 250VAC Capacity (Power Rating) Current: 5A (1,250VA) Type Connection Screw terminals DIMENSIONS & WIRING DETAILS ø 4, ø , ø ø ø ,3.29 M20 34, mm inch BPS 333 (Ideal for use in the food industry) VDC 40 ma BNS333-01y L+ L- 5 MISALIGNMENT ALLOWANCE Actuating directions 169

170 SERIES BNS16 Coded-Magnet Sensors Features & Benefits Sealed for submersibility assures long-term reliability in the most hostile environments. Tamper-resistant cannot be bypassed with simple magnets. Satisfies EN954 Category 4 when used with appropriate Series AES safety controller. Shock and vibration tolerant designed to withstand mechanical abuse. Rugged, corrosion-resistant housing tolerates most industrial environments. Long-life no mechanical wear due to non-contact design Same mounting as Series AZ16 ideal alternative in wet, dirty environments. AVAILABLE STANDARD MODELS (BNS16 actuator sold separately) Description The Series BNS16 coded-magnet sensors are designed for use as a safety interlock on movable machine guards. Each sensor set consists of a multiple reed switch unit and a coded-magnet actuator. The sensor outputs will only change state in the presence of their matched magnetic field array. Both switch and magnet assembly are sealed to IP67 (submersible) standards. The unit features the same mounting dimensions as our popular Series AZ16 keyed safety interlock switches... providing an attractive alternative in applications characterized by alignment problems and/or harsh environments. Operation The reed switch assembly is typically mounted to a stationary portion of a guard structure, with the coded-magnet assembly mounted to the movable element of the machine guard. When the guard is closed, and the matched magnetic field aligns with the reed switch unit, the switches will close. When the guard is open, or the required magnetic-field array is not properly aligned with the reed switch assembly, the sensor output will remain off. Typical Applications The sealed, compact BNS16 is ideal for use on movable machine guards in hostile environments or where space is limited. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and articulating robot arm rest position sensing. Part Number BNS16-12ZD BNS16-12ZU BNS16-12ZV BNS16-12ZR BNS16-12ZL BNS16-12ZLR BPS16 Actuator Plane Front cover Back Top Right Left Dual actuation - both Left and Right (2) BPS16 actuators required Coded-magnet actuator Actuating Planes Important Note: Series BNS coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series AES safety controller. (Please see selection chart on Page 189.) Use with any other safety controller may damage sensor and/or void warranty.! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY. 170

171 BNS16 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Switching Distance S * On : 8mm (0.315") Off : 18mm (0.700") Maximum Switching 5H (in combination with Series AES Frequency safety controller) Degree of Protection IP67 per IEC Operating Temperature 25 C to +70 C ( 13 F to +158 F) Operating Principle Magnetic Shock Resistance 30g/11ms Vibration Resistance 10 to 55 Hz, amplitude 1mm Conformity to Standards EN /PDF-M CE *When no ferromagnetic material is present in vicinity of the sensor or actuator. AXIAL TOLERANCE ELECTRICAL SPECIFICATIONS Maximum Contact Rating* 100VAC/DC Maximum Continuous 0.4A Current Rating Maximum Switching 10VA Capacity (Power Rating) Type Connection 3 removable cable entries (M20x1.5) give access to screw terminals with self-lifting clamps for up to 13AWG (2.5mm 2 ) flexible stranded wire. *Inductive loads (e.g. contactors, relays, etc.) are to be suppressed by means of a suitable circuit. DIMENSIONS WIRING DETAILS 1 NO 5 2 NC Contacts shown with gate closed 171

172 SERIES BZ16 Dual-Channel Non-Contact Safety Interlock Switch (with tamper-resistant actuating key) Features & Benefits Tamper-resistant cannot be bypassed with simple magnets. 10 mm actuating distance extends application versatility. Rugged, corrosion-resistant housing tolerates most industrial environments. IP 67 rated ideal for wash-down applications. Shock and vibration tolerant designed to withstand mechanical abuse. Non-contact operation tolerant to minor misalignment. Integral positive-guided relays heightens reliability. AVAILABLE STANDARD MODELS (Includes 1/2" NPT Plastic Adaptor) Actuating Key sold separately... see below Description The BZ16 is a non-contact safety interlock switch with an internal dual-channel design. The assembly consists of the switch and a coded actuating key. The switch can be actuated from the front, top, and rear with each version available with 1 NO/1 NC or 2 NC contacts. Operation When 24VDC is applied to the switch an internal oscillator is energized. The operating frequency is sent to a transmitting solenoid in the active area of the switch. When the actuating key is in the proper location it receives the signal, modifies it, and returns it to the switch. This signal is then sent to a monitoring module. In addition a permanent magnet is located in the actuator. When the actuator is in place, the magnetic field activates a Hall-effect sensor in the active area. This signal is sent to a second monitoring module. Thus this dual-channel device only operates if both channels are actuated concurrently. Any fault in either channel will be recognized by the next switching cycle such that authorized operation is prevented. Part Number BZ16-02D BZ16-02V BZ16-02U BZ16-11D BZ16-11V BZ16-11U BZ16 - B1! Part Number Contact Configuration* 2 NC Description Front Top Rear Front 1 NO & 1 NC Top Rear ACTUATING KEY (Sold separately) Description Actuating Key A SAFETY CONTROLLER MAY BE REQUIRED TO MEET SAFETY CONTROL CATEGORIES 3 OR 4. Typical Applications The BZ16 safety interlock switch is suitable for sliding, hinged, or lift-off safety guards. It is ideal for food processing and other washdown applications. 172

173 BZ16 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Fiberglass reinforced thermoplastic Self-extinguishing Degree of Protection IP67 Actuator Non-contact (via coded actuator) Switching Distance* On : Max. 10mm (Note a minimum distance of 2 mm must be maintained when approaching the switch laterally) Off : Min. 20mm Maximum Switching 1Hz Frequency Operating Temperature 0 C to 55 C Operating Principle Magnetic & Hall Effect Conformity to Standards EN /PDF-M EN 954-1, EN 1088 CE *When no ferromagnetic material is present in the vicinity of the sensor or actuator. ELECTRICAL SPECIFICATIONS Operating Voltage 24VDC ± 15% Contact Configuration 1 NO & 1 NC (or) 2 NC Power Consumption <4W Maximum Switching Voltage 250VAC Maximum Switching 250VAC (max), 1000VA, 4A Capacity DC13, 24VDC, 60W, 2.5A Switching-on time Approx. 200 ms Type Connection Screw terminals with self-lifting clamps (max. 2x2.5mm 2, AWG26-14 solid or stranded wires) (max. 2x1.5mm 2, AWG26-14 with ferrule) DIMENSIONS WIRING DIAGRAM Attention: During mounting the orientation markings on the switch must match with those of the actuating key! } } BZ16-11 BZ The output contact configuration is a function of the model BZ16 selected: BZ16-11 (1NO & 1NC output contacts) or BZ16-02 (2NC output contacts) Contacts shown with gate closed 24VDC (BZ16-11) (BZ16-02) 173

174 SERIES BNS-B20 New! Coded-Magnet Sensor with Safety Door Handle Features & Benefits Tamper-resistant cannot be bypassed with simple magnets Sealed for submersibility assures long-term reliability in the most hostile environments. Dual-function latch & sensor integral magnetic holding latch (with force of 100N). Application flexibility 3-contact design compatible with 35mm, 40mm, and 45mm aluminum profiles Long-life no mechanical wear due to non-contact design. Satisfies EN 954 Safety Control Category 4 when used with compatible SCHMERSAL Series AES safety controller. Easy-to-install optional M12 x 1 quick disconnect & LED status indicator in NC circuit Application diversity suitable for hinged & sliding guards, available for left- or right-hand doors/guards. Integral LED displays switch status (non-led models also available). Description The Series BNS-B20 is designed for use as a combination door handle and safety interlock switch for use on light to medium weight hinged and sliding machine guards. Each unit consists of a door handle assembly equipped with two multiple reed switch arrays and coded magnet actuators. In addition, the unit features two latching magnets that attract pole pieces in the sensor unit providing a holding force of approximately 100 Newtons. The reed switches will only close in the presence of their matched magnetic field array thus enabling machine operation. Both switch and magnet assemblies are sealed to IP67 standards. Their tamper-resistant design prevents bypassing with simple magnets. The unit also features an LED display of switch status and an optional M12x1 quickconnect for ease of wiring and installation. Operation The unit consists of two components the door handle unit and the sensor unit. The sensor unit is typically mounted to the stationary portion of the guard structure, with the codedmagnet/handle assembly mounted to the movable element of the machine guard. When the guard is closed, the matched magnetic fields align with the reed switch arrays, closing the switches and enabling machine operation. When the guard is open, or the magnetic fields are not properly aligned with their reed switch arrays, the sensor output will remain off. Typical Applications The sealed low-profile, ergonomic door handle system is ideal for use on movable machine guards in hostile environments. The absence of protruding elements eliminate/reduce risk of injury and unintentional opening of the guard. Typical applications include food processing equipment, chemical processing equipment, woodworking machinery, packaging machinery, and printing equipment. 174 AVAILABLE STANDARD MODELS & ACCESSORIES* (Please order sensor, actuator-door handle unit and optional connector separately) Part Number Description Termination BNS-B20-12ZG-L BNS-B20-12ZG-R BNS-B20-12ZG-H BNS-B20-12ZG-ST-L BNS-B20-12ZG-ST-R Sensor unit for left-hand hinged door Sensor unit for right-hand hinged door Sensor unit for both rightand left-hand hinged door Sensor unit for left-hand hinged door Sensor unit for right-hand hinged door BNS-B20-B-01 Actuator-door handle unit N/A M12-8P-5M 5m cable with M12x1, N/A 8-pin connector Note: Sensor unit is also available for ASI Safety-at-Work bus systems. Please add suffix -AS to sensor part number. ** 3, 5, and 10 meter cable lengths available on request; add suffix -XXm 1 meter of bottom-mounted cable** 1 meter of rear-mounted cable** Bottom-mounted M12 conncetor (M12x1, 8-pin) *Important Note: Series BNS coded-magnet sensors are for use in safety applications only when used with a SCHMERSAL Series safety controller. Compatible models include: AES 1135 AES 2335 AES 1165 AES 2285 AES 1235 AES 1102 AES 1265 AES 1112 AES 2135 SRB 207AN AES 2165 SRB 301LCB! USE WITH ANY OTHER SAFETY CONTROLLER MAY DAMAGE SENSOR AND/OR VOID WARRANTY.

175 SERIES BNS-B20 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Operating Principle Maximum Sensing Gap (Sar) (Sao) Protection Class Ambient Operating Temperature Maximum Storage Temperature Switching Frequency Resistance to Shock Resistance to Vibration Max. door/guard weight Glass fiber reinforced thermoplastic Magnetic 22mm 0mm IP67 25 C to +70 C 25 C to +70 C 5 Hz 30g/11ms 10-55Hz, amplitude 1mm Hinged guard: 5Kg Sliding guard: 3Kg Conformity to Standards IEC BG-GS-ET-14 UL CSA Maximum Latching Force Approx. 100N (22 lbs.) Safety Control Category Up to Safety Control Category 4 per EN when used with appropriate SCHMERSAL Series AES safety controller Compatible Extrusion 35mm, 40mm, 45mm Frames ELECTRICAL SPECIFICATIONS Maximum Switching Voltage 24 VDC Maximum Switching Current 10mA Maximum Switching Capacity 240mW Indication of Switching LED (Illuminated when guard Condition is closed) Termination M12x1 or cable (LiYY 6 x 0.25mm 2 ) Contact Configuration 1 N.O. & 2 N.C. (LED in N.C. circuit) Note: Available in ASI Safety-at-Work configuration. WIRING DETAILS Contacts shown with gate closed DIMENSIONS PIN configuration M12, 8 pins Note: Loads with high switch-on or switch-off voltage spikes must be suppressed by an appropriate protective circuit

176 SERIES CSS 180 New! Pulse-Echo Based Non-Contact Safety Sensor Features & Benefits Non-contact sensing for long term reliability. Sealed for moisture protection ideal for most hostile environments. Tamper-resistant frequency-matched sensor and actuator required for operation. Integral LED diagnostic indicators facilitate easy installation and troubleshooting. Integral self-monitoring satisfy requirements of Safety Control Category 4. *See note below. Designed for daisy chaining up to 200m. Dual PNP 500mA safety outputs for application versatility. AVAILABLE MODELS AND ACCESSORIES (Accessories Ordered Separately) Model Number Description CSS P-E-L End or single device with pre-wired cable Description The CSS 180 non-contact, electronic safety sensor is designed for application in safety circuits and is used for monitoring the position of movable safety guards. In this application the safety sensor monitors the closed position of hinged, sliding or removable guards with the aid of a coded actuator. The CSS 180 Safety Sensor fulfills the requirements for proximity devices with defined behavior under fault conditions according to EN with the classification PDF-M (self-monitoring). Operation The CSS 180 Safety Sensor and CST 180 actuator are a matched pair. As the actuator approaches the sensor, the sensor excites the actuator at a predetermined resonant frequency and the reads back the actuator oscillation. The sensor evaluates the actuator frequency and its distance to the actuator. Identification of the actuator is interpreted as a closed guard by the safety sensor, and the safety outputs are enabled. The safety sensor is a dual channel design with two shortcircuit proof, safe PNP outputs, each of which can switch up to 500 ma. Due to continuous internal function tests and the monitoring of the safety outputs, a number of CSS 180 Safety Sensors can be wired in series without detriment to the control category. Series wired safety sensors continue to fulfill the requirements of Control Category 4 according to EN CSS P+D-E-L CSS P-Y-L CSS P+D-M-L CST CSA-M-1 End or single device with diagnostic output, pre-wired cable Series device with double pre-wired cable Series device with diagnostic output, pre-wired cable Actuator Magnetic latch H-18 Mounting clamp Sensors available with M12 cable connector Add ST after L in catalog number Safety Control Module Requirements Dual-channel safety inputs, suitable for PNP semiconductor outputs. The internal function tests of the sensor cause the outputs to periodically switch off for a millisecond. This must be tolerated by the control module. The following SCHMERSAL safety control modules are recommended for this application: SRB 301 LCB and SRB 324ST *Note: A safety control module may be required for reset function and/or feedback monitoring functions, as well as increased output current requirements. Typical Applications The sealed, compact units are ideal for use on movable machine guards where multiple guard monitoring on a machine is required, and/or where hostile environments exist. Typical applications include printing machinery, textile machinery, paper converting equipment, material handling systems, packaging machinery, chemical processing equipment, and woodworking machinery. 176

177 SERIES CSS 180 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass fiber reinforced thermoplastic Degree of Protection IP67 Switching Distance 8mm (Nominal) 7.0mm to 9.5mm (Maximum) Operating Temperature 25 C to +55 C Storage Temperature 25 C to +85 C Hysteresis 0.5mm Repeatability 0.2mm Response Time 30ms Vibration Resistance 10-55Hz, amplitude 1mm Shock Resistance 30g/11ms Conformity to Standards CE BG EN UL EN IEC ELECTRICAL SPECIFICATIONS Mode of Operation Inductive Rated Operating Voltage 24 VDC -15%/+10% Rated Operating Current 1.0A No Load Current 0.05A Residual Current 0.5mA Rated Impulse 0.8kV Withstand Voltage Rated Insulation Voltage 32 VAC/VDC Safety Outputs (2) PNP, short-circuit proof Safety Output Current 0.5A per output Safety Output Max. 0.5V Voltage Drop Signaling Output PNP, short-circuit proof Signaling Output Max. 4V below rated operating Operating Voltage voltage Signaling Output Max. 0.05A Operating Current Type Interconnection 4x0.5mm 2, 5x0.34mm 2, or Cable 7x0.25mm 2 DIMENSIONS CST Actuator CSS 180 Safety Sensor 5.6mm hole diameter Refer to order information for cable types, cable length and cable crosssectional area. 5 Mounting Clamp Magnetic Latch , ,2 5,

178 SERIES CSS 180 TECHNICAL DATA SWITCHING DISTANCES, FLUSH MOUNTING Typical Response Range of the Sensor CSS 180 S ON Switch-on point S ON <S H <S OFF S OFF Switch-off point S H = Hysteresis area S ao S ar Assured operation point Assured release point according to EN Switching distance S Offset The envelope curves indicate the switch-on and switch-off points of the CSS 180 sensor relative to the target. The maximum offset of the target from sensor axis is approx. 5mm. Flush-mounting of the sensor or actuator reduces the switching distance. Changes in temperature have only a slight effect on the switching points. Minimum distance between two sensor sets: approximately 100mm FLUSH MOUNTING OF THE SENSOR CSS 180 The CSS 180 sensor and the CST 180 actuator can be flush-mounted, however, the switching distance is reduced by approximately 1.5 2mm. When the sensor and actuator protrude 2mm out of their mountings the switching distance is not reduced. Function table of visual diagnostic LED, electronic diagnostic output and safety outputs Visual diagnostic (red) Cause of fault 1 pulse Fault on Output Y1 2 pulses Fault on Output Y2 3 pulses Cross-wire short Y1/Y2 4 pulses 5 pulses Continuous Ambient temperature too high Incorrect or defective actuator Internal fault Sensor condition Diagnostic LED color in sensor end cap Electronic diagnostic output 24 VDC, 50 ma No target/power on Green 0 V 0 V Actuated Yellow 24 V 24 V Actuated in limit area Flashes yellow 2 Hz cycle 24 V Fault Flashes red 10 s delay 24 V -> 0 V Six different fault conditions are signalled by the diagnostic LED flashing with predefined pulse sequence or with continuous red light. Safety outputs 1 min delay 24 V -> 0 V 178

179 SERIES CSS 180 WIRING EXAMPLE 1 Safety Sensors in large systems The sensors have separate input and output cables. The output of one sensor can be directly wired into the input of the next sensor. The sensor chain can be built up over a length of two hundred meters. Sensors used: 1 Safety Sensor CSS P-E-L: This sensor has one output cable. It is designed for the beginning of a chain or for use as a single device. 3 Safety Sensors CSS P-Y-L: These sensors have separate input and output cables. The output of the first sensor is wired into the input of the next sensor and so on. This type of sensor can also be used as the first sensor in a chain, if the supply voltage is bridged to the safety inputs. SERIES CONNECTION OF CSS CSS P-Y-L Input Gray cable Operating Voltage (BN) brown P (+24 V) (BU) blue 0 V Safety Input (BK) black channel 1 (WH) white channel 2 Output Black cable Operating Voltage (BN) brown P (+24 V) (BU) blue 0 V Safety Output (BK) black channel 1 (WH) white channel 2 5 CSS P-E-L Output Black cable Operating Voltage (BN) brown P (+24 V) (BU) blue 0 V Safety Output (BK) black channel 1 (WH) white channel 2 179

180 SERIES CSS 180 WIRING EXAMPLE 2 Series connection of Safety Sensors CSS 180 in small systems with a centralized control cabinet or wiring via junction boxes. SERIES CONNECTION OF CSS Sensors used: 1 Safety Sensor CSS P+D-E-L: This sensor has one output cable. It is designed for the beginning of a chain or for use as a single device. 3 Safety Sensors CSS P+D-M-L: The inputs and outputs of the sensors are brought out in one cable. The sensors are wired together in series in the control cabinet or in junction boxes. This type of sensor can also be used as the first sensor in a chain, if the supply voltage is bridged to the safety inputs. For very long sensors chains it is recommended to feed the power supply directly to the first sensor in the chain to avoid excessive voltage drop. The safe outputs of the last sensor in the chain are connected to the safety control module. If junction boxes are used, standard installation cable can be used for the wiring between junctions. When laid together with control cables in a separated cable channel, shielding is not necessary. Note: CSS units should be connected to the same regulated power supply. CSS P+D-M-L Operating Voltage (BN) brown P (+24 V) (BU) blue 0 V Safety Input (WH) white channel 1 (VT) violet channel 2 Safety Output (RD) red channel 1 (BK) black channel 2 (GY) gray diagnostic output CSS P+D-E-L Operating Voltage (BN) brown P (+24 V) (BU) blue 0 V Safety Output (BK) black channel 1 (WH) white channel 2 (GY) gray diagnostic output 180

181 SERIES CSS 180 APPLICATION NOTES 200 m Series wiring of the Safety Sensor CSS 180: A number of CSS 180 safety sensors can be wired together in series to form a chain. The redundant outputs of the first sensor are in this case wired to the inputs of the second sensor, and so on. The safety sensors in the chain are selfmonitoring. The last sensor in the chain provides the two short-circuit proof, PNP outputs each rated at 500mA for further connection to the safety control circuit. The safety requirements according to EN 954-1, Control Category 4 remain fulfilled for the complete chain. Faults within the chain, e.g., a cross-wire short, are detected. This includes faults in the wiring to the safety control monitor, which are also automatically detected. To make cable routing and interconnection of the safety sensors as simple as possible, a wide range of pre-wired options are available: For large, extensive guard systems, the Safety Sensor is available with separate input and output cables. The series wired safety sensors can then be built up to a length of over two hundred meters by daisy chaining the devices. When the cables are routed in control cable channels, the cables do not need to be shielded. The Y in the part number of the Safety Sensor CSS 180 identifies this version. For compact systems, or where the control cables are parallel routed to a centralized control cabinet, the input and output leads of the safety sensor are combined in one cable. The series wiring of a number of sensors in this case can be realized in the control cabinet or junction box. This version is identified by an M in the part number of the Safety Sensor CSS 180. A single cable version is available for individual sensor monitoring and is also suitable for the first sensors in a series. The E in the part number of the Safety Sensor CSS 180 identifies this version. Note on the total length of a safety sensor chain The voltage drop over a long sensor chain should be taken into account when planning cable routing. The exact value of the operating voltage, wire cross-section and cable length, its temperature, the number of sensors connected and the input load of the safety control monitor are all factors that must be considered. An approximately 200m long sensor chain consisting of six sensors has at 20 C, 100mA input current into the safety control monitor and 0.5mm 2 cable cross-section, a voltage drop of approximately 1.5V. If 5 junction boxes are installed, a cable with 1.5mm 2 cross-section should be laid between the junction boxes. When the cables are routed in control cable channels, shielding is not necessary. The cables must however be routed separately from supply and power cables. Local sources of external interference must be properly suppressed. The power supply for the CSS 180 safety sensors must provide protection against permanent overvoltage. Therefore, SELF or PELF mains supply units are recommended. The maximum permissible fuse protection for the sensor chain is 1.6A gl/gg. 181

182 SERIES CSS 180 APPLICATION NOTES Misalignment in the safety guard can be easily compensated. The application, mounting and usage Both the sensor and actuator are small and compact. They can be fitted easily in any position on a machine guard or other object to be monitored. The actuator has two sets of fixing holes for attachment parallel or square to the mounting surface. The sensor can be attached using a mounting clamp (accessory) or with the two M18 nuts (supplied). If required, both the actuator and the sensor can be flush mounted using the M18 x 1mm standard housing threads. The sensor and actuator are encapsulated, vibration-resistant and suitable for application in harsh, dusty or dirty environments. They comply to the requirements for the degree of protection IP 67. Adjustment is simple. A large switching distance and the possibility of also being able to operate the sensor and actuator with an offset enables large tolerances to be accommodated on the safety guard. The small hysteresis of 0.5mm and a repeatability of 0.2mm result in precise, repeatable switching points throughout its operational lifetime. The correct functioning of the sensor, a fault in the sensor output, a crosswire short and actuation of the sensor itself by the actuator are signalled by the visual diagnostic 3 color LED. The LED can also be used as an adjustment aid during fitting. The electronic diagnostic output indicates an actuated sensor. If a sensor is operated near the limit of its switching distance, for example due to the sagging of a guard door, it is detected even before the safety outputs are disabled, and results in an intermittent pulse on the electronic diagnostic output and visual diagnostic LED. In a similar way, faults which do not immediately compromise the safe operation of the sensor, for example a crosswire short, are signalled as an advance warning. The machine can in this case be run down in a controlled manner. 182

183 COMPATIBLE CSS 180 SAFETY CONTROLLERS SRB 301 LCB TECHNICAL FEATURES Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual channel) Monitored Monitored Contact N.C. (Dry Contacts) or Configuration PNP-switching Number & Type Safety 3 N.O. (Dry Contacts) Outputs Number & Type Auxilliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Manual (24 V Leading Edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 4 Rating Per EN ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 1.7 W (max.), 1.9 VA Fuse (Input Power) Internal glass fuse F1: T 0.25 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable supressor circuit) Switching Capacity 24 VDC, 2 A (Auxilliary Contacts) Application Category AC 15 / DC 13, EN Pick-up Delay 30 ms Drop-out Delay 50 ms Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Cleaner & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN MECHANICAL SPECIFICATIONS Dimensions (W x H x D) 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") Ambient Operating -25 C to +45 C Temperature Range (-13 F to +113 F) Mechanical Life >10 7 switching cycles Expectancy Weight 230 gm (0.5 lbs.) Mounting DIN rail (35mm) 5 Terminal Connections For Use With CSS 180 Supply Voltage Monitored Input #1 (N.C.) Monitored Input #2 (N.C.) Safety Output #1 (N.O.) A1 A2 S12 S Safety Output #2 (N.O.) Safety Output #3 (N.O.) Feedback Monitoring with Automatic or Manual (Leading Edge) Reset Auxiliary Output (N.C.) X1 X

184 SERIES CSS 34 Pulse-Echo Based Compact Non-Contact Safety Sensor New! Features & Benefits Compact size ideal for limited space applications. Non-contact sensing for long term reliability. Four different actuating surfaces for a variety of mounting options. Sealed for moisture protection ideal for most hostile environments. Meets both IP65 and IP67 requirements. Tamper-resistant frequency-matched sensor and actuator required for operation. Integral LED diagnostic indicators facilitate easy installation and troubleshooting. Integral self-monitoring satisfy requirements of Safety Control Category 4. *See note below. Designed for daisy chaining up to 200m. Dual PNP 500mA safety outputs for application versatility. Integrated mounting plate included allows for easy and accurate alignment of sensor and actuator. AVAILABLE MODELS AND ACTUATORS (Actuators Ordered Separately) Model Number Description Description The CSS 34 non-contact, electronic safety sensor is designed for application in safety circuits and is used for monitoring the position of movable safety guards. In this application the safety sensor monitors the closed position of hinged, sliding or removable guards with the aid of a coded actuator. The CSS 34 Safety Sensor fulfills the requirements for proximity devices with defined behavior under fault conditions according to EN with the classification PDF-M (self-monitoring). Operation The CSS 34 Safety Sensor and CST 34 actuator are a matched pair. As the actuator approaches the sensor, the sensor excites the actuator at a predetermined resonant frequency and the reads back the actuator oscillation. The sensor evaluates the actuator frequency and its distance to the actuator. Identification of the actuator is interpreted as a closed guard by the safety sensor, and the safety outputs are enabled. The safety sensor is a dual channel design with two shortcircuit proof, safe PNP outputs, each of which can switch up to 250 ma. Due to continuous internal function tests and the monitoring of the safety outputs, a number of CSS 34 Safety Sensors can be wired in series without detriment to the control category. Series wired safety sensors continue to fulfill the requirements of Control Category 4 according to EN CSS12-34-VDML CSS12-34-VDMST CSS14-34-SDML CSS14-34-SDMST CST34-S-1 CST34-V-1 Top Actuating surface with diagnostic output Top Actuating surface with diagnostic output, M12 cable connector Side Actuating surface with diagnostic output Side Actuating surface with diagnostic output, M12 cable connector Side surface actuator Top surface actuator Sensors available with a serial diagnostic cable, for use with a PROFIBUS DP network. Please consult factory. Safety Control Module Requirements Dual-channel safety inputs, suitable for PNP semiconductor outputs. The internal function tests of the sensor cause the outputs to periodically switch off for a millisecond. This must be tolerated by the control module. The following SCHMERSAL safety control module is recommended for this application: SRB 301 LCB, SRB 324 ST *Note: A safety control module may be required for reset function and/or feedback monitoring functions, as well as increased output current requirements. Typical Applications The sealed, compact units are ideal for use on movable machine guards where multiple guard monitoring on a machine is required, and/or where hostile environments exist. Typical applications include printing machinery, textile machinery, paper converting equipment, material handling systems, packaging machinery, chemical processing equipment, and woodworking machinery. 184

185 SERIES CSS 34 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass fiber reinforced thermoplastic Degree of Protection IP65 and IP67 Switching Distance Top (V) 12mm Nominal 10-15mm (Maximum) Side (S) 14mm Nominal 12-17mm (Maximum) Operating Temperature 25 C to +70 C Storage Temperature 25 C to +85 C Hysteresis 1mm Repeatability 0.5mm Response Time 30ms Vibration Resistance 10-55Hz, amplitude 1mm Shock Resistance 30g/11ms Conformity to Standards CE BG EN UL/CSA EN IEC ELECTRICAL SPECIFICATIONS Mode of Operation Inductive Rated Operating Voltage 24 VDC -15%/+10% Rated Operating Current 0.6A No Load Current 0.1A Residual Current 0.5mA Rated Impulse 1 kv Withstand Voltage Rated Insulation Voltage 32 VAC/VDC Safety Outputs (2) PNP, short-circuit proof Safety Output Current 0.25A per output Safety Output Max. 0.5V Voltage Drop Signaling Output PNP, short-circuit proof Signaling Output Max. 4V below rated operating Operating Voltage voltage Signaling Output Max. 0.05A Operating Current Interconnection Cable: Y-UL2517/8xAWG22 (8x0.35mm 2 ), 2m Connector: M12x1, 8 pin quick connect DIMENSIONS CST Actuator CSS 34 Safety Sensor 5 Integrated Mounting Plate (included with delivery) 185

186 SERIES CSS 34 TECHNICAL DATA SWITCHING DISTANCES The actuating curves represent the points at which the CSS 34 sensor switches on and off upon the approach of the actuator. Actuation From Side Actuation From Top Legend S Switching Distance V, V1, V2 Possible misalignment (see drawings at right) S ON Switch-on point S OFF Switch-off point S H Hysteresis area S H = SOFF SON Sao Assured operation point Sar Assured release point (according to EN ) Minimum distance between two sensor sets: approximately 100mm Sideways Misalignment Horizontal: Max ±10mm (V2) Vertical: Max ±18mm (V1) Top Misalignment Horizontal: Max ±8.5mm (V) Function table of visual diagnostic LED, electronic diagnostic output and safety outputs Visual diagnostic (red) Cause of fault 1 pulse Fault on Output Y1 2 pulses Fault on Output Y2 3 pulses Cross-wire short Y1/Y2 4 pulses 5 pulses Continuous Ambient temperature too high Incorrect or defective actuator Internal fault Sensor condition Diagnostic LED color in sensor end cap Electronic diagnostic output 24 VDC, 50 ma No target/power on Green 0 V 0 V Actuated Yellow 24 V 24 V Actuated in limit area Flashes yellow 2 Hz cycle 24 V Fault Flashes red 10 s delay 24 V -> 0 V Six different fault conditions are signalled by the diagnostic LED flashing with predefined pulse sequence or with continuous red light. Safety outputs 30 min delay 24 V -> 0 V 186

187 SERIES CSS 34 WIRING EXAMPLE 1 Series wiring with single diagnostic output The supply voltage is wired to both safety inputs of the last sensor of the chain (starting from the safety controller). The safety outputs of the first sensor are wired to the safety controller. The sensor chain can be built up over a length of two hundred meters. Sensors used: Safety Sensor CSS14-34-SDML: This sensor has one output cable. The output of the first sensor is wired into the input of the next sensor and so on. SERIES CONNECTION OF CSS 34 5 CSS14-34-SDML Operating Voltage (BN) brown P (+24 V) (BU) blue 0 V Safety Input (WH) white channel 1 (VT) violet channel 2 Signal Output (GY) gray diagnostic (PK) pink nonfunction Safety Output (BK) black channel 1 (RD) red channel 2 187

188 188 Safer by Design

189 BNS SERIES - COMPATIBLE SERIES AES SAFETY CONTROLLERS SELECTION CHART AVAILABLE STANDARD MODELS Safety Controller Suitable for use with Coded-Magnet Sensor Part Numbers below BNS BNS33... BNS BNS BNS33... BNS BNS16-12Z BNS33-12Z-2187 BNS BNS33... BNS } } } BNS16-12Z BNS33-12Z Z or 12ZG 11Z or 11ZG 11Z Max. Number of Directly- Connected BNS Series Sensors (without daisy chaining ) Safety Controller Part Number (and available supply voltages) Number of Safety Outputs (Enabling Paths) Max. Achievable Safety Control Category per EN Type of Reset Feedback Circuit AES1102 (24VAC, 24VDC, 110VAC) AES1112 (24VAC, 24VDC, 110VAC) AES1135 (24VDC) AES1165 (24VDC) /3* 1/3* Automatic Automatic Automatic Automatic No No No No 1 AES1235 (24VDC) 2 3 Automatic Yes 2 AES1265 (24VDC) 2 3 Automatic Yes 1 AES2135 (24-230V AC/DC) 1 1/3* Automatic No 2 AES2165 (115VAC) 1 1/3* Automatic No 1 AES2335 (24-230V AC/DC) 3 3 Automatic Yes 1 SRB211AN (24VAC/DC) 2 Stop Cat. 0 4 Automatic Yes 1 Stop Cat. 1 or Manual 1 AES1337 (24VAC/DC) 3 4 Automatic Yes or Manual 6 AES Automatic Yes SRB207AN-230V (48-240VAC) or Manual 5 *Category 3 when safety controller is directly connected to load. 189

190 AES 1102/AES 1112 BNS Compatible Controllers Features Control Category 1 to EN enabling path Monitoring of 1 or a number of guard devices Connection of BNS.. -12z magnetic safety sensors with 1 NO and 2 NC contacts LED function indicators Available for various operational voltages Dimensions 22.5 x 100 x 121 mm Model Designation AES VDC AES VAC AES VAC AES VAC AES VAC AES VDC AES VAC AES VAC AES VAC AES VAC Approvals BG UL CSA 190

191 AES 1102/AES 1112 Typical Application Typical Wiring Diagram U e YE GN YE GN YE GN BN WH BN WH BN WH PK GY PK GY PK GY L1 A1 A2 S22 S32 S14 C VDC K2 K1 AES 1102 K3 14 N K4 3 M 5 Application Notes AES to secure a number of guard devices using series-parallel circuits for Control Category 1 to EN Only suitable for the connection of magnetic safety sensors. Monitoring a number of guard devices using BNS z-2187 range magnetic safety sensors with isolated contacts. The wiring diagram is with guard devices closed and shows the deenergized condition. Use with multiple daisy-chained inputs does not permit identification of which guard/coded-magnet sensor is in an open/fault condition Circuit Options Monitoring One Guard Device Monitoring one guard device using a BNS.. -12z Series coded-magnet safety sensor. 191

192 AES 1135/AES 1165 BNS Compatible Safety Controllers Features Control Category 3 to EN enabling circuit Enable delay time can be modified Monitoring of mechanical position switches, safety switches, solenoid interlocks, coded magnet sensors or E-stops Can be used as emergency-stop controller for Category 0 to EN Monitoring for short-circuit between connections with NO-NC contact combination Connection of input expansion modules possible Dimensions 22.5 x 100 x 121 mm Model Designation AES VDC AES VDC Function Table Additional semiconductor output Y Function of output Y Switching Condition AES 1135 Y1 Enable Enable circuit closed Y2 No enable Enable circuit open Approvals BG UL CSA 192

193 AES 1135/AES 1165 Typical Applications Typical Wiring Diagram +24 VDC 100mA A1 max. A2 A1 A S13 S14 S21 S22 13 K1 K2 L1 AES 1145/ Y1 Y2 X AZM VDC 100m A 0V A1 S1 3 max. S1 4 S21 S2 31 S1 S2 K1 K2 A2 S S S2 1 S2 14 L1 AES 1165/ V N M N K3 K4 3 M N M SK3 K3 SK1 K4 3 M Application Notes AES to achieve up to Control Category 3. Monitoring a sliding, hinged or removable guard device using a solenoid interlock. The NC contact must have positive opening function when the guard device is opened. Control Category 3 to EN can be achieved by substantiation and documentation of exclusion of faults due to breakage or loosening of the actuator or in the solenoid interlock. If the load is directly switched by the AES, the complete system can be classified in Control Category 3 to EN If one or two external relays or contactors are used to switch the load, the system can then only be classified in Control Category 3 to EN if exclusion of the fault Failure of the external contactors can be substantiated and is documented, e.g. by using reliable de-rated contactors. A second contactor leads to an increase in the level of security by redundant switching of the load. The wiring diagram is with guard device closed and shows the de-energized condition. 5 Circuit Options Extension of 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 under the cover of the unit. Monitor 2 NC Contacts Jumper A1 (24 VDC) to X1 193

194 AES 1235/AES 1265 BNS Compatible Safety Controllers Dimensions ISD 22.5 x 100 x 121 mm The following faults are recognized by the safety controller and indicated by means of ISD Failure of door contacts to open or close Short-circuits on or between the switch connections Interruption of the switch connections Failure of the unit s internal safety relay to pull-in or drop-out Faults on the input circuits or on the relay control of the guard door monitor Features Control Category 3 to EN enabling circuits Enable delay time can be modified Monitoring of mechanical position switches, safety switches, solenoid interlocks, coded magnet sensors or E-stops NO-NC contact combination can be connected Can be used as emergency-stop controller for Stop Category 0 to EN Monitoring for short-circuit between connections with NO-NC contact combination ISD Integral System Diagnostics 2 short-circuit proof additional transistor outputs Feedback circuit to monitor external relays Start function Operational voltage 24 VDC Connection of input expansion modules possible Additional contact by means of output expansion modules Model Designation AES VDC AES VDC Function Table Additional semiconductor output Y Function of output Y Switching Condition AES 1235 Y1 Authorized operation Enabling paths closed Y2 No authorized operation Enabling paths open AES 1265 Y1 Authorized operation Enabling paths closed Y2 No authorized operation Enabling paths open Approvals BG UL CSA 194

195 AES 1235/AES 1265 Typical Applications Typical Wiring Diagram L1 0V +24 VDC A1 A2 Y1 X max. 100mA K1 K2 AES 1235 AES 1236 S13 S14 S21 S Application Notes 0V K3 SK3 AES achieve Control Category 3 to EN Monitoring a sliding, hinged or removable guard device, each using a coded magnet sensor A. The feedback circuit monitors positions of the contactors K3 and K4. K4 3 M If only one external relay or contactor is used to switch the load, the system can be classified in Control Category 3 to EN if exclusion of the fault Failure of the external contactor can be substantiated and is documented, e.g. by using a reliable de-rated contactor. A second contactor leads to an increase in the level of security by redundant switching of the load. The wiring diagram is with guard devices closed and shows the deenergized condition. 5 Circuit Options Start Pushbutton s A start pushbutton (NO) can optionally be connected to the inputs in the feedback circuit. With the guard device closed, the enabling circuits are then not closed until the start pushbutton has been operated. Feedback Circuit A feedback circuit is shown connected in the wiring diagram. If no feedback circuit is used, input X1 must be connected to 24 VDC supply or a jumper between output Y2 and input X1. Extension of 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 under the cover of the unit. 195

196 AES 2135 BNS Compatible Safety Controllers Features Control Category 3 to EN enabling circuit Enable delay time can be modified Monitoring of mechanical position switches, safety switches, solenoid interlocks, coded magnet sensors or E-stops Can be changed from NO-NC to NC-NC contact combination Can be used as emergency-stop controller for Category 0 to EN Monitoring for short-circuit between connections with NO-NC contact combination ISD Integral System Diagnostics Connection of input expansion modules possible 2 semiconductor auxiliary outputs (nonsafety) Dimensions 45 x 100 x 121 mm ISD The following faults are recognized by the safety controller and indicated by means of ISD Failure of door contacts to open or close Short-circuits on or between the switch connections Interruption of the switch connections Failure of the unit s internal safety relay to pull-in or drop-out Faults on the input circuits or on the relay control of the guard door monitor Model Designation AES V AC/DC Function Table Additional semiconductor output Y Function of output Y Switching Condition AES 2135 Y1 Enable Enable circuit closed Y2 No enable Enable circuit open Approvals BG UL CSA 196

197 AES 2135 Typical Applications Typical Wiring Diagram 5 Application Notes AES to achieve Control Category 3 to EN Monitoring a sliding, hinged or removable guard device, each using a safety coded magnet A. If the load is directly switched by the AES, the complete system can be classified in Control Category 3 to EN If one or two external relays or contactors are used to switch the load, the system can then only be classified in Control Category 3 to EN if exclusion of the fault Failure of the external contactors can be substantiated and is documented, e.g. by using reliable de-rated contactors. A second contactor leads to an increase in the level of security by redundant switching of the load. The wiring diagram is with guard devices closed and shows the de-energized condition. Circuit Options Modification for 2 NC Contacts The controller can be modified to monitor two normally closed contacts by jumping between the terminals X3 and X4. The short circuit monitoring between connections then becomes inoperative. Extension of Enable Delay Time The enable delay time can be increased from 0.1 s to 1 s by jumping between the terminals X7 and X8. 197

198 AES 2335 BNS Compatible Safety Controllers Dimensions ISD 45 x 100 x 121 mm The following faults are recognized by the safety controller and indicated by means of ISD Failure of door contacts to open or close Short-circuits on or between the switch connections Interruption of the switch connections Failure of the unit s internal safety relay to pull-in or drop-out Faults on the input circuits or on the relay control of the guard door monitor Failure of or functional fault on the safety controller Features Control Category 3 to EN enabling circuits Enable delay time can be modified Monitoring of mechanical position switches, safety switches, solenoid interlocks, coded magnet sensors or E-stops NO-NC contact combination can be connected Can be used as emergency-stop controller for Category 0 to EN Monitoring for short-circuit between connections ISD Integral System Diagnostics Available for various operational voltages Short-circuit proof additional transistor outputs Feedback circuit to monitor external relays Start function Connection of input expansion modules possible Additional contact by means of output expansion modules Model Designation AES V AC/DC Function Table Additional semiconductor output Y Function of output Y Switching Condition AES 2335 Y1 High (+24V) Enable circuit closed Y2 High (+24V) Enable circuit open Approvals BG UL CSA 198

199 AES 2335 Typical Applications Typical Wiring Diagram Application Notes The wiring diagram shown achieves Control Category 1 to EN Monitoring a sliding, hinged or removable guard device. To achieve Control Category 3 to EN 954-1, the feedback circuit must be connected. In addition, exclusion of faults due to breakage or loosening of the actuator or in the solenoid interlock is to be substantiated and documented. The NC contact A must have positive opening function when the guard device is opened. If only one external relay or contactor is used to switch the load, the system can be classified in Control Category 3 to EN if exclusion of the fault Failure of the external contactor can be substantiated 5 and is documented, e.g. by using a reliable de-rated contactor. A second contactor leads to an increase in the level of security by redundant switching of the load. The wiring diagram is with guard device closed and shows the deenergized condition. Circuit Options Start Pushbutton s A start pushbutton (NO) can optionally be connected to the inputs in the feedback circuit. With the guard device closed, the enabling circuits are then not closed until the start pushbutton has been operated. Feedback Circuit For this purpose, the positive-drive contacts of the external contactors can be connected to input X1-X2. The power supply to this feedback circuit is either from semiconductor output Y2 or, if this is already used, with 24 VDC from terminal S13 or S21. Modification for 2 NC Contacts The controller can be modified to monitor two normally closed contacts by jumping between the terminals X3 and X4. The short circuit monitoring between connections then becomes inoperative. 199

200 AES 1337 BNS Compatible Safety Controllers TECHNICAL FEATURES Model AES 1337 shown. Description The above general-purpose safety controllers are designed for use with safety devices having Normally-Open (N.O.) or Normally-Closed (N.C.) outputs. Each is equipped for connection of one input device in dual-channel configuration. In addition they feature user-selectable monitoredmanual or automatic reset, feedback monitoring of positiveguided controlled loads and cross-short recognition (on selected models). Input Voltage 24 VAC/DC # Discrete Input Devices 1 (Dual-Channel) Monitored Monitored Contact Configuration 1 N.O. 1 N.C. Number & Type Safety Outputs 3 N.O. (Dry Contacts) Number & Type Auxiliary 1 N.C. 24 VDC (Non-Safety or Signalling Output) Typical Input Devices Monitored E-stops (N.C.) Interlock switches (N.C.) Type of Reset Monitored-manual (24 VDC trailing edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category Rating 4 Per EN Type Fuse Hybrid Selected Features Cross-short recognition Selectable monitoredmanual or automatic reset Feedback monitoring Front View AVAILABLE MODELS Model Number Operating Voltage AES 1337 AES V AC/DC Model AES 1337 shown. 200

201 AES 1337 MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) 10 7 switching cycles 230 gm DIN rail (35mm) ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 2.4 W (max.), 3.8 VA Fuse (Input Power) 24 V Internal electronic (hybrid) Fuse F1, Tripping current > 0.6 A (Resets after interruption of supply voltage) Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable surge supressor) Switching Capacity 24 VDC, 100mA (Auxiliary Contacts) Application Category AC 15 / DC 13, EN Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Self-lifting, plug-in screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN

202 SERIES SRB 211 AN BNS Compatible Safety Controllers TECHNICAL FEATURES New! Description The Model SRB 211 AN is a general purpose unit designed for use with safety devices having Normally-Open and Normally-Closed dry contact switching outputs. It is equipped for connection of one monitored input device in dual-channel configuration. In addition it features userselectable monitored-manual or automatic reset, stop category 0 & 1 safety outputs, and feedback monitoring of positive-guided controlled loads. Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Dual-Channel) Monitored Compatible Input Device N.O./N.C (Dry Contacts) Contact Configuration Number & Type 3 N.O. (1 delayed : 1-30 sec.) Safety Outputs (dry contacts) Number & Type Auxiliary PNP (Non-Safety or Signalling Outputs) Typical Input Devices E-stops (N.C./N.O.) Monitored Interlock switches (N.C./N.O.) Type of Reset Monitored-manual (Selectable) (24 VDC trailing edge) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) K3/4 (safety relay 3 & 4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 (2 safety outputs) 1 (1 safety output) Safety Control Category 4 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition Stop category 0 & 1 safety outputs Selectable trailing edge or automatic reset Resetable electronic fuse Feedback monitoring AVAILABLE MODELS Model Number SRB 211 AN Operating Voltage 24 V AC/DC 202

203 SERIES SRB 211 AN MECHANICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 255 gm DIN rail Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 5.2 W, 7.2 VA (max.), plus signaling output Y1 Fuse (Input Power) Internal electronic Fuse F1, Tripping current > 1.5A (Resets approx. 1 second) Fuse (Safety Outputs) 4 A Slow-blow (Recommended) Switching Capacity 230 VAC, 4 A Resistive (Safety Outputs) (inductive with suitable suppressor circuit) Switching Capacity 24 VDC 100mA (Auxiliary Contacts) Application Category AC 15 / DC 13 : EN Pick-up Delay 40 ms Drop-out Delay 50 ms Contact Type & AgSnOAgNi, self cleaning, positive-guided Materials Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Plug-in, self-lifting, screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN

204 AES 2285/SRB 207 AN BNS Compatible Safety Controllers TECHNICAL FEATURES Description The Model SRB 207 AN is a general purpose unit designed for use with safety devices having Normally- Open (N.O.) and Normally-Closed (N.C.) dry contacts. Each is equipped for connection with up to six input devices such as E-stop push button and BNS coded magnets. In addition it features user-selectable monitoredmanual or automatic reset, six (non-safety) semiconductor outputs for signalling/annunciation, and two safety outputs. Input Voltage See available models below # Discrete Input Devices 6 (Dual-Channel) Monitored Compatible Input Device N.O./N.C. (Dry Contacts) Contact Configuration Number & Type 2 N.O. (Dry Contacts) Safety Outputs Number & Type Auxiliary 6 - short circuit proof, PNP-type (Non-Safety or semiconductor Y1 - Y6 max 20mA Signalling Outputs) 1 - N.C. Auxiliary output Typical Input Devices Interlocks (N.O./N.C.) Monitored Limit switches (N.O./N.C.) Type of Reset Monitored-manual (trailing edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 3 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition Up to 6 monitored devices Seven auxiliary outputs Selectable monitored-manual or automatic reset Front View AES 2285/SRB 207 AVAILABLE MODELS Model Number Operating Input Voltage New! AES 2285 SRB 207 AN-230V 24 VDC VAC 204

205 AES 2285/SRB 207 AN MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting 45mm x 100mm x 121mm (1.77" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 300 gm DIN rail TYPICAL WIRING DIAGRAM (shown with 1 input) ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 48 VAC-240VAC, Hz Power Consumption 3.0 W max. (For 24 VDC) Approx. 6.8 VA (For 230 VAC) (Plus signalling contacts Y1-Y6) Fuse (Input Power) 24 V Internal electronic Fuse F1, Tripping current > 1 A (Resets after approx. 1 second) 230 V Primary : Fuse (glass), tripping current > 1 A Secondary : Internal electronic fuse, tripping current > 0.12 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity Y1-Y6: 24 VDC, 20mA (PNP) (Auxiliary Contacts) 31-32: 24 VDC, 2 A (Dry) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable supressor circuit) Application Category AC-15 / DC-13 : EN Pick-up Delay 120 ms/ 30ns (auto start/reset button) Drop-out Delay 20 ms Contact Type & Material AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Self-lifting, plug-in screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN

206 206 Safer by Design

207 HINGED SAFETY INTERLOCK SWITCHES Switch Series SELECTION GUIDE Housing Material Angular Displacement for Contact Opening Contact Configurations Catalog Page ES95 SB Glass-fiber, reinforced thermoplastic 7 1 NO & 1 NC 2 NC 208 TVS335 Die-cast aluminum, enamel finish 2 1 NO & 1 NC 2 NC 210 TV8S-521 T.C 235 Die-cast zinc, enamel finish Die-cast zinc, enamel finish NO & 2 NC 1 NO & 1 NC 2 NC 1 NC T.C 236 Glass-fiber, reinforced thermoplastic NO & 1 NC 2 NC 1 NC 214 New! TESF Die-cast zinc Adjustable 1 NO & 2 NC 2 NO & 2 NC 220 TESZ Glass-fiber, NO & 2 NC 224 reinforced thermoplastic 3 NC 207

208 Series ES95 SB Hinged Safety Interlock Switch Typical Applications The ES95 SB is intended for use as a safety interlock switch on hinged, movable machine guards which, when open, expose operator/maintenance personnel to machine hazards. Their sealed design (IP67) and oil-tolerant seals make them ideal for use in hostile environments. Features & Benefits Tamper-resistant integral actuator shaft prevents bypassing. Positive-break NC contacts ensure circuit interruption upon only 7 of guard displacement. Watertight, oiltight design meets IP67 washdown and immersion requirements. Rugged, corrosion-resistant housing tolerates the most hostile environments. Meets rigid safety agency standards CSA, IEC and BG. Four 90 actuator head positions provide installation flexibility. Description The ES95 SB Series are designed for use with hinged movable machine guards which must be closed for operator safety. Their tamper-resistant design and positive-opening NC contacts provide a significantly higher level of safety than conventional, spring-driven limit switches often used to monitor hinged-guard position. Their IP67 rating make them ideal for interlocking safety guards in hostile environments. Part Number ES95-SB10/1S ES95-SB20 AVAILABLE STANDARD MODELS Contacts (Guard Closed) 1 NO & 1 NC 2 NC Description* Hinged safety interlock switch with 10mm diameter shaft bore hole *The actuator head may be rotated into any one of four 90 positions. Shown with Safety-Rated Positive-Break limit switch. Operation The ES95 SB is a single-piece, electromechanical safety interlock switch which is designed to mount to a hinged machine guard. After opening the guard only 7, the unit s positive-break, normally-closed contacts are forced to open by a direct (non-resilient) actuating mechanism. These positive-break contacts ensure circuit interruption (and machine stoppage). 208 is a trademark of SCHMERSAL

209 ES95 SB TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fibre reinforced, selfextinguishing thermoplastic Displacement Angle 7 for Contact Opening Degree of Protection IP67 Operating Temperature 22 F to +195 F Mechanical Life 10 million operations Operating Rate 3,600 operations/hour (maximum) Mounting Arrangement Mounts on 9mm diameter shaft via mounting screw Conformity to Standards BG CSA SUVA ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges 5A/24VAC 6A/400VAC Slow-action, positive-break NC contacts 500VAC 6kV Screw terminals with self-lifting clamps for up to 13AWG SWITCHING DIAGRAM ES95 SB 1O/1S ES95 SB 2O DIMENSIONS , , ø4, mm inch M Additional fixing holes can be broken out if required. 209

210 Series TVS335 Hinged Safety Interlock Switch Features & Benefits Tamper-resistant integral actuation shaft prevents bypassing. Positive-break NC contacts ensure circuit interruption upon only 3 of guard displacement. Watertight design meets IP67 washdown and immersion requirements. Rugged, corrosion-resistant housing tolerates the most hostile environments. Meets rigid safety agency standards IEC, BG, UL and CSA. Four 90 actuator head positions provide installation flexibility. Optional LED indicators provide visual display of supply voltage and switch operation. Description The TVS335 Series are designed for use with hinged movable machine guards which must be closed for operator safety. Their tamper-resistant design and positive-opening NC contacts provide a significantly higher level of safety than conventional, spring-driven limit switches often used to monitor hinged-guard position. Their IP67 rating make them ideal for interlocking safety guards in hostile environments. Part Number TV8S Z TV8S Z AVAILABLE STANDARD MODELS Contacts (Guard Closed) 1 NO & 1 NC 2 NC Description* Hinged safety interlock switch with 8mm diameter shaft bore hole Operation The TVS335 is a single-piece, electromechanical safety interlock switch which is designed to mount to a hinged machine guard. After opening the guard only 3, the unit s positive-break, normally-closed contacts are forced to open by a direct (non-resilient) actuating mechanism. These positivebreak contacts ensure circuit interruption (and machine stoppage). Optional Safety Controller. See Page 328. TV10S Z TV10S Z TV8S ZG24 TV8S ZG24 1 NO & 1 NC 2 NC 1 NO & 1 NC 2 NC Hinged safety interlock switch with 10mm diameter shaft bore hole Hinged safety interlock switch with 8 mm diameter shaft bore and integral LED indicators for supply voltage (green) and switch operation (yellow) TV10S ZG24 TV10S ZG24 1 NO & 1 NC 2 NC Hinged safety interlock switch with 10 mm diameter shaft bore and integral LED indicators for supply voltage (green) and switch operation (yellow) *The actuator head may be rotated into any one of four 90 positions. 210 is a trademark of SCHMERSAL

211 TVS335 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Diecast aluminum, enamel finish Displacement Angle 3 for Contact Opening Degree of Protection IP67 Operating Temperature 22 F to +158 F Mechanical Life >10 6 operations Operating Rate 5,000 operations/hour (maximum) Conformity to Standards IEC EN DIN VDE BG-GS-ET15 UL CSA DIMENSIONS ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Electrical Connections Fine silver Double-pole, double-break with electrically-separated contact bridges 4A (230VAC) 2.5A (400VDC) 1A (500VAC) Slow-action, positive-break NC contacts Fuse 6A (time-delay) 500VAC 6kV Screw terminals with selflifting clamps 13AWG (2.5mm 2 ) maximum wire size mm inch *Travel positive break SWITCHING DIAGRAMS & CONTACT SCHEMATICS TV8S z TV10S z TV8S z TV10S z LED Indicators Green LED (gn) indicator for supply voltage and yellow LED (ge) indicator for switch operation for 24VDC. The LED s must not be wired, however, in the safety circuit! Shown here: TV8S zG24 Shown here: NO contact (model -11ZG24) serves for alarm and signaling purposes. 6 Protected against wrong polarity connection. Protected against transient voltages. 211

212 Series TV8S-521 Hinged Safety Interlock Switch Features & Benefits Tamper-resistant geometrically-matched mating actuator prevents bypassing. Positive-break NC contacts ensure circuit interruption upon only 14 of guard displacement. Watertight design meets IP67 washdown and immersion requirements. Rugged, corrosion-resistant housing tolerates the most hostile environments. Meets rigid safety agency standards IEC and BG. Flat design permits opening of hinged guard 180. AVAILABLE STANDARD MODELS Part Number Contacts (Guard Closed) Description* Description The TV8S-521 Series are designed for use with hinged movable machine guards which must be closed for operator safety. Their flat design permits opening the door 180. Their tamper-resistant design and positive-opening NC contacts provide a significantly higher level of safety than conventional, spring-driven limit switches often used to monitor hingedguard position. Their IP67 rating make them ideal for interlocking safety guards in hostile environments. TV8S /11Z TV8S /20Z 2 NO & 2 NC 2 NO & 2 NC Two-piece hinged safety interlock switch with two contact blocks, each having 1 NO & 1 NC contact Two-piece hinged safety interlock switch with one contact block having 2 NO contacts and one contact block having 2 NC contacts Operation The TV8S-521 is a two-piece, electromechanical safety interlock switch which is designed to mount to a hinged machine guard. After opening the guard only 6, the unit s normally-closed contacts are forced to open by a direct (nonresilient) actuating mechanism achieving positive-break at 14. These positive-break contacts ensure circuit interruption (and machine stoppage). Note: The TV8S-521 models consist of a base unit, universal shaft assembly and a fixed hinge block. Please consult factory for assistance in ordering. * Please see switch travel diagrams for operating characteristics. Typical Applications The TV8S-521 Series is intended for use as a safety interlock switch on hinged, movable machine guards which, when open, expose operator/maintenance personnel to machine hazards. Their sealed design (IP67) and oil-tolerant seals make them ideal for use in hostile environments. 212 is a trademark of SCHMERSAL

213 TV8S-521 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Diecast zinc, enamel finish Displacement Angle 6 for Contact Opening Degree of Protection IP67 Operating Temperature 13 F to +158 F Mechanical Life >106 operations Conformity to Standards EN 1088 EN DIN VDE BG-GS-ET15 UL & CSA Displacement angle 14 for positive-break ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Electrical Connections Fine silver Double-pole, double-break with electrically-separated contact bridges 4A (230VAC) Slow-action, positive-break NC contacts Fuse 6A (Slow-blow) 250VAC 4kV Screw terminals, maximum (13AWG wiring including conductor ferrules) DIMENSIONS Base Unit R 11, ø6, ,6.38 5, Fixed Hinge Block M mm inch SWITCHING DIAGRAMS & CONTACT SCHEMATICS S S S S2 14 TV8S /11z TV8S /20z S S S S Base Unit 213

214 Series T.C 235/236 Hinged Safety Interlock Switch Features & Benefits Tamper-resistant integral actuator arm prevents bypassing by operator. Positive-break NC contacts ensure circuit interruption upon only 4.5 of guard displacement. Watertight design meets IP67 washdown and immersion requirements. Rugged, corrosion-resistant housing tolerates the most hostile environments. Meets rigid safety agency standards IEC, BG, UL and CSA. Four 90 actuator head positions provide installation flexibility. Description The T.C 235/236 Series are designed for use with hinged movable machine guards which must be closed for operator safety. Their tamper-resistant design and positive-opening NC contacts provide a significantly higher level of safety than conventional, spring-driven limit switches often used to monitor hinged-guard position. Their IP67 rating make them ideal for interlocking safety guards in hostile environments. Operation The T.C 235/236 is a single-piece, electromechanical safety interlock switch which is designed to mount to a hinged machine guard. After opening the guard only 4.5, the unit s positive-break, normally-closed contacts are forced to open by a direct (non-resilient) actuating mechanism. These positivebreak contacts ensure circuit interruption (and machine stoppage). Part Number T3C235-11Z T3C236-11Z T3C235-02Z T3C236-02Z AVAILABLE STANDARD MODELS Contacts (Guard Closed) 1 NO & 1 NC 2 NC Description* Hinged safety interlock switch with actuating lever to right in rest position Typical Applications The T.C 235/236 is intended for use as a safety interlock switch on hinged, movable machine guards which, when open, expose operator/maintenance personnel to machine hazards. Their sealed design (IP67) and oil-tolerant seals make them ideal for use in hostile environments. T3C235-01Z T3C236-01Z T4C235-11Z T4C236-11Z T4C235-02Z T4C236-02Z T4C235-01Z T4C236-01Z 1 NC 1 NO & 1 NC 2 NC 1 NC Hinged safety interlock switch with actuating lever vertical to switch body in rest position T5C235-11Z T5C236-11Z T5C235-02Z T5C236-02Z 1 NO & 1 NC 2 NC Hinged safety interlock switch with actuating lever to left in rest position T5C235-01Z T5C236-01Z 1 NC *The actuator head may be rotated into any one of four 90 positions. 214 is a trademark of SCHMERSAL

215 T.C 235/236 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing (Series 235): Diecast zinc, enamel finish (Series 236): Glass-fiber, reinforced, self-extinguishing thermoplastic Displacement Angle 4.5 for Contact Opening Degree of Protection IP67 Operating Temperature 22 F to +175 F Mechanical Life >106 operations Operating Rate 5,000 operations/hour (maximum) Conformity to Standards IEC EN DIN VDE BG-GS-ET15 DIN-EN50047 UL CSA ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Electrical Connections Fine silver Double-pole, double-break with electrically-separated contact bridges 4A (230VAC) 2.5A (400VDC) 1A (500VAC) Slow-action, positive-break NC contacts Fuse 6A (time-delay) as a positive-break switch 500VAC 6kV Screw terminals with self-lifting clamps for 13AWG (2.5mm2) maximum wire size Optional Safety Controller. See Page

216 T.C 235 TECHNICAL DATA Contact function diagrams Slow action 1 NO + 1 NC ,5 3,5 0 4, T3C z 90 3,5 0 3, ,5 4,5 4,5 12, T4C z Slow action 2 NC ,5 4,5 12,5 4, T3C z 90 4,5 0 4, ,5 12,5 4,5 4,5 12,5 12, T4C z Slow action 1 NC ,5 4, T3C z 90 4,5 0 4, ,5 12, T4C z Dimensions mm inch M20 M20 Types of Actuator Levers Lever 3 C Lever 4 C Slow action T3C z T4C z Part No Slow action Slow action T3C z T3C z T4C z T4C z 216

217 T.C 235 TECHNICAL DATA 0 3, ,5 12,5 0 4,5 12, ,5 12,5 T5C z T5C z 0 4,5 12, T5C z M20 Lever 5 C T5C z T5C z T5C z 6 217

218 T.C 236 TECHNICAL DATA Contact function diagrams Slow action 1 NO + 1 NC ,5 3,5 0 4, T3C z 90 3,5 0 3, ,5 4,5 4,5 12, T4C z Slow action 2 NC ,5 4,5 12,5 4, T3C z 90 4,5 0 4, ,5 12,5 4,5 4,5 12,5 12, T4C z Slow action 1 NC ,5 4, T3C z 90 4,5 0 4, ,5 12, T4C z Dimensions mm inch Types of Actuator Levers Lever 3 C Lever 4 C Slow action T3C z T4C z Part No Slow action Slow action T3C z T3C z T4C z T4C z 218

219 T.C 236 TECHNICAL DATA 0 3, ,5 12,5 0 4,5 12, ,5 12,5 T5C z T5C z 0 4,5 12, T5C z Lever 5 C T5C z T5C z T5C z 6 219

220 SERIES TESF Description The TESF Series is designed for use with movable hinged machine guards which must be closed for operator safety. Their tamper-resistant design and positive-opening NC contacts provide a significantly higher level of safety than conventional, spring-driven limit switches or proximity switches often used to monitor hinged guard positions. Their compact, low-profile design and IP65 rating make them ideal for interlocking hinged safety guards in industrial environments. Designed to mount directly on the hinged guard and its stationary frame, it is easy to install on a wide range of extruded aluminum guard sizes and other guard styles. Among its unique features is its ability to adjust the switching point in the field to meet specific application requirements.* Once adjusted, the switching point is easily permanently locked to prevent further adjustment by unauthorized personnel. In addition it features top or bottom cable entries, 1 NO or 2 NO and 2 NC contacts, designs suitable for insideor outside-guard mounting, and the ability to open a full 180. *Note: The unit is delivered factory set with a switching point at a 3 opening angle with positive-break occurring at 5. Please note that with use this factory-set point may increase 2 during lifetime. This should be considered... especially where finger or hand protection is desired. Operation The installed TESF features two integral contact blocks each featuring a NO and a NC contacts. NC contacts are positive-opening, while the NO contact(s) may be used for signaling purposes. The electromechanical switch elements are actuated when the hinged guard is opened to the user s desired switching position (angle of opening). At this point the unit s positive-break, normally-closed contacts are forced to open by a direct (non-resilient) actuating mechanism, while the normally-open contacts close. The opening of the positivebreak NC contacts ensure circuit interruption and machine stoppage. Machine restart is not possible while the guard remains opened. 220 New! is a trademark of SCHMERSAL Adjustable Switching Point Hinged Interlock Switch Features & Benefits Tamper-resistant integral switch elements and actuator prevent bypassing. Positive-break NC contacts ensure circuit interruption when guard is opened to user s desired switching position (angle of opening). User-selectable switching point makes unit suitable for a wide range of applications. Models available for inside-of-guard or front-of-guard mounting for application versatility. Choice of top or bottom cable entry for installation flexibility. Permits wide guard opening up to 180. Splash-proof design meets IP65 environmental requirements. Slotted mounting holes permit installation to most 30mm to 60mm aluminum profiles. Rugged construction tolerates mechanical abuse and hostile environments. Meets rigid safety standards UL, CSA, & BG (in preparation). AVAILABLE STANDARD MODELS (Includes hinge switch assembly and additional hinge) Part Number (Contacts) TESF/O (2NO & 2NC) TESF/180 (2NO & 2NC) TESF/U (2NO & 2NC) TESF/ST24.1PE/U (1NO & 2NC) TESF/ST24.2PE/U (1NO & 2NC) TESF/ST24.1PE/O (1NO & 2NC) TESF/ST24.2PE/O (1NO & 2NC) TESF/ST24.1PE/180 (1NO & 2NC) TESF/ST24.2PE/180 (1NO & 2NC) TESFA/180 (2NO & 2NC) TESFA/ST24.1PE/180 (1NO & 2NC) TESFA/ST24.2PE/180 (1NO & 2NC) Part Number TESF/S TESFA/S TESF-14 Description For front installation with factory set switching point at 3 For inside installation with factory set switching point at 3 For front or inside installation with user adjustable switching point For front or inside installation with user adjustable switching point For front or inside installation with user adjustable switching point For front installation with factory set switching point at 3 For front installation with factory set switching point at 3 For inside installation with factory set switching point at 3 For inside installation with factory set switching point at 3 Hinged interlock with integral fixedto-movable guard frame alignment aid. For inside installation with factory set switching point at 3 Hinged interlock with integral fixedto-movable guard frame alignment aid. For inside installation with factory set switching point at 3 Hinged interlock with integral fixedto-movable guard frame alignment aid. For inside installation with factory set switching point at 3 AVAILABLE ACCESSORIES Description Switching Point Adjustment Tool Type Connections Screw terminals Screw terminals Screw terminals 24VDC Quick disconnect (bottom entry) 24VDC Quick disconnect (top entry) 24VDC Quick disconnect (bottom entry) 24VDC Quick disconnect (top entry) 24VDC Quick disconnect (bottom entry) 24VDC Quick disconnect (top entry) Screw terminals 24VDC Quick disconnect (bottom entry) 24VDC Quick disconnect (top entry) A 22 mm gap between the door and door frame is required for models with the alignment aid and for inside mount models. Additional hinge assembly (without alignment aid) Additional hinge assembly (with integral alignment aid)

221 SERIES TESF TECHNICAL DATA MECHANICAL SPECIFICATIONS Materials of Construction Housing & hinge: die-cast zinc Cover: thermoplastic Factory Set Displacement 3 Angle for NC Contact Opening and NO Contact Closing Degree of Protection IP65 Maximum Opening Angle 180 Operating Temperature 10 F to +148 F Mechanical Life > 10 6 Operations (minimum) Mechanical Loading Capacity F1: 5000 N (110 lbs.) (See dimensional drawings) F2: 5000 N (110 lbs.) F3: 2000 N (45 lbs.) Installed Position Random Operating Rate 1200 operations/hour (maximum) Shock Tolerance 30g/18ms Vibration Tolerance 20g, Hz Cable Entry M16 x 1.5 Maximum Actuation Speed 180 /0.3 seconds Conformity to Standards UL, CSA, & BGIA (in preparation) ELECTRICAL SPECIFICATIONS Contacts Silver-nickel, gold-plated Contact Rating 2A/250 VAC (AC15) 1A/24 VDC (DC13) Contact System Cross Point System Contact Force 1N per contact Switching Action Slow-acting, positive-break NC contacts Short-Circuit Protection 2.0 A (Slow blow) Rated Impulse 2.5 kv Withstand Voltage Rated Insulation Voltage 250 VAC Thermal Rated Current 2.5 A Rated Operating Voltage 250 VAC Switching of Small Loads 5 VDC/1 ma (minimum) Electrical Connections* Screw terminals for 15AWG maximum stranded wire or 24 VDC quick disconnect: M12 (8 Pole) Front installation: Guard closed CONNECTOR PIN CONFIGURATION Front installation: Guard opened through 180 Inside installation: Guard closed SWITCHING DIAGRAMS & CONTACT SCHEMATICS Inside installation: Guard opened through The unit is delivered factory set with a switching point at a 3 opening angle and positive-break occurring at 5 (with consideration of the tolerances and wear at the end of the mechanical lifetime, relative to the factory preset). Please note that with use this factory-set point may increase 2 during lifetime. This should be considered especially where finger or hand protection is desired. Note: On connector models contact is not wired. 221

222 SERIES TESF TECHNICAL DATA DIMENSIONS (SWITCH & HINGE ASSEMBLY SHOWN WITH ALIGNMENT AIDS) M16 x 1.5 (Top) Optional Alignment Aids F3 (Bottom) F1 F2 DIMENSIONS (ADDITIONAL HINGE SHOWN WITH ALIGNMENT AIDS) F3 F1 F2 222

223 SERIES TESF TECHNICAL DATA DETERMINING THE DOOR GAP AS DEPENDENT ON OPENING ANGLE, DOOR WIDTH AND OVERLAP Opening angle ß of the door Door width C in mm Door gap D in millimeters with overlap B = 0 mm , , , , , , , , , , , Calculation example The actual door gap D1 is calculated from the door gap D calculated according to the above table less the overlap of door and frame B : D1 = D B Example: A door made of 40 mm aluminium profile with a length of 950 mm is to be secured with a TESF. According to the technical data sheet the safety contact of the TESF opens at 3 in new state (5 at end of useful life). In new state a door gap of approx mm is derived from the above table. The actual door gap, calculated using the above formula D1 = D B produces ( = 9.7); D1 = 9.7 mm. At the end of useful life there is a door gap of approx mm and an actual door gap of ( = 42.8); D1 = 42.8 mm

224 Series TESZ Hinged Safety Interlock Switch Features & Benefits Tamper-resistant integral switch element and actuator prevents bypassing. Positive-break NC contacts ensure circuit interruption upon only 4 of guard displacement. Splashproof design meets IP65 environmental requirements. Rugged construction tolerates mechanical abuse and hostile environments. Meets rigid safety agency standards IEC, BG. (UL and CSA pending) Easy to install fits most popular extruded hinged guard designs. Compatible with popular extruded profile widths. Optional integral manual reset please consult factory. AVAILABLE STANDARD MODELS Description The TESZ Series are designed for use with hinged movable machine guards which must be closed for operator safety. Their tamper-resistant design and positive-opening NC contacts provide a significantly higher level of safety than conventional, spring-driven limit switches often used to monitor hinged-guard position. Their compact, low-profile design and IP65 rating make them ideal for interlocking hinged safety guards in industrial environments. Designed to mount directly on the hinged guard and its stationary frame, it is easy to install on a wide range of guard styles and sizes. Part Number* TESZ1102/30 TESZ1110/30 TESZ1102/35 TESZ1110/35 TESZ1102** TESZ1110** TESZ1102/45 TESZ1110/45 Contacts (Guard Closed) 1 NO & 2 NC 3 NC 1 NO & 2 NC 3 NC 1 NO & 2 NC 3 NC 1 NO & 2 NC 3 NC Description Hinged safety interlock switch for 30mm width extruded guards Hinged safety interlock switch for 35mm width extruded guards Hinged safety interlock switch for 40mm width extruded guards Hinged safety interlock switch for 45mm width extruded guards Operation The installed TESZ features an integral electromechanical switch element which is actuated when opening a hinged machine guard. After opening the guard only 4, the unit s positive-break, normally-closed contact(s) are forced to open by a direct (non-resilient) actuating mechanism. These positive-break contacts ensure circuit interruption and machine stoppage. The normally-open signalling contact closes after 13.5 of guard displacement. Note: Adjustable switching point series TESF hinge model available. Suitable for front of guard or inside mounting. Please consult factory. SWITCHING DIAGRAMS & CONTACT SCHEMATICS *Includes hinge assembly with switch, switch actuator and an additional hinge assembly (without switch or switch actuator). **Available with stainless-steel hinges. (Please consult factory) AVAILABLE ACCESSORIES Part Number* Description TESZ/S/30 TESZ/S/35 TES/S TESZ/S/45 *Includes hinge and hinge pin. Hinge assembly (without switch or switch actuator) for 30mm width extruded guards Hinge assembly (without switch or switch actuator) for 35mm width extruded guards Hinge assembly (without switch or switch actuator) for 40mm width extruded guards Hinge assembly (without switch or switch actuator) for 45mm width extruded guards TESZ TESZ

225 SERIES TESZ TECHNICAL DATA MECHANICAL SPECIFICATIONS Materials of Construction Hinge: Aluminum Switch Cover: Thermoplastic Displacement Angle for 4 NC Contact Opening Degree of Protection IP65 Displacement Angle for 13.5 NO Contact Closing DIMENSIONS* Maximum Opening Angle 135 Operating Temperature 13 F to +149 F Mechanical Life >10 mm 6 operations Mechanical Loading Maximum torque of 3KN/m at Capacity inch 1m distance from hinge Operating Rate 1,200 operations/hour (maximum) Shock Tolerance 30g/18ms Vibration Tolerance 20g/10 200Hz Conformity to Standards IEC EN DIN VDE 0660 EN 1088 UL CSA ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Electrical Connections Fine silver Double-pole, double-break with electrically-separated contact bridges 2A (250VAC), AC-15, DC-13 Slow-acting, positive-break NC contact 6.0A (Slow blow) 250VAC (maximum) 2.5kV Screw terminals for 15 AWG maximum stranded wire size DIMENSIONS TESZ1102 & TESZ1110 SERIES 135 Part Number Dimension A Dimension B Dimension C TESZ1102/30 TESZ1110/30 TESZ1102/35 TESZ1110/35 TESZ1102 TESZ1110 TESZ1102/45 TESZ1110/ " (34mm) 1.53" (39mm) 1.73" (44mm) 1.93" (49mm) 5.28" (132mm) 5.28" (132mm) 3.62" (92mm) 5.28" (132mm) 4.41" (112mm) 4.41" (112mm) 2.44" (62mm) 4.41" (112mm) M TESZ/S SERIES mm inch "C" "B" "A" "A" is a trademark of SCHMERSAL 225

226 226 Safer by Design

227 SAFETY-RATED LIMIT SWITCHES Switch Series Housing Material Housing Dimensions Z/T235 Die-cast zinc 1 1 4" 1 1 4" 2 1 2" Z/T236 Glass-fibre reinforced thermoplastic 1 1 4" 1 1 4" 2 1 2" Z/T335 Die-cast aluminum 1 1 2" 1 1 4" 3" Z/T336 Glass-fibre reinforced thermoplastic 1 1 2" 1 1 2" 3" Z332 Die-cast aluminum 1 1 2" 1 1 2" 3" SELECTION GUIDE Degree of Protection IP67 IP67 IP67 IP67 IP65 Contact Configurations 1 NO & 1 NC 2 NO 2NC 1 NO & 1 NC 2 NO 2NC 1 NO & 1 NC 2 NO 2NC 1 NO & 1 NC 2 NO 2NC 1 NO & 1 NC (snap-action only) Catalog Page C50 Glass-fibre reinforced thermoplastic 1" 1 1 8" 3 4" IP30 1 NO & 1 NC

228 SERIES Z/T235 Safety-Rated, Positive-Break Miniature DIN Limit Switches Features & Benefits Positive-Break NC contacts won t stick or weld shut. Watertight design meets IP67 washdown requirements. Rugged, corrosion-resistant housing tolerates hostile environments. Six popular actuator styles for application versatility. Four 90 actuator mounting positions provide installation flexibility. Slow or snap-action operation choose to best satisfy application requirements. Safety-system approved models with positive-break contacts approved for use in machine guarding applications. Meets rigid safety agency standards IEC, BG, VDE, UL and CSA. Description The Z/T235 Series limit switches are designed for use with movable machine guards/access gates which must be closed for operator safety and for any other presence/position sensing application normally addressed with conventional limit switches. Their positive-opening NC contacts provide a higher level of safety and reliability than conventional spring-driven switches whose contacts can weld or stick shut. Each is available with a choice of six standard actuators rounded plunger, roller plunger, roller rocking lever, rod rocking lever, adjustable roller rocking lever and one-way roller lever mountable in any one of four 90 positions. All rocking levers are positively-locked to the shaft, and are adjustable throughout 360 in 10 increments. Units are available with a choice of slow-action or snap-action contacts. Their rugged metal housing and IP67 rating make them ideal alternatives to conventional limit switches. ORDERING GUIDE FOR FEATURE: SPECIFY: 1. Contact operation: Slow Action T Snap Action Z 2. Operating head V 3. Roller lever 12 H 4. Body size No. of NO contacts 1 6. No. of NC contacts 1 7. Degree of protection IP 67 z 8. Sealing of operating head (optional) z* Example 1: TV12 H z Example 2: ZV 12 H z *Available on rocking lever actuator style only. Typical Applications The Z/T235 Series may be used in any presence/position sensing application normally addressed with conventional limit switches. Models with positive-break NC contacts are approved for use in safety systems. For safety applications the switch must be mounted such that the actuating element of the machine displaces the switch actuator far enough to exceed the positive-break point. (See contact function diagrams: symbol *). Optional Safety Controller. See Page is a trademark of SCHMERSAL

229 Z/T235 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Chromated diecast zinc with brown enamel finish Operating Temperature 22 F to +175 F ( 30 C to +80 C) Mechanical Life 20 million operations Minimum Cam Speed Z235 Series: 0.04m./minute (Referenced to Plunger) T235 Series: 2.4m./minute Maximum Operating Rate 5000 operations/hour Bounce Time Z235 Series: 3 ms T235 Series: Function of cam speed Changeover Time Z235 Series: 5 ms for minimum cam speed T235 Series: Function of cam speed Degree of Protection IP67 Conformity to Standards IEC EN DIN VDE 0660 Part 200 BG-GS-ET15 DIN EN CSA-C22.2 UL508 ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges Z235 Series: 2x0.08 inches (2x2mm) T235 Series: 2x0.14 inches (2x3.5mm) 4A/230VAC 2.5A/400VAC Snap-action, positive-break NC contacts (Z235) Slow-action, positive-break NC contacts (T235) Fuse: 10A (time delay) 2.5A (no time delay 6A (time delay) as positive-break position switch 500VAC 6kV Screw terminals, maximum 2.5mm (AWG13) wire CONTACT SYSTEMS Series T235 Slow-action switch Series Z235 Snap-action switch 6 229

230 Z/T235 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC 0 2,5 4, ZS z 0 2,5 4, ZR z Slow action 1 NO + 1 NC (break before make) 0 3,5 6 2,5 3, TS z 0 3,5 6 2,5 3, TR z 0 3, ,5 6 2 NO (simultaneous) 3, TS z 3, TR z 2 NC (simultaneous) 0 2,5 3,8 6 2,5 3, TS z 0 2,5 3,8 6 2,5 3, TR z Dimensions mm inch Types of Actuators Actuating force/-torque Actuating speed Z/T at Rounded plunger Style S 9 N (19 N positive break) 0 : min. 10/60 mm/min, max. 1 m/s Roller plunger Style R 9 N (19 N positive break) 30 : min. 20/120 mm/min, max. 1 m/s Snap Action positive break ZS z ZR z Part No Slow action Slow action TS z TS z* TR z TR z* Slow action TS z TR z 230 * Not for use in safety applications

231 Z/T235 TECHNICAL DATA 0 2, , ,6 9,3 4, Z4S z 4, Z4R z , ZK z , , , ,2 9,3 2,5 3, T4S z 2,5 3, T4R z 3,6 5, TK z 0 3, , ,2 9, T4S z T4R z TK z 3,5 3,5 5,2 0 2,5 3, ,5 3, ,6 5,5 9,3 2,5 3, T4S z 2,5 3, T4R z 3,6 5, TK z Rounded plunger (central mounting) Style 4S 9 N (19 N positive break) 0 : min. 10/60 mm/min, max. 1 m/s Top roller plunger (central mounting) Style 4R 9 N (19 N positive break) 30 : min. 20/120 mm/min, max. 1 m/s One-way roller lever Style K 8 N (18 N positive break) 30 : min. 24/240 mm/min, max. 1 m/s 6 Z4S z Z4R z ZK z T4S z T4R z TK z T4S z* T4R z* TK z* T4S z T4R z TK z * Not for use in safety applications 231

232 Z/T235 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC ZV12H z ZV14H z Slow action 1 NO + 1 NC (break before make) 2 NO (simultaneous) 2 NC (simultaneous) TV12H z TV12H z TV12H z TV14H z TV14H z TV14H z Dimensions mm inch Types of Actuators Actuating force/-torque Actuating speed Z/T at Snap Action positive break Roller rocking lever Style 12H 15 Ncm (18.5 Ncm positive break) 30 : min. 687/4122 mm/min, max. 1 m/s ZV12H z Roller rocking lever Style 14H 15 Ncm (18.5 Ncm positive break) 30 : min. 687/4122 mm/min, max. 1 m/s ZV14H z Part No Slow action Slow action TV12H z TV12H z* TV14H z TV14H z* Slow action TV12H z TV14H z 232 * Not for use in safety applications

233 Z/T235 TECHNICAL DATA ZV7H z ZV10H z 0 1,2 2, , Z3K z TV7H z TV10H z ,8 4, T3K z TV7H z TV10H z T3K z TV7H z TV10H z 0 2,8 4,3 7 2,8 4, T3K z Adjustable roller rocking lever* Style 7H 15 Ncm (18.5 Ncm positive break) 30 : min. 240/1440 mm/min, max. 1 m/s Rod rocking lever* Style 10H 15 Ncm (18.5 Ncm positive break) 30 : min. 687/4122 mm/min, max. 1 m/s One-way roller lever Style 3K 9 N (19 N positive break) 30 : min. 27/160 mm/min, max. 1 m/s 6 ZV7H z* ZV10H z* Z3K z TV7H z* TV10H z* T3K z TV7H z* TV10H z* T3K z* TV7H z* TV10H z* T3K z * Not for use in safety applications 233

234 Z/T235 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC , Z4K z 0 1,8 4,9 12, , ZK z Slow action 1 NO + 1 NC (break before make) , T4K z 0 7,2 12,8 4,9 7, TK z 2 NO (simultaneous) T4K z 0 7,2 12,8 7, TK z 2 NC (simultaneous) 0 5 7, , T4K z 0 4,9 7,7 12,8 4,9 7, TK z Dimensions mm inch Types of Actuators One-way roller lever Style 4K One-way roller lever Style K4 Actuating force/-torque Actuating speed Z/T at 6 N (16 N positive break) 30 : min. 44/264 mm/min, max. 1 m/s 6 N (16 N positive break) 30 : min. 56/336 mm/min, max. 1 m/s Snap Action positive break Z4K z ZK z Part No Slow action Slow action T4K z T4K z* TK z TK z* Slow action T4K z TK z 234 *Not for use in safety applications.

235 Safer by Design 6 235

236 SERIES Z/T236 Safety-Rated, Positive-Break Miniature DIN Limit Switches Features & Benefits Positive-Break NC contacts won t stick or weld shut. Watertight design meets IP67 washdown requirements. Rugged, corrosion-resistant housing tolerates hostile environments. Six popular actuator styles for application versatility. Four 90 actuator mounting positions provide installation flexibility. Slow or snap-action operation choose to best satisfy application requirements. Safety-system approved models with positive-break contacts approved for use in machine guarding applications. Meets rigid safety agency standards IEC, BG, VDE, UL and CSA. Description The Z/T236 Series limit switches are designed for use with movable machine guards/access gates which must be closed for operator safety and for any other presence/position sensing application normally addressed with conventional limit switches. Their positive-opening NC contacts provide a higher level of safety and/or reliability than conventional spring-driven switches whose contacts can weld or stick shut. Each is available with a choice of six standard actuators rounded plunger, roller plunger, roller rocking lever, rod rocking lever, adjustable roller rocking lever and one-way roller lever mountable in any one of four 90 positions. All rocking levers are positively-locked to the shaft, and are adjustable throughout 360 in 10 increments. Units are available with a choice of slow-action or snap-action contacts. Their rugged fiberglass-reinforced housing and IP67 rating make them ideal alternatives to conventional limit switches. Typical Applications The Z/T236 Series may be used in any presence/position sensing application normally addressed with conventional limit switches. Models with positive-break NC contacts are approved for use in safety systems. For safety applications the switch must be mounted such that the actuating element of the machine displaces the switch actuator far enough to exceed the positive-break point. (See contact function diagrams: symbol *). ORDERING GUIDE FOR FEATURE: SPECIFY: 1. Contact operation: Slow Action T Snap Action Z 2. Operating head V 3. Roller lever 7 H 4. Body size No. of NO contacts 1 6. No. of NC contacts 1 7. Degree of protection IP 67 z 8. Sealing of operating head (optional) z* Example 1: TV7 H z Example 2: ZV7 H z *Available on rocking lever actuator style only. 236 is a trademark of SCHMERSAL

237 Z/T236 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass fiber reinforced selfextinguishing thermoplastic Operating Temperature 22 F to +175 F ( 30 C to +80 C) Mechanical Life 20 million operations Minimum Cam Speed Z236 Series: 0.04m./minute (Referenced to Plunger) T236 Series: 2.4m./minute Maximum Operating Rate 5000 operations/hour Bounce Time Z236 Series: 3 ms T236 Series: Function of cam speed Changeover Time Z236 Series: 5 ms for minimum cam speed T236 Series: Function of cam speed Degree of Protection IP67 Conformity to Standards IEC EN DIN VDE 0660 Part 200 BG-GS-ET15 DIN EN CSA-C22.2 UL508 ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges Z236 Series: 2x0.08 inches (2x2mm) T236 Series: 2x0.14 inches (2x3.5mm) 4A/230VAC 2.5A/400VAC Snap-action, positive-break NC contacts (Z236) Slow-action, positive-break NC contacts (T236) Fuse: 10A (time delay) 2.5A (no time delay 6A (time delay) as positive-break position switch 500VAC 6kV Screw terminals, maximum 2.5mm (AWG13) wire CONTACT SYSTEMS Series T236 Slow-action switch Series Z236 Snap-action switch 6 237

238 Z/T236 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC 0 2,5 4, ZS z 0 2,5 4, ZR z Slow action 1 NO + 1 NC (break before make) 0 3,5 6 2,5 3, TS z 0 3,5 6 2,5 3, TR z 0 3, ,5 6 2 NO (simultaneous) 3, TS z 3, TR z 2 NC (simultaneous) 0 2,5 3,8 6 2,5 3, TS z 0 2,5 3,8 6 2,5 3, TR z Dimensions mm inch Types of Actuators Actuating force/-torque Actuating speed Z/T at Rounded plunger Style S 9 N (19 N positive break) 0 : min. 10/60 mm/min, max. 1 m/s Roller plunger Style R 9 N (19 N positive break) 30 : min. 20/120 mm/min, max. 1 m/s Snap Action positive break ZS z ZR z Part No Slow action Slow action TS z TS z* TR z TR z* Slow action TS z TR z 238 * Not for use in safety applications

239 Z/T236 TECHNICAL DATA 0 2, , ,6 9,3 4, Z4S z 4, Z4R z , ZK z , , , ,2 9,3 2,5 3, T4S z 2,5 3, T4R z 3,6 5, TK z 0 3, , ,2 9, T4S z T4R z TK z 3,5 3,5 5,2 0 2,5 3, ,5 3, ,6 5,5 9,3 2,5 3, T4S z 2,5 3, T4R z 3,6 5, TK z Rounded plunger (central mounting) Style 4S 9N (19N positive break) 0 : min. 10/60 mm/min, max. 1 m/s Top roller plunger (central mounting) Style 4R 9 N (19N positive break) 30 : min. 20/120 mm/min, max. 1 m/s Top roller lever Style K 8 N (18 N positive break) 30 : min. 24/240 mm/min, max. 1 m/s 6 Z4S z Z4R z ZK z T4S z T4R z TK z T4S z* T4R z* TK z* T4S z T4R z TK z * Not for use in safety applications 239

240 Z/T236 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC ZV1H z 0 2,7 5, Z1R z Slow action 1 NO + 1 NC (break before make) TV1H z 0 2, T1R z NO (simultaneous) TV1H z 0 2, T1R z ,3 2 NC (simultaneous) TV1H z 0 1 2, T1R z ,3 Dimensions mm inch Types of Actuators Actuating force/-torque Actuating speed Z/T at Roller rocking lever Style 1H 15 Ncm (18.5 Ncm positive break) 30 : min. 92/492 mm/min, max. 1 m/s Top roller lever Style 1R 15 Ncm (18.5 Ncm positive break) 30 : min. 27/160 mm/min, max. 1 m/s Snap Action positive break ZV1H z Z1R z Part No Slow action Slow action TV1H z TV1H z* T1R z T1R z* Slow action TV1H z T1R z 240 * Not for use in safety applications

241 Z/T236 TECHNICAL DATA , ZV7H z ZV10H z 5, Z3K z , TV7H z TV10H z ,8 4, T3K z TV7H z TV10H z T3K z TV7H z TV10H z 0 2,8 4, T3K z ,8 4,3 Adjustable roller rocking lever* Style 7H 15 Ncm (18.5 Ncm positive break) 30 : min. 240/1440 mm/min, max. 1 m/s Rod rocking lever* Style 10H 15 Ncm (18.5 Ncm positive break) 30 : min. 687/4122 mm/min, max. 1 m/s One-way roller lever Style 3K 9 N (19 N positive break) 30 : min. 27/160 mm/min, max. 1 m/s 6 ZV7H z* ZV10H z* Z3K z TV7H z* TV10H z* T3K z TV7H z* TV10H z* T3K z* TV7H z* TV10H z* T3K z * Not for use in safety applications 241

242 Z/T236 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC , Z4K z 0 1,8 4,9 12, , ZK z Slow action 1 NO + 1 NC (break before make) , T4K z 0 7,2 12,8 4,9 7, TK z 2 NO (simultaneous) T4K z 0 7,2 12,8 7, TK z 2 NC (simultaneous) 0 5 7, , T4K z 0 4,9 7,7 12,8 4,9 7, TK z Dimensions mm inch Types of Actuators One-way roller lever Style 4K One-way roller lever Style K4 Actuating force/-torque Actuating speed Z/T at 6 N (16 N positive break) 30 : min. 44/264 mm/min, max. 1 m/s 6 N (16 N positive break) 30 : min. 56/336 mm/min, max. 1 m/s Snap Action positive break Z4K z ZK z Part No Slow action Slow action T4K z T4K z* TK z TK z* Slow action T4K z TK z 242 * Not for use in safety applications

243 Safer by Design 6 243

244 SERIES Z/T335 Heavy-Duty Safety-Rated, Positive-Break Limit Switches Features & Benefits Positive-Break NC contacts won t stick or weld shut. Watertight design meets IP67 washdown requirements. Rugged, corrosion-resistant housing tolerates hostile environments. Six popular actuator styles for application versatility. Four 90 actuator mounting positions provide installation flexibility. Slow or snap-action operation choose to best satisfy application requirements. Safety-system approved models with positive-break contacts approved for use in machine guarding applications. Meets rigid safety agency standards IEC, BG, VDE, UL and CSA. Optional LED indicators provide visual display of supply voltage and switch operation. Description The Z/T335 Series limit switches are designed for use with movable machine guards/access gates which must be closed for operator safety and for any other presence/position sensing application normally addressed with conventional limit switches. Their positive-opening NC contacts provide a higher level of safety and/or reliability than conventional spring-driven switches whose contacts can weld or stick shut. Each is available with a choice of six standard actuators rounded plunger, roller plunger, roller rocking lever, rod rocking lever, adjustable roller rocking lever and one-way roller lever mountable in any one of four 90 positions. All rocking levers are positively-locked to the shaft, and are adjustable throughout 360 in 10 increments. Units are available with a choice of slow-action or snap-action contacts. Their rugged metal housing and IP67 rating make them ideal alternatives to conventional limit switches. ORDERING GUIDE FOR FEATURE: SPECIFY: 1. Contact operation: Slow Action T Snap Action Z 2. Operating head 4V 3. Roller lever H 4. Body size No. of NO contacts 1 6. No. of NC contacts 1 7. Degree of protection IP 67 z 8. Sealing of operating head (optional) z Example 1: T4VH z Example 2: Z4VH z Note: The Z/T335 Series is also available with 1 NO and 2 NC and with 3 NC contacts. Please consult factory. Typical Applications The Z/T335 Series may be used in any presence/position sensing application normally addressed with conventional limit switches. Models with positive-break NC contacts are approved for use in safety systems. For safety applications the switch must be mounted such that the actuating element of the machine displaces the switch actuator far enough to exceed the positive-break point. (See contact function diagrams: symbol *). Optional Safety Controller. See Page 328. is a trademark of SCHMERSAL INC. 244

245 Z/T335 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Diecast aluminum with enamel finish Operating Temperature 22 F to +195 F ( 30 C to +90 C) Mechanical Life 30 million operations Maximum Operating Rate 5000 operations/hour Bounce Time Z335 Series: < 2 ms T335 Series: Function of cam speed Changeover Time Z335 Series: < 2 ms for cam speed of 1 mm/minute T335 Series: Function of cam speed Degree of Protection IP67 Conformity to Standards IEC EN DIN VDE 0660 Part 200 BG-GS-ET-15 DIN EN CSA-C22.2 No. 14 (Suffix -1577) UL508 (Suffix -1594) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges Z335 Series: 2x0.03 inches T335 Series: 2x0.16 inches 4A/230VAC 2.5A/400VAC Z335 Series: Snap-action with positive-break NC contacts T335 Series: Slow-action, positive-break NC contacts Fuse: 10A (time delay) 16A (no time delay 6A (time delay) as positivebreak position switch 500VAC 6kV Screw terminals, maximum 2.5mm 2 (AWG13) wire SNAP ACTION CONTACT SYSTEMS SLOW ACTION CONTACT SYSTEMS Slow Action Switch T335 Snap Action Switch Z335 LED INDICATOR MODELS Green LED (gn) indicator supply voltage and yellow LED (ye) indicator for switch operation of NO or NC contacts for 24VDC. Available for all models of Series 335. Shown here: Z4VH zG24 Wiring diagram: 6 Shown here: indication of operation of NC contact (terminals 21-22); for indication of operation of NO contact use terminals protected against wrong polarity connection protected against transient voltages 700V Attention: no inductive loads 245

246 Z/T335 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC , , ,9 6 ZS z , , ,9 6 ZR z 2 NC ZS z ZR z ,8 0,8 Slow action 1 NO + 1 NC break before make or make before break 2 NO simultaneous contacts staggered (2-step) 2 NC simultaneous contacts staggered (2-step) 1 NC + 1 NC (CW-CCW) -11z -20z -02z , ,8 6 TS ,7 4, ,3 0 3,7 4, zu -20zh -02zh -11z -20z -02z , ,8 6 TR ,7 4, ,3 0 3,7 4, zu -20zh -02zh 2 2,8 2 2,8 2 2,8 2 2,8 Dimensions mm inch Types of Actuators Rounded plunger Style S Roller plunger Style R Actuating Force Actuating Force Snap Action positive break ZS z 12 N ZR z 12 N Snap Action positive break ZS z 12 N ZR z 12 N Part No Slow Action Make before break Slow Action 2-step TS z TS zu TS z* TS zh* 15 N 17 N TR z TR zu TR z* TR zh* 15 N 17 N Slow Action 2-step TS z TS zh 14 N TR z TR zh 14 N Slow Action 1 NC CW + 1 NC CCW * Not for use in safety applications

247 Z/T335 TECHNICAL DATA Z4VH z Z4V7H z Z4V10H z Z4VH z Z4V7H z Z4V10H z z -20z -02z T4VH zu -20zh -02zh -11z -20z T4V7H zu -20zh -11z -20z T4V10H zu -20zh /01zh z zh -02z zh 4V operating head with roller rocking lever Style H 4V operating head with adjustable roller rocking lever Style 7H* 4V operating head with rod rocking lever Style 10H* Z4VH z Actuating Force 27 Ncm Z4V7H z* Actuating Force 27 Ncm Z4V10H z* Actuating Force 27 Ncm 6 Z4VH z 27 Ncm Z4V7H z* 27 Ncm Z4V10H z* 27 Ncm T4VH z T4VH zu 27.5 Ncm T4V7H z* T4V7H zu* 27.5 Ncm T4V10H z* T4V10H zu* 27.5 Ncm T4VH z* T4VH zh* 28 Ncm T4V7H z* T4V7H zh* 28 Ncm T4V10H z* T4V10H zh* 28 Ncm T4VH z T4VH zh 27.5 Ncm T4V7H z* T4V7H zh* 27.5 Ncm T4V10H z* T4V10H zh* 27.5 Ncm TVH /01z 26.5 Ncm (other levers upon request) * Not for use in safety applications 247

248 Z/T335 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC 0 0 2,1 1 1,6 6, , ,3 Z1K z 0 4,5 2,2 0 3, , Z3K z 2 NC 4,2 4, Z1K z 8,8 8, Z3K z ,8 1,4 Slow action 1 NO + 1 NC break before make or make before break 2 NO simultaneous contacts staggered (2-step) 2 NC simultaneous contacts staggered (2-step) 1 NC + 1 NC (CW-CCW) -11z -20z -02z 0 3,2 6,3 2,1 0 6,3 3 3,2 0 2,1 3 6,3 2,1 3 T1K ,2 6,3 0 3,2 6,3 1, ,3 2, zu -20zh -02zh -11z -20z -02z 0 6,6 11 4,5 6, ,6 0 4,5 6,3 11 4,5 6,3 T3K ,6 11 8,2 9,9 0 6,6 11 2,8 0 4,5 8,2 11 9,9 4,5 6, zu -20zh -02zh Dimensions mm inch Types of Actuators One-way roller lever Style 1K One-way roller lever Style 3K Actuating Force Actuating Force Snap Action positive break Z1K z 12 N Z3K z 5.0 N Snap Action positive break Z1K z 12 N Z3K z 5.0 N Part No Slow Action Make before break Slow Action 2-step T1K z T1K zu T1K z* T1K zh* 15 N 17 N T3K z T3K zu T3K z* T3K zh* 6.3 N 7.2 N Slow Action 2-step T1K z T1K zh 14 N T3K z T3K zh 6.0 N 248 * Not for use in safety applications

249 Safer by Design 6 249

250 SERIES Z/T336 Heavy-Duty Safety-Rated, Positive-Break Limit Switches Features & Benefits Positive-Break NC contacts won t stick or weld shut. Watertight design meets IP67 washdown requirements. Rugged, corrosion-resistant housing tolerates hostile environments. Six popular actuator styles for application versatility. Four 90 actuator mounting positions provide installation flexibility. Slow or snap-action operation choose to best satisfy application requirements. Safety-system approved models with positive-break contacts approved for use in machine guarding applications. Meets rigid safety agency standards IEC, BG, VDE, UL and CSA. Description The Z/T336 Series limit switches are designed for use with movable machine guards/access gates which must be closed for operator safety and for any other presence/position sensing application normally addressed with conventional limit switches. Their positive-opening NC contacts provide a higher level of safety and/or reliability than conventional spring-driven switches whose contacts can weld or stick shut. Each is available with a choice of six standard actuators rounded plunger, roller plunger, roller rocking lever, rod rocking lever, adjustable roller rocking lever and one-way roller lever mountable in any one of four 90 positions. All rocking levers are positively-locked to the shaft, and are adjustable throughout 360 in 10 increments. Units are available with a choice of slow-action or snap-action contacts. Their rugged fiberglass-reinforced thermoplastic housing and IP67 rating make them ideal alternatives to conventional limit switches. ORDERING GUIDE FOR FEATURE: SPECIFY: 1. Contact operation: Slow Action T Snap Action Z 2. Operating head 4V 3. Roller lever H 4. Body size No. of NO contacts 1 6. No. of NC contacts 1 7. Degree of protection IP 67 z 8. Sealing of operating head (optional) z* Example 1: T4VH z Example 2: Z4VH z *Available on rocking lever actuator style only. Typical Applications The Z/T336 Series may be used in any presence/position sensing application normally addressed with conventional limit switches. Models with positive-break NC contacts are approved for use in safety systems. For safety applications the switch must be mounted such that the actuating element of the machine displaces the switch actuator far enough to exceed the positive-break point. (See contact function diagrams: symbol *). 250 is a trademark of SCHMERSAL

251 Z/T336 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass fiber reinforced selfextinguishing thermoplastic Operating Temperature 22 F to +195 F ( 30 C to +90 C) Mechanical Life 30 million operations Maximum Operating Rate 5000 operations/hour Bounce Time Z336 Series: < 2 ms T336 Series: Function of cam speed Changeover Time Z336 Series: < 2 ms for cam speed of 1 mm/minute T336 Series: Function of cam speed Degree of Protection IP67 Conformity to Standards IEC EN DIN VDE 0660 Part 200 BG-GS-ET-15 DIN EN CSA-C22.2 No. 14 (Suffix -1577) UL508 (Suffix -1594) ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges Z336 Series: 2x0.03 inches T336 Series: 2x0.16 inches 4A/230VAC 2.5A/400VAC Z336 Series: Snap-action with positive-break NC contacts T336 Series: Slow-action, positive-break NC contacts Fuse: 10A (time delay) 16A (no time delay 6A (time delay) as positivebreak position switch 500VAC 6kV Screw terminals, maximum 2.5mm (AWG13) wire SNAP ACTION CONTACT SYSTEMS SLOW ACTION CONTACT SYSTEMS Slow Action Switch T336 Snap Action Switch Z

252 Z/T336 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC , , ,9 6 ZS z , , ,9 6 ZR z 2 NC ZS z ZR z ,8 0,8 Slow action 1 NO + 1 NC break before make or make before break 2 NO simultaneous contacts staggered (2-step) 2 NC simultaneous contacts staggered (2-step) 1 NC + 1 NC (CW-CCW) -11z -20z -02z , ,8 6 TS ,7 4, ,3 0 3,7 4, zu -20zh -02zh -11z -20z -02z , ,8 6 TR ,7 4, ,3 0 3,7 4, zu -20zh -02zh 2 2,8 2 2,8 2 2,8 2 2,8 Dimensions mm inch Types of Actuators Rounded plunger Style S Roller plunger Style R Actuating Force Actuating Force Snap Action positive break ZS z 12 N ZR z 12 N Snap Action positive break ZS z 12 N ZR z 12 N Part No Slow Action Make before break Slow Action 2-step TS z TS zu TS z* TS zh* 15 N 17 N TR z TR zu TR z* TR zh* 15 N 17 N Slow Action 2-step TS z TS zh 14 N TR z TR zh 14 N Slow Action 1 NC CW + 1 NC CCW * Not for use in safety applications

253 Z/T336 TECHNICAL DATA Z4VH z Z4V7H z Z4V10H z Z4VH z Z4V7H z Z4V10H z z -20z -02z T4VH zu -20zh -02zh -11z -20z T4V7H zu -20zh -11z -20z T4V10H zu -20zh /01zh z zh -02z zh 4V operating head with roller rocking lever Style H 4V operating head with adjustable roller rocking lever Style 7H* 4V operating head with rod rocking lever Style 10H* Z4VH z Actuating Force 27 Ncm Z4V7H z* Actuating Force 27 Ncm Z4V10H z* Actuating Force 27 Ncm 6 Z4VH z 27 Ncm Z4V7H z* 27 Ncm Z4V10H z* 27 Ncm T4VH z T4VH zu T4VH z* T4VH zh* T4VH z T4VH zh 27.5 Ncm 28 Ncm 27.5 Ncm T4V7H z* T4V7H zu* T4V7H z* T4V7H zh* T4V7H z* T4V7H zh* 27.5 Ncm 28 Ncm 27.5 Ncm T4V10H z* T4V10H zu* T4V10H z* T4V10H zh* T4V10H z* T4V10H zh* 27.5 Ncm 28 Ncm 27.5 Ncm TVH /01z 26.5 Ncm (other levers upon request) * Not for use in safety applications 253

254 Z/T336 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC 0 0 2,1 1 1,6 6, , ,3 Z1K z 0 4,5 2,2 0 3, , Z3K z 2 NC 4,2 4, Z1K z 8,8 8, Z3K z ,8 1,4 Slow action 1 NO + 1 NC break before make or make before break 2 NO simultaneous contacts staggered (2-step) 2 NC simultaneous contacts staggered (2-step) 1 NC + 1 NC (CW-CCW) -11z -20z -02z 0 3,2 6,3 2,1 0 6,3 3 3,2 0 2,1 3 6,3 2,1 3 T1K ,2 6,3 0 3,2 6,3 1, ,3 2, zu -20zh -02zh -11z -20z -02z 0 6,6 11 4,5 6, ,6 0 4,5 6,3 11 4,5 6,3 T3K ,6 11 8,2 9,9 0 6,6 11 2,8 0 4,5 8,2 11 9,9 4,5 6, zu -20zh -02zh Dimensions mm inch Types of Actuators One-way roller lever Style 1K One-way roller lever Style 3K Actuating Force Actuating Force Snap Action positive break Z1K z 12 N Z3K z 5.0 N Snap Action positive break Z1K z 12 N Z3K z 5.0 N Part No Slow Action Make before break Slow Action 2-step T1K z T1K zu T1K z* T1K zh* 15 N 17 N T3K z T3K zu T3K z* T3K zh* 6.3 N 7.2 N Slow Action 2-step T1K z T1K zh 14 N T3K z T3K zh 6.0 N 254 * Not for use in safety applications

255 Safer by Design 6 255

256 SERIES Z332 Heavy-Duty Safety-Rated, Positive-Break Limit Switches Features & Benefits Positive-Break NC contacts won t stick or weld shut. Watertight design meets IP65 washdown requirements. Rugged, corrosion-resistant housing tolerates hostile environments. Five popular actuator styles for application versatility. Four 90 actuator mounting positions provide installation flexibility. Safety-system approved for use in machine guarding applications. Meets rigid safety agency standards IEC, BG, VDE, and CSA. Description The Z332 Series limit switches are designed for use with movable machine guards/access gates which must be closed for operator safety and for any other presence/position sensing application normally addressed with conventional limit switches. Their positive-opening NC contacts provide a higher level of safety and/or reliability than conventional spring-driven switches whose contacts can weld or stick shut. Each is available with a choice of five standard actuators rounded plunger, roller plunger, roller rocking lever, rod rocking lever and adjustable roller rocking lever mountable in any one of four 90 positions. All rocking levers are positively-locked to the shaft, and are adjustable throughout 360 in 10 increments. Their rugged metal housing and IP65 rating make them ideal alternatives to conventional limit switches. ORDERING GUIDE FOR FEATURE: SPECIFY: 1. Contact operation: Snap Action Z 2. Operating head 4V 3. Roller lever H 4. Body size No. of NO contacts 1 6. No. of NC contacts 1 7. Degree of protection IP 65 y Example: Z4VH y Typical Applications The Z332 Series may be used in any presence/position sensing application normally addressed with conventional limit switches. Featuring positive-break NC contacts, they are approved for use in safety systems. For safety applications the switch must be mounted such that the actuating element of the machine displaces the switch actuator far enough to exceed the positive-break point. (See contact function diagrams: symbol *). 256 is a trademark of SCHMERSAL

257 Z332 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Diecast aluminum with enamel finish Operating Temperature 22 F to +195 F ( 30 C to +90 C) Mechanical Life 1 million operations Minimum Cam Speed 1 mm/minute (Referenced to Plunger) Maximum Operating Rate 5000 operations/hour Bounce Time 2 ms Changeover Time 1.5 ms for minimum cam speed Degree of Protection IP65 Conformity to Standards IEC EN DIN VDE 0660 Part 200 BG-GS-ET-15 DIN EN CSA-C22.2 No. 14 (Suffix -1220) Contact System ELECTRICAL SPECIFICATIONS Contacts Contact Configuration Contact Gap Contact Rating Switching Action Short Circuit Protection Rated Insulation Voltage Rated Impulse Withstand Voltage Type Terminals Fine silver Double-pole, double-break with electrically-separated contact bridges in. immediately after switching in. with full travel of actuator 2.5A/250VAC Z332 Series: Snap-action with positive-break NC contacts Fuse: 20A (time delay) 25A (no time delay 6A (time delay) as positivebreak position switch 250VAC 6kV Screw terminals, maximum 2.5mm (AWG13) wire Magnetic storage snap-action system SNAP ACTION CONTACT SYSTEMS Snap-action switching, 1 NO 1 NC Change-over, double-gap with four terminals Two electrically separated moving contacts Plated solid silver contacts Positive-break NC contact with snap-action switching Reliable change-over, even with slow plunger actuation Snap-action system separated from contact system Full contact force right up to operating point Constant operating position, as independent of contact burning Short, constant flight time of only 1.5 ms Short bounce time High short-circuit resistance High vibration resistance of 10 g still only 0.01 mm before operating point Wide contact gap of mm immediately after switching point 6 257

258 Z332 TECHNICAL DATA Contact function diagrams Snap action positive break 1 NO + 1 NC , ZS y , ZR y ,4 1,4 Dimensions mm inch Types of Actuators Rounded plunger Style S Roller plunger Style R Actuating Force Actuating Force Part No Snap Action positive break ZS y 31 N ZR y 31 N 258

259 Z332 TECHNICAL DATA Z4VH y Z4V7H y Z4V10H z 4V operating head with roller rocking lever Style H Actuating Force 4V operating head with adjustable roller lever Style 7H* Actuating Force 4V operating head with rod rocking lever Style 10H* Actuating Force Z4VH y 35 Ncm Z4V7H y* 35 N Z4V10H y* 35 Ncm * Not for use in safety applications 6 259

260 SERIES C50 Compact, Safety-Rated, Positive-Break Limit Switches Features & Benefits Positive-Break NC contact won t stick or weld shut. Compact size ideal where space is limited. Rugged, corrosion-resistant housing tolerates hostile environments. Meets rigid safety standards IEC, VDE. Electrically-insulated contacts for added safety. Part Number AVAILABLE STANDARD MODELS Contact Configuration Actuator Type C50R C50ST 1 NO & 1 NC 1 NO & 1 NC Roller plunger Adjustable plunger Description The C50 Series limit switches are designed for use with movable machine guards/access gates which must be closed for operator safety and for any other presence/position sensing application normally addressed with conventional limit switches. Their positive-opening NC contact provides a higher level of safety and reliability than conventional spring-driven limit switches whose contacts can weld or stick shut. Typical Applications The C50 Series may be used in any presence/position sensing application normally addressed with conventional limit switches. Operation The C50 Series are designed to mount to a machine structure such that when the guard is open, it directly drives the switch actuator to force open the unit s positive-break, normallyclosed contact. The positive-break NC contact ensures circuit interruption (and machine stoppage). Note that for safety applications, these switches must be mounted in the positivemode. Optional Safety Controller. See Page 328. is a trademark of SCHMERSAL 260

261 SERIES C50 TECHNICAL DATA MECHANICAL SPECIFICATIONS Housing Glass-fiber reinforced (UL94-V0), self-extinguishing thermoplastic Operating Temperature 13 F to +167 F Degree of Protection IP30 Maximum Operating Rate 1,800 operations/hour Mechanical Life >5 million operations Repeat Accuracy +/ mm Conformity to Standards IEC EN DIN VDE 0660 Part 200 EN UL & CSA ELECTRICAL SPECIFICATIONS Contacts Fine silver Contact Configuration Double-pole, double-break with electrically-separated bridges Contact Rating 4A/400VAC (AC-15) Switching Action Slow-action, positive-break NC contacts Electrical Connections Screw terminals (M3), maximum 13AWG wire Short Circuit Protection 4A (Slow-blow) DIMENSIONS & SWITCHING DIAGRAMS ø ,5.30 2,5.10 Switching Diagram 21,5.85 ø5.20 C50 R 7,5.30 mm inch Circuit Diagram C50 ST ø4,2.17 3, , C50 Series 21,

262 262 Safer by Design

263 SAFETY LIGHT CURTAINS & BEAMS SELECTION GUIDE Series Description Range Catalog Page SLC/G mm & 30mm 5m (14mm) 18m (30mm) 273 SLB 200 Safety Category 2 Light Beam 4m 304 SLB 400 Safety Category 4 Light Beam 15m

264 264 Safer by Design

265 Safety light curtains and safety light grids System features: Control Category 2 and 4 acc. to EN or acc. to EN 61496, Type 2 and Type 4 Different integrated functions: Start/Restart interlock Contactor monitoring Muting Blanking Master/Slave configuration Diagnostic display Optical synchronisation Maintenance- free Compact design Simple, flexible mounting and adjustment 7 265

266 Introduction Optoelectronic safety sensors EN The field of automation is subject to a permanent and innovative change of products and applications. The focus is on increasing the productivity and realising a smoothrunning production process with a minimum of human interventions on machinery and systems. The ideal, a fully automatic and totally safe machine however will always remain a dream, though the robots used in production plants already are a big step towards this aim. Human intervention and knowledge will always be required for the commissioning, monitoring and maintenance of modern industrial systems. Man however is not infallible and ignorance or lack of information, thoughtlessness or negligence often leads to damages. For these reasons, harmonised standards, i.e. the Machinery Directive EC 98/37/EC and other regulations, were implemented at European level. These standards aim at detecting and constructively avoiding all possible risks and hazards during the planning and project phase of machines and systems. Safety components must be used to minimise or eliminate the residual risks. In this way, manufacturers and users are making equivalent efforts to set up an optimal process flow, which offers the highest possible protection to the operating staff. The challenge for all manufacturers of safety components is to design efficient and safe product solutions for mechanical engineers. Flaps and doors are the simplest means of access to the machine. These separating hardguarding safety solutions offer an efficient and effective protection against hazardous movements and products being ejected from the machine. When these safety guards are opened, the machine is brought to standstill (through the corresponding safety sensor transmitting the stop signal to the control), which interrupts and therefore slows down the production. In case of continuous processes, which must not be interrupted, solenoid interlocks protect man and the work piece against damages. Safety fences are not suitable for production processes requiring the material to be transported into the working area by means of conveyor belts, as it does not allow for an ergonomic and optimal work sequence. A virtual safety guard in the form of an active optoelectronic device (AOPD), e.g. a safety light curtain, is a perfect solution, offering both an optimal protection of human life and uninterrupted production process. 266

267 Typical applications: Power-driven machines Power-driven presses in metalworking, plastics, leather, stone working and rubber processing industry Folding presses and attachments Filter presses Punching machines in leather, textile and plastics processing Robots stations and welding booths Printing and injection moulding machines Transport engineering Pallet loaders and palletizers Materials handling and storage technology and so on Depending on the application, the AOPD are used for danger point, danger zone and perimeter guarding. The user can choose from a large range of different optoelectronic safety solutions e.g. light barriers, light grids, light curtains and laser scanners

268 Design and operating principle Optoelectronic Safety light barriers The safety light barrier systems of the SLB range are active optoelectronic protective devices (AOPD) fulfilling the Control Category 2 or 4 in accordance with EN or EN These systems are used as entry guards on hazardous zones, danger points and entrances. They protect human life without restricting the production flow. Typical applications for safety light barriers are on robots, automatic-processing plants, transfer lines, rack storages and pallet loaders. The entire safety light barrier system includes a light emitter, a light receiver and a safety monitoring module. The safety monitoring module evaluates the signals of the emitter. If the light beam is interrupted, a signal is emitted to bring the dangerous movement of the machine to standstill. The safety monitoring module integrates functions such as start and restart interlock as well as a contactor monitoring. The maintenance-free safety sensors of the system with protection class IP 67 have an integrated soiling check. Because of their small size, safety light barriers can be fitted almost everywhere. Safety light grids / light curtains The safety light curtains and safety light grids of the SLC and SLG meet the requirements of Control Category 2 or 4 to EN and Type 2 or Type 4 to EN They safeguard danger points and hazardous areas on different applications, e.g. presses, robot stations, injection moulding machines, pallet machines, etc. In these active optoelectronic protective devices (AOPD), the emitter and receiver are fitted in two separate enclosures. An invisible infrared signal is sent from the emitter and evaluated by the receiver. If the light beam is interrupted by an object or a person, a stop signal is emitted to bring the machine to standstill. The protection field is defined by the height and width of the protection field. The protected height is the range between the first and last infrared light beam of a light curtain. The protected height defines the physical size of the system to be used. The protected width or operating range is the distance between the transmitter and receiver unit. For an accurate detection of objects with different sizes in the hazardous area, the user can choose between light grids and light curtains with different resolutions. Here, the following rule applies: the smaller the distance between two adjacent light beams, the more accurate the detection sensitivity of the AOPD. For the detection of body parts, a distinction is made between finger, hand and body protection. EN 999 or EN 294 sets the biometric data for finger protection to 14 mm, for hand detection to 40 mm, for leg detection up to 70 mm and for body detection to over 70 mm. Safety light grids with 2, 3 or 4 individual beams are generally used to detect the penetration of the entire human body. Safety light curtains are multiple beam systems (> 5 individual beams) and can also detect smaller objects in case of intrusion into the protected field. The maintenance- free safety light curtains and light grids can be smoothly fitted using an M12 connector and have a diagnostic LED indication for status messages. Depending on the type of safety light curtain or light grid used, the components have an integrated evaluation with Protected width (operating range) start/restart interlock and contactor monitoring. Additional functions such as blanking, muting and cascading of the light curtains are available as well. These functions are simply configured in the AOPD through the contact configuration (no configuration software required). The SLC and SLG product series therefore offer a maximum of flexibility for safeguarding different danger points. Protectied height 268 Light beam

269 safety systems Important conditions for the use of optoelectronic safety devices: In order to choose the appropriate active optoelectronic protective device (AOPD) such as light barriers and light curtains/grids and to use them correctly, both the requirements of the standards (EN 61496, EN 999,EN 294, C standards etc.) and product-specific features (detection sensitivity, range, etc.) must be taken into account. AOPD s can be used, provided that: the dangerous movement can be stopped at all times and that it is ensured that the danger point can only be reached after the movement has come to standstill, the run-out time of the machine and all safety components is known, no objects (work pieces, sparks, liquids, etc.) can be ejected, the AOPD meet the requirements of Type 2 or Type 4 acc. to EN 61496, the danger point can only be reached by passing through the protected field of the AOPD, reaching over, under or through the protected field is impossible, the start or restart command devices are fitted in such a way that the entire hazardous area is completely visible from the outside and that it cannot be activated from outside the hazardous area and the safety distance is calculated and constructively applied in accordance with EN 999. The effectiveness of the safety guard corresponds to the risk assessment, which was carried out during the planning and design phase, taking all important boundary conditions, e.g. environment, machine and function

270 Application Safety distance EN 999 Safety distances for light curtains Between the interruption of a light beam and the standstill of the machine, a certain time expires. The safety light grid or light curtain must be sized and installed such that a stop would be signalled and the hazard ceased prior to a person or a body member accessing the hazard. The standard EN 999 provides the user with detailed information about the calculation of the minimum safety distances. These include the following important influencing factors: run-out time of the entire system, taking the different reaction times of the individual systems into account (e.g. machine, safety monitoring module, AOPD etc.) capacity of the AOPD to detect body parts (fingers, hand and entire human body) set-up of the safety guard in normal condition (vertical fitting), parallel condition (horizontal fitting) or at an arbitrary angle in front of the safety guard and the speed at which the protection field is approached. For the calculation of the minimum safety distance S to the hazardous area, EN 999 presents the following general formula: S = K x T + C Where: S the safety distance to the danger point (mm) K the approach speed of the body or the body part (mm/s) T the entire reaction time of the system(s) (including the machine s runout time, the reaction time of the safety guard and the safety monitoring module etc.) C additional distance (mm) in front of the safety guard Normal approach for light curtains: (resolution: max. 40 mm) The minimum safety distance S is calculated in the following way: S = 2000 T + 8 (D-14) (D = resolution). This formula applies to safety distances up to 500 mm. The minimum safety distance Smin may not be less than 100 mm. If the calculation produces a distance larger than 500 mm for S, the calculation can be repeated with a lower approach speed: S = 1600 T + 8 (D-14) In this case, Smin may not be less than 500 mm. Light curtain Approach direction If the danger point of the machine is accessible from the top because of its particular construction, the height H of the topmost beam of the light barrier must be at least 1800 mm above the base G of the machine. Normal approach for light curtains: (resolution: from 40 mm up to max. 70mm) The minimum safety distance S is calculated in the following way: S = 1600 T The height of the topmost light beam must be at least 900 mm, the height of the lowermost light beam maximum 300 mm above the bottom (for the protection of children younger than 14: 200 mm) Danger point Reference floor 270

271 Normal approach for light grids: (resolution: > 70 mm) The minimum safety distance S is calculated using the following formula: S = 1600 T For safety guards with multiple beams, height H (mm) above the reference floor of the individual beams must be Number Height above the of beams reference floor 2 400, , 700, , 600, 900,1200 applied in the following way: When using light curtains or light grids, particular attention must be paid to the tampering possibilities of the safety guard and to the mechanical risks (e.g. crushing, shearing, cutting, ejection). Horizontal approach for light curtains/grids (resolution: > 50 mm) The minimum safety distance S is calculated using the following formula: S = 1600 T H Here, Smin is 850 mm. The lowest authorised height H depends on the resolution D of the light curtain: H = 15 (D-50) For this type of safety guard, the maximum height H is 1000 mm. In the risk analysis, special attention must be paid to the prevention of unintentional undetected access from underneath the protection field. Further calculation examples can be found in DIN EN 999 as well as in the mounting instructions of the SLC/SLG safety sensors. Danger point Danger point Light curtain /grid Direction of approach Direction of approach Light curtain /grid 7 Reference floor Reference floor 271

272 Modes of operation and functions Master/Slave cascading For the SLC/SLG M/S product series, the master light curtain can be extended with another (slave) light curtain (cascading). In this way, multiple protection fields can be generated. A protection field is created between the emitter and receiver of the master as well as other protection fields between the slave components. This device cascading provides for a comfortable and efficient protection of contiguous protection fields against reaching over or through the protection field. The slave light curtains are connected to the master by means of an M12 connector. The master and slave light curtains are available in different sizes and resolutions and allow for almost any combination. Muting If goods or objects must be transported in or out of the hazardous area without stopping the machine, the safety light curtain must be automatically and temporarily suspended by the safetyrelated parts of the control system. To this end, two or four muting sensors are used to detect whether a person is approaching the hazardous area or a transport system enters or leaves the hazardous area. Suitable muting sensors are light barriers, proximity switches or position switches. The integrated safety-muting controller of the safety light curtain or light grid monitors and controls the muting process. The safety outputs are not disabled.when the muting function is used, an external muting lamp must be connected as well in order to enable the system being activated. Any malfunction of the monitored signal source will cause the OSSD s to be switched off. Depending on the application, different light curtains with integrated muting function as well as external or internal muting sensors are available. Detailed product information can be found in this brochure from page 33. Blanking /Floating Blanking If continuity of the production process is required, a part of the protection field can be blanked without triggering a stop signal In this way, objects such as work pieces can be fed or a conveyor belt can be positioned at a fixed position in the protection field. The integrated floating blanking function of the SLC B light curtains enables a flexible blanking of up to three adjacent light beams in the protection field of the light curtain. This function is required to ensure that one, two or three adjacent light beams can be interrupted at an undefined position in the protection field. In this way, objects such as fixtures or materials with slightly varying heights can be fed through the light curtain without triggering a stop signal. Five different floating blanking functions are available. The distinguishing feature of the different modes is the number of light beams that can be interrupted by an object. In addition to that, it can be defined whether the object may interrupt the protection field permanently or only temporarily. The interrupted light beams can be at any position in the protection field. Aport from the first infrared light beam (the beam closest to the connector), any light beam can be used for floating blanking. A complex programming through software and computer or complicated teach-in procedures is not required, as the floating blanking functions are configured in the connector of the AOPD s receiver unit. When floating blanking is applied, the resolution of the light curtain changes. The technical documentation of the different light curtains includes the tables with the effective resolutions D to calculate the minimum safety distance to EN 999. Further technical product information can be found in this brochure. Master Slave Floating-Blanking-Area 2 movable object

273 Safety light curtains and safety light grids Selection table Type Detection Protected Range Contactor Start/ Master / Muting Blanking Page EN sensitivity height monitoring restart Slave (mm) (mm) (m) interlock SLC/G X X SLC/G RF SLC/G RFM/S 277 SLC/G RFLC SLC/G X X SLC/G RF SLC/G RFM/S 281 SLC B 90 X X 282 SLC BM X X 282 SLC/G SLG 412-P SLC/G 415I SLG 415L , 810 2,5 289 SLG 415T , 810 3,5 X only in combination with safety monitoring module integrated not available

274 274 Safer by Design

275 Safety light curtains and safety light grids SLC 210 Safety light curtain Control category Type 2 to IEC/EN , -2 Resolution 20, 30, 40, 50 and 90 mm Protection field height from 160 mm to 1810 mm Range from m Self-test every 0.5 s semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght (B + 91 mm) B: Protection field height C: 85 mm (SLC) Approvals Ordering details SLC 210-E/R➀-➁-12-➂ No. Replace Description ➀ xxxx Height of protection field Available lengths: 0160 mm*** 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm 1660 mm 1810 mm ➁ 20, 30 Resolution 20, 30 mm 40, 50 Resolution 40, 50 mm 90 Resolution 90 mm ➂ Range 6 m H Range m High Range SLG 210 Safety light grid 2-, 3- or 4-beam light grid Protection field heights 510 mm, 810 mm or 910 mm Approvals Ordering details SLG 210-E/R➀-12-➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam ➁ Range m H Range m High Range Mounting brackets and T-slots are included in the delivery. *** only for resolution 20, 30 mm Technical data Standards: IEC/EN /-2 Control Category to IEC/EN , -2 Type 2 Enclosure: Aluminium Enclosure dimensions: 35 x 45 mm Connection: connector plug M 12, 5-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 5,5 28 ms (depends on length and resolution) Detection sensitivity (Resolution): 20, 30, 40, 50 and 90 mm Protection field height: (Resolution: 20, 30 mm): mm (Resolution: 40, 50, 90 mm): mm (2-, 3-, 4-beam): 510, 810, 910 mm Protection field width, range: m (Standard), m (High range) Start/restart interlock: * Contactor control: * Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics display LED indication Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC * only in combination with safety monitoring module ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for Emitter/ Receiver KD M m KD M m for Emitter/ Receiver (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S Further accessories can be found on page

276 Safety light curtains and safety light grids SLC RF Safety light curtain Control category Type 2 to IEC/EN , -2 Resolution 20, 30, 40, 50 and 90 mm Protection field height from 160 mm to 1810 mm Integrated start/restart interlock Integrated contactor control Range from m Self-test every 0.5 s Semiconductor outputs Optical synchronisation Status display Protection class IP 65 SLG RF Safety light grid 2-, 3- or 4-beam light grid Protection field heights 510 mm, 810 mm or 910 mm Legend: A: Total lenght (B + 91 mm) B: Protection field height C: 85 mm (SLC) Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 2 Enclosure: Aluminium Enclosure dimensions: 35 x 45 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 12, 8-pole Max. cable length: 100 m (Master/Slave) 50 m Protection class: IP 65 to EN Response time: 5,5-28 ms (depends on length and resolution) Detection sensitivity (Resolution): 20, 30, 40, 50 and 90 mm Protection field height: (Resolution: 20, 30 mm): mm (Resolution 40, 50, 90 mm): mm (2-, 3-, 4-beam): 510, 810, 910 mm Protection field width, range: m Start/restart interlock: integrated Contactor control: integrated Cascading (Master/Slave) Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: * Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Approvals Ordering details SLC 210-E/R➀-➁-RF No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm** 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm 1660 mm 1810 mm ➁ 20 Resolution 20 mm 30 Resolution 30 mm 40 Resolution 40 mm 50 Resolution 50 mm 90 Resolution 90 mm 276 Approvals Ordering details SLG 210-E/R➀-RF No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam Mounting brackets and T-slots are included in the delivery. ** only for resolution 20, 30 mm * In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m for emitter (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m Further accessories can be found on page 4-24.

277 Safety light curtains and safety light grids SLC RFM/S Safety light curtain Control category Type 2 to IEC/EN , -2 Resolution 30, 40 and 50 mm Protection field height-master from 310 mm to 1510 mm Protection field height-slave from 160 mm to 1510 mm Integrated start/restart interlock Integrated contactor control Cascading of Master and Slave devices Range from m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 SLG RFM/S Safety light grid 2- oder 3-beam light grid Protection field heights 510 mm, or 810 mm Legend: A: Total lenght Slave / Master (B + 91 mm) B: Protection field height C: 85 mm (SLC) Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 2 Enclosure: Aluminium Enclosure dimensions: 35 x 45 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 12, 8-pole Max. cable length: 100 m (Master/Slave) 50 m Protection class: IP 65 to EN Response time: 5,5-28 ms (depends on length and resolution) Detection sensitivity (Resolution): 30, 40 and 50 mm Protection field height: (Resolution 30 mm): mm (Resolution 40, 50 mm): mm (2-, 3-beam): 510, 810mm Protection field width, range: m Start/restart interlock: integrated Contactor control: integrated Cascading (Master/Slave): possible Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: * Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Approvals Ordering details SLC 210-E/R➀-➁-RF➂ No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm ➁ 30 Resolution 30 mm 40 Resolution 40 mm 50 Resolution 50 mm ➂ M Masterfunktion S Slavefunktion Approvals Ordering details SLG 210-E/R➀-RF-➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam ➁ M Master function S Slave function Mounting brackets and T-slots are included in the delivery. Different lengths and resolutions can be combined for Master/Slave. * In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m for emitter (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m for Master/ Slave connection Further accessories can be found on page VL M/S-M12-5-0,3 m VL M/S-M m VL M/S-M m VL M/S-M m 277

278 Safety light curtains and safety light grids SLC RFLC Safety light curtain Control category Type 2 to IEC/EN , -2 Resolution 30 and 40 mm Protection field heights from 160 mm to 1210 mm Range m Self-test every 0.5 s Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght (B + 91 mm) B: Protection field height C: 85 mm(slc), 135 mm (SLG) SLG RFLC Safety light grid 2-, 3- or 4-beam light grid Protection field heights 510 mm, 810 mm or 910 mm Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 2 Enclosure: Aluminium Enclosure dimensions: 45 x 35 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 12, 8-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 2-25 ms (depends on length and resolution) Detection sensitivity (Resolution): 30 and 40 mm Protection field height: (Resolution 30 and 40 mm): mm (2-, 3-, 4-beam): 510, 810, 910 mm Protection field width, range: m (Standard) Start/restart interlock: integrated Contactor control: integrated Cascading (Master/Slave): Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Approvals Approvals ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details SLC 210-E/R➀-➁-RFLC No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm* 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm ➁ 30 Resolution 30 mm 40 Resolution 40 mm 278 Ordering details SLG 210-E/R➀-RFLC No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam Mounting brackets and T-slots are included in the delivery. * only for resolution 30 mm Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m Further accessories can be found on page 4-24.

279 Safety light curtains and safety light grids SLC 410 Safety light curtain Control category Type 4 to IEC/EN , -2 Resolution 14, 20, 30, 40, 50 and 90mm Protection field heights from 160 mm to 1810 mm Range m or m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght (B + 91 mm) B: Protection field height C: 85 mm (SLC), 135 mm (SLG) Approvals Ordering details SLC 410-E/R➀-➁-12 No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm*** 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm 1660 mm 1810 mm ➁ 14 Resolution 14 mm 20 Resolution 20 mm 30 Resolution 30 mm 40 Resolution 40 mm 50 Resolution 50 mm 90 Resolution 90 mm SLG 410 Safety light grid 2-, 3- or 4-beam light grid Protection field heights 510 mm, 810 mm or 910 mm Range m Approvals Ordering details SLG 410-E/R➀-12 No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam Mounting brackets and T-slots are included in the delivery. *** only for resolutions 14, 20, 30 mm Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 35 x 45 mm Connection: connector plug M 12, 5-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 6-27 ms (depends on length and resolution) Detection sensitivity (Resolution): 14, 20, 30, 40, 50 and 90 mm Protection field height: (Resolution 14, 20, 30 mm): mm (Resolution 40, 50, 90 mm): mm (2-, 3-, 4-beam): 510, 810, 910 mm Protection field width, range: (Resolution 14mm): m (Resolution 20 to 90 mm): m (2-, 3-, 4-beam): m Start/restart interlock: * Contactor control: * Cascading (Master/Slave): Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC * only in combination with safety monitoring module ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter/ receiver KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S Further accessories can be found on page

280 Safety light curtains and safety light grids SLC RF Safety light curtain Control category Type 4 to IEC/EN , -2 Resolution 14, 20, 30, 40, 50 and 90mm Protection field height from 160 mm to 1810 mm Integrated start/restart interlock Integrated contactor control Range m or m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght (B + 91 mm) B: Protection field height C: 85 mm (SLC) 135 mm (SLG) Approvals Ordering details SLC 410-E/R➀-➁-RF No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm 1660 mm 1810 mm ➁ 14 Resolution 14 mm 20 Resolution 20 mm 30 Resolution 30 mm 40* Resolution 40 mm 50* Resolution 50 mm * Resolution 90 mm SLG RF Safety light grid 2-, 3- or 4-beam light grid Protection field heights 510 mm, 810 mm or 910 mm Range m Approvals Ordering details SLG 410-E/R➀-RF No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam Mounting brackets and T-slots are included in the delivery. * for resolution 40, 50 and 90 mm, minimum protection field height 310 mm Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 50 x 60 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 12, 8-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 6-27 ms (depends on length and resolution) Detection sensitivity (Resolution): 14, 20, 30, 40, 50 and 90 mm Protection field height: (Resolution 14, 20, 30 mm): mm (Resolution 40, 50, 90 mm): mm (2-, 3-, 4-beam): 510, 810, 910 mm Protection field width, range: (Resolution 14mm): m (Resolution 20 bis 90 mm): m (2-, 3-, 4-beam): m Start/restart interlock: Integrated Contactor control: Integrated Cascading (Master/Slave): Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: * Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC * In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m Further accessories can be found on page 4-24.

281 Safety light curtains and safety light grids SLC RFM/S Safety light curtain Control category Type 4 to IEC/EN , -2 Resolution 14, 20, 30 and 50 mm Protection field height from 160 mm to 1510 mm Integrated start/restart interlock Integrated contactor control Cascading of Master and Slave devices Range m or m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght Slave / Master (B + 91 mm) B: Protection field height C: 85 mm (SLC), 135 mm (SLG) Approvals Ordering details SLC 410-E/R➀-➁-RF➂ No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm ➁ 14 Resolution 14 mm 20 Resolution 20 mm 30 Resolution 30 mm 50** Resolution 50 mm ➂ M** Masterfunktion S*** Slavefunktion SLG RFM/S Safety light grid 2- or 3-beam light grid Protection field heights 510 mm or 810 mm Range m Approvals Ordering details SLG 410-E/R➀-RF➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam ➁ M Masterfunktion S Slavefunktion Mounting brackets and T-slots are included in the delivery. ** minimum protection field height 310 mm *** for resolution 50 mm, minimum protection field height 310 mm Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 35 x 45 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 12, 8-pole Max. cable length: 100 m Max. cable length: Master/Slave 50 m Protection class: IP 65 to EN Response time: 3-27 ms (depends on length and resolution) Detection sensitivity (Resolution): 14, 20, 30 and 50 mm Protection field height: (Resolution 14, 20, 30 mm): mm (Resolution 50 mm): mm (2-, 3-beam): 510, 810mm Protection field width, range: (Resolution 14 mm): m (Resolution 20, 30, 50 mm): m (2-, 3-beam): m Start/restart interlock: integrated Contactor control: integrated Cascading (Master/Slave): possible Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: * Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC * In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m For Master/Slave connection VL M/S-M12-5-0,3 m VL M/S-M m VL M/S-M m VL M/S-M m Further accessories can be found on page

282 Safety light curtains SLC B Safety light curtain Control category Type 4 to IEC/EN , -2 Resolution 14, 20, 40 and 90 mm Protection field height from 160 mm to 1810 mm Integrated blanking function Cascading of Master and slave devices Range m or m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght B: Protection field height C: 85 mm (SLC), 135 mm (SLG) Approvals Ordering details SLC 410-E/R➀-➁-B➂ No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0160 mm 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm ➁ 14 Resolution 14 mm 20 Resolution 20 mm 40 Resolution 40 mm 90*** Resolution 90 mm ➂ M Master function (for resolution 14 and 20 mm) 282 SLC BM Safety light curtain Master function Approvals Note The SLC 410 BM Master can be combined with all slaves of the SLC RFS series. Mounting brackets and T-slots are included in the delivery. *** minimum protection field height 610 mm Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 35 x 45 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 12, 8-pole Max. cable length: 100 m Max. cable length: Master/Slave 50m Protection class: IP 65 gem. EN Response time: 6-27 ms (depends on length and resolution) Detection sensitivity (Resolution): 14, 20, 40 and 90 mm Protection field height: (Resolution 14, 20, 40 mm): mm (Resolution 90 mm): mm Protection field width, range: (Resolution 14 mm): m (Resolution 20, 40, 90 mm): m Start/restart interlock: * Contactor control: * Cascading (Master/Slave): only for SLC BM Blanking function: 5 modes Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC * only in combination with safety monitoring module ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m For Master/Slave connection VL M/S-M12-5-0,3 m VL M/S-M m VL M/S-M m VL M/S-M m Further accessories can be found on page 4-24.

283 Safety light curtains and safety light grids for high operating range SLC 412 Safety light curtain High operating range m Control category Type 4 to IEC/EN , -2 Resolution 40 mm Protection field heightn from 510 mm to 1210 mm Integrated start/restart interlock Integrated contactor control Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Total lenght (B + 91 mm) B: distance of the outermost beams C: 85 mm (SLC), 135 mm (SLG) SLG 412 Safety light grid 2-, 3- or 4-beam light grid Protection field heights 510 mm, 810 mm or 910 mm Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 50 x 60 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 23, 19-pole Max. cable length: 100 m Protection class: IP 65 gem. EN Response time: 7 28,5 ms (depends on length and resolution) Detection sensitivity (Resolution): 40 mm Protection field height: (Resolution 40 mm): 610, 910, 1210 mm (2-, beam): 510, 810, 910 mm Protection field width, range: (Resolution 40 mm): 0 60 m (High Range) (2-, beam): m (Standard), 0 60 m (High Range) Start/restart interlock: integrated Contactor control: integrated Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Approvals Approvals ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details SLC 412-E/R➀ H No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0610 mm 0910 mm 1210 mm 40 Resolution 40 mm Ordering details SLG 412-E/R➀-12-➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam ➁ Range m H Range m (High Range) Mounting brackets and T-slots are included in the delivery. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S for receiver KD M m KD M m KD M m KD M m KD M m Further accessories can be found on page

284 Safety light grid (retro-reflector) SLG 412-P Safety light grid Emitter and receiver in one enclosure (retro reflector) Control category Type 4 to IEC/EN , -2 Protection field heightn 510 mm 2-beam light grid Integrated start/restart interlock Integrated contactor control Range m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 50 x 60 mm Connection: (Emitter/Receiver): connector plug M 12, 8-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 7 ms Detection sensitivity (Resolution): Protection field height: 510 mm Protection field width, range: m Start/restart interlock: integrated Contactor control: integrated Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Legend: A: Total lenght B: Distance of the outermost beams C: 120 mm ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Approvals Ordering details SLG 412-P-E/R Ordering details Accessories: Connector plug M 12 x 1 for emitter/receiver KD M m KD M m Further accessories can be found on page

285 Safety light curtains and safety light grids with integrated muting function System features: Control Category 4 acc. to EN or acc. to IEC 61496, Type 4 Integrated muting sensors ( T & L models) External and internal muting sensors Integrated override function Diagnostics display Optical synchronisation Compact design Simple, flexible mounting and adjustment

286 Safety light curtains and safety light grids with integrated muting function SLC/SLG 415I The SLC/SLG 415I is a system for universal use with integrated muting function. The M12 connectors allow a direct connection and flexible positioning of the different muting sensors (e.g. inductive, capacitive or optical sensors). In this way, a safe triggering of the muting function can be obtained for objects of different sizes. The additional integrated override function allows for a controlled restart of the machine to transport the accumulated material out of the protection field after a failure. The safety light curtains/grids with muting function enable a smooth and trouble-free material feeding (input and output), whilst offering a permanent protection of human life. Integrated muting function for material transport in 1 or 2 directions Connection of 2 or 4 external muting sensors Connection of different muting sensors Direct connection (M12) of the muting sensors to the SLC/SLG Muting controller for crosswise or parallel arrangement of the external sensors Adjustable muting time of 30s, 90 min or unlimited Integrated override function Range up to 16m or 60m Optional muting box with integrated muting lamp, restart and override function SLG 415L The SLG 415L is a safety light grid with integrated muting function. The muting sensors are integrated in the horizontal arms and mechanically and electrically connected to the light grid. This simplifies fitting and positioning of the prepared muting sensors and provides a fault free installation. The additional integrated override function allows for a controlled restart of the machine to transport accumulated material out of the protection field after a failure. The SLG 415L allows for a smooth and trouble-free material output (e.g. on pallet loaders) whilst offering a permanent protection of human life. Integrated muting function for transporting material out of the hazardous area 2 integrated optical muting sensor blocks Muting controller for crosswise and parallel arrangement of the integrated sensors Adjustable muting time of 30s or 90min Integrated override function Range: with crosswise arranged sensors: between m; with parallel arranged sensors: between 0 2 m Integrated sensors with adjustable height and angle position Optional muting box with integrated muting lamp, restart and override function Parallel muting sensors with green light for the detection of transparent objects (glass, bottles, film, etc.) 286

287 Safety light curtains and safety light grids with integrated muting function SLG 415T The SLG 415T is a safety light grid with integrated muting function. The muting functions are integrated in two horizontal arms and mechanically and electrically connected to the light grid (right and left). This simplifies fitting and positioning of the muting sensor block and provides for a fault free installation. The additional integrated override function allows for a controlled restart of the machine to transport accumulated material out of the protection field after a failure. The SLG 415T safety light grid enables a smooth and trouble-free material feeding (input and output), whilst offering a permanent protection of human life. Integrated muting function for material transport in 2 directions Integrated optical muting sensor blocks Muting controller for crosswise and parallel arrangement Adjustable muting time of 30s, 90min or unlimited Integrated override function Range: crosswise arranged sensors: between m; parallel arranged sensors: between 0 2 m Integrated sensors with adjustable height and angle position Optional muting box with integrated muting lamp, restart and override function Parallel muting sensors with green light for the detection of transparent objects (glass, bottles, film etc.) 287

288 Safety light curtains and safety light grids with integrated muting function SLC 415I Safety light curtain Control category Type 4 to IEC/EN , -2 Resolution 30, 40 and 90 mm Protection field heights from 310 mm to 1810 mm Integrated start/restart interlock Integrated contactor control Integrated muting and override function Range m or m Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Ordering details SLC 415I-E/R➀-➁-12-➂ No. Replace Description ➀ xxxx Protected heights (mm) Available lengths: 0310 mm 0460 mm 0610 mm 0760 mm 0910 mm 1060 mm 1210 mm 1360 mm 1510 mm 1660 mm 1810 mm ➁ 30*** Resolution 30 mm 40 Resolution 40 mm 90 Resolution 90 mm ➂ Range m H** Range m High Range 288 SLG 415I Safety light grid 2-, 3-, 4-beames light grid Protection field heights 510 mm, 810 mm or 910 mm Legend: A: Height of the receiver B: Protection field height C: 72 mm (SLC), 120 mm (SLG) Approvals Approvals Ordering details SLG 415I-E/R➀-12-➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam mm, 4-beam ➁ Range m H Range m High Range ** only for resolution 40 mm *** Protection field height 1210 mm Mounting brackets and T-slots are included in the delivery. Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 50 x 60 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 23, 19-pole, (Muting sensors): 2 x connector plug M 12, 5-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 7 28,5 ms (depends on length and resolution) Detection sensitivity (Resolution): 30, 40 and 90 mm Protection field height: (Resolution 30 mm): mm (Resolution 40, 90 mm): mm (Resolution 40 (H)): 610, 910, 1210 mm (2-, 3-, 4-beam): 510, 810, 910 mm Protection field width, range: (Resolution 30, 40 mm): m (Srandard) (Resolution 40 (H)): 0 60 m (High Range) (2-, beam): m (Standard) 0 60 m (High Range) Start/restart interlock: integrated Contactor control: integrated Muting and override function: integrated Muting sensors: 2 or 4 external sensors Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: * Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC * In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m for muting sensors KSW M m (without cable, angled) KWS M12-5 (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S Connector plug M 23 x 1 for receiver Further accessories can be found on page KD M m KD M m KD M m KD M m KD M m

289 Safety light curtains and safety light grids with integrated muting function SLG 415L Safety light grid Control category Type 4 to IEC/EN , -2 2-, 3-beam light grid Integrated start/restart interlock Integrated contactor control Integrated muting and override function Integrated muting sensors Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Height of the receiver C: 72 mm SLG 415L...PB Safety light grid Muting-Sensors parallel crosswise Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 50 x 60 mm Connection: (Emitter): connector plug M 12, 5-pole, (Receiver): connector plug M 23, 19-pole, (Muting sensors, integrated): 2 x connector plug M 12, 5-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 7 28,5 ms (depends on length and resolution) Detection sensitivity (Resolution): Protection field height: 510, 810 mm Muting-Sensoren, range: (2 parallel): ,0 m (PB = parallele beams) (2 crosswise): ,5 m Start/restart interlock: integrated Contactor control: integrated Muting and override function: integrated Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Approvals Approvals ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details SLG 415L-E/R➀-12-➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam ➁ PB Muting-Sensors parallel crosswise Note Mounting brackets and T-slots are included in the delivery. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S Connector plug M 23 x 1 for receiver Further accessories can be found on page KD M m KD M m KD M m KD M m KD M m 289

290 Safety light grids with integrated muting function SLG 415T Safety light grid Control category Type 4 to IEC/EN , -2 2-, 3-beam light grid Integrated start/restart interlock Integrated contactor control Integrated muting and override function Integrated muting sensors Semiconductor outputs Optical synchronisation Status display Protection class IP 65 Legend: A: Height of the receiver C: 72 mm SLG 415T...PB Safety light grid Muting-Sensors parallel crosswise Technical data Standards: IEC/EN /-2 Control category to IEC/EN , -2 Type 4 Enclosure: Aluminium Enclosure dimensions: 50 x 60 mm Connection: (Emitter): connector plug M 12, 5-pole; (Receiver): connector plug M 23, 19-pole; (Muting sensors, integrated): 2 x connector plug M 12, 5-pole Max. cable length: 100 m Protection class: IP 65 to EN Response time: 7 28,5 ms (depends on length and resolution) Detection sensitivity (Resolution): Protection field height: 510, 810 mm Muting-Sensoren, range: (4 parallel): ,0 m (PB = parallele beams) (2 crosswise): ,5 m Start/restart interlock: integrated Contactor control: integrated Muting and override function: integrated Light emission wavelength: 950 nm (infrared), coded Ue: 24 VDC ± 20% Safety outputs: 2 x PNP, 500 ma Leakage current: ** Safety outputs: < 0,3 ma Power consumption: Emitter 2 W, Receiver 3 W Data interface: Status and diagnostics: 7-segment and LED display Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 20 C + 70 ºC Approvals Approvals ** In case of failure (interruption of the 0 V supply) the maximum leakage current is 0.3 ma. Ordering details SLG 415T-E/R➀-12-➁ No. Replace Description ➀ Distance between outermost beams: mm, 2-beam mm, 3-beam ➁ PB Muting-sensors parallel crosswise 290 Note Mounting brackets and T-slots are included in the delivery. Ordering details Accessories: Connector plug M 12 x 1 for emitter KD M m KD M m (pre-wiring possible, however without cable) R = angled connector KD M12-5-R S = straight connector KD M12-5-S Connector plug M 23 x 1 for receiver Further accessories can be found on page KD M m KD M m KD M m KD M m KD M m

291 Accessories for safety light curtains / grids with integrated muting function Control unit SLG-MCB Control unit for the SLC/SLG 415/412 series Integrated restart pushbutton Integrated muting lamp Integrated override key selector switch Two safety relay outputs and one signalling contact DIP switch to configure the light grid/light curtain Plug-in terminal blocks for cable connection Possibility to connect an external muting lamp Possibility to connect an internal or external feedback loop Cable entry for machine connection Technical data Enclosure: glass-fibre reinforced thermoplastic Fixation: 4 mounting holes Connection: M23 or M12 connector, metric thread coupling Protection class: Gehäuse IP 66 gem. EN Ue: VDC Ie: depending on the connected SLC/SLG type Input signal "1": > 12 VDC Input signal "0": > 5 VDC Max. cable length: 100 m Outputs: 2 enabling paths Utilisation category: AC-15, DC-13 Switching voltage: max. 250 VAC Load current: max. 2 A (cos ϕ = 1) Switching capacity: max. 500 VA Short-circuit protection: 6 A (slow blow) Signalling output: 1 relay output (NO contact) for SLG- MCB3/4 EMC rating: EMC Directive to EN Overvoltage category: II to DIN VDE 0110 Ambient temperature: - 10 C + 55 ºC Storage and transport temperature: 10 C + 55 ºC Dimensions: 110 x 180 x 110 mm Note Inductive loads (contactors, relays, etc.) are to be suppressed by means of a suitable circuit. Approvals Ordering details SLG-MCB➀ No. Replace Description ➀ 1 Restart pushbutton, key selector switch for override function, muting lamp, 2 safety relays per enabling contact 2 Restart pushbutton, 2 safety relays per enabling contact Ordering details No. Replace Description 3 Restart pushbutton, key selector switch for override function, muting lamp, 2 safety relays per enabling contact, 1 signalling contact 4 Restart pushbutton, 2 safety relays per enabling contact, 1 signalling contact Ordering details Accessories for emitter mutingbox for receiver mutingbox VL MB-M m VL MB-M m VL MB-M m VL MB-M m VL MB-M m VL MB-M m 291

292 Accessories for safety light curtains / grids with integrated muting function System components System components System components Deflecting mirror SMB Deflecting mirror ST LGM Mounting angle BF SMB Selection table: Deflecting mirror SMB: Protected Number Deflecting height of beams mirror SLC SLG SMB Selection table: Floor-stand with integrated deflecting mirror ST LGM A = 1000 mm A = 1200 mm A = 1330 mm A = 1970 mm ST LGM-02 ST LGM-03 ST LGM-04 ST LGM-2000 Floor-stand STB LG Mounting angle BF LC-01-D Ordering details Deflecting mirror: Mirror height 250 mm SMB 250 Up to 1900 mm SMB 1900 Other heights available on request Ordering details Floor-stand with integrated deflecting mirror Floor-stand (empty enclosure) ST LGM-02 ST LGM-03 ST LGM-04 ST LGM-2000 ST LG Ordering details Mounting angle for deflecting mirror Floor-stand base for ST LG/LGM Mounting angle (rotating) BF SMB STB LG BF LC-01-D 292

293 Accessories for safety light curtains / grids with integrated muting function System components System components System components Vibration absorber VA 15-6 Alignment kit LAT SLC-2 Test rods Vibration absorber VA 210/410-2/-3 Alignment kit LAT SLC-4 Ordering details Vibration absorber VA 15-6 Vibration absorber VA 210/410-2 VA 210/410-3 Ordering details Alignment kit LAT SLC-2 LAT SLC-4 Ordering details Test rods with resolution 14 mm with resolution 20 mm with resolution 30 mm with resolution 40 mm with resolution 50 mm SLC TR-14 SLC TR-20 SLC TR-30 SLC TR-40 SLC TR

294 294 Safer by Design

295 Safety monitoring modules for optoelectronic safety components Besides the traditional safety relay controls, Schmersal offers CE-type tested safety controls or other safetyoriented bus systems (e.g. AS-i Safety at Work) for different levels of complexity and combination depths, which provide the user with many visualization and diagnostic possibilities.

296 Safety monitoring modules for optoelectronic safety systems SCR 1R Suitable for signal processing of outputs connected to potentials (AOPDs), e.g. safety light grids/curtains 1 or 2 channel control 2 enabling paths, Stop 0 Reset with edge detection or automatic start 2 LEDs to show operating conditions Control Category 4 to EN Technical data Standards: IEC/EN , EN 954-1, BG-GS-ET-20 Stop category 2x Stop 0 Control category: 4 Start conditions: Reset button with edge detection, auto start Enclosure: glass-fibre reinforced thermoplastic Connection: screw terminals Cable section: max. 2.5 mm 2 solid or multi-strand lead (incl. conductor ferrules) Ue: 24 VDC 15 % / + 20 %, residual ripple max. 10% Ie: max A Protection class: terminals IP 20 enclosure IP 40 to EN Power consumption: max. 2.6 VA Max. fuse rating: Internal electronic trip F1, tripping current > 0.6 A, reset after approx. 1 s Monitored inputs 1 or 2 channels Drive circuits: max. 28 VDC Enabling contacts: 2 enabling paths Utilisation category: AC-15, DC-13 Switching capacity: enabling paths: 6 A/230 VAC, 6 A/24 VDC Fuse rating: enabling paths: 6 A gg D-fuse Max. switching frequency: 5 Hz Contact material: AgNi, AgSnO, self-cleaning, positive action Contact resistance: max. 100 mω in new condition Pull-in delay: 330 ms / 720 ms (start button / auto start) Drop-out delay: 20 ms Air clearances and creepage distances: DIN VDE (04.97), 4 kv/2 Overvoltage category: III to DIN VDE 0110 Degree of pollution: 2 to DIN VDE 0110 Ambient temperature: 25 C + 45 C (Derating curve on request) Mechanical life: 10 million operations Function display: 2 LEDs Weight: 190 g Dimensions: 22.5 x 82 x 98.8 mm Approvals H Ordering details SCR 1R 296

297 Safety monitoring modules for optoelectronic safety systems Note Input level: dual-channel control (Example AOPD, with two OSSDs with external start/restart button J). The control recognises cable break and earth leakages in the monitoring circuit. Si1 = electronic fuse Relay outputs: Suitable for 2 channel control, for increase in capacity or number of contacts by means of contactors or relays with positive-guided contacts. Wiring diagram For a 1-channel control, connect NC contact to Y1/S1 and bridge S1/S2 Connect potential (p-type) outputs of safety light grids/curtains to S1/S2. The devices must have the same reference potential. Automatic start: The automatic start is programmed by connecting the feedback circuit to the terminals X1/X3. If the feedback circuit is not required, establish a bridge LED Function indication: The integrated LEDs indicate the following operational states. Position relay K1 Position relay K2 Note The wiring diagram is shown for the de-energised condition. 297

298 Safety monitoring modules for optoelectronic safety systems SRB 301 LCB Suitable for signal processing of outputs connected to potentials (AOPDs), e.g. safety light grids/curtains 1 or 2 channel control 3 enabling paths, Stop 0 1 indication contact (NC) Reset with edge detection or automatic start 4 LEDs to show operating conditions Control Category 4 to EN Technical data Standards: IEC/EN , EN 954-1, BG-GS-ET-20 Stop category 3x Stop 0 Control category: 4 Start conditions: Reset button with edge detection, auto start Enclosure: glass-fibre reinforced thermoplastic, ventilated Connection: screw terminals Cable section: max. 2.5 mm 2 solid or multi-strand lead (incl. conductor ferrules) Ue: 24 VDC 15%/+20%, residual ripple max. 10% 24 VAC 15%/+10% Frequency range: 50/60 Hz (on AC operational voltage) Ie: max A Protection class: terminals IP 20 enclosure IP 40 to EN Power consumption: max. 3.8 VA, 2.4 W Max. fuse rating: Internal glass fuse F1, tripping current > 0.25 A, Monitored inputs 1 or 2 channels Feedback circuit: yes Drive circuits: S11/S12, S21/S22: max. 28 VDC Enabling contacts: 3 enabling paths Utilisation category: AC-15, DC-13 Switching capacity: enabling paths: 6 A/230 VAC, 6 A/24 VDC Max. switching frequency: 5 Hz Fuse rating: enabling paths: 6 A gg D-fuse Signalling contacts: 1 NC contact Switching capacity: Indicating contact: 2 A/24 VDC Contact material: AgNi, AgSnO, self-cleaning, positive action Contact resistance: max. 100 mω in new condition Pull-in delay: 30 ms Drop-out delay: 50 ms Air clearances and creepage distances: DIN VDE (04.97), 4 kv/2 Overvoltage category: III to DIN VDE 0110 Degree of pollution: 2 to DIN VDE 0110 Ambient temperature: 25 C + 45 C (Derating curve on request) Mechanical life: 10 million operations Function display: 4 LEDs Weight: 230 g Dimensions: 22.5 x 100 x 121 mm Approvals Ordering details SCR 301 LCB 24 VAC/DC SCR 402R

299 Safety monitoring modules for optoelectronic safety systems Note Wiring diagram Input level: dual-channel control (Example AOPD, with two OSSDs with external start/restart button J. The control recognises cable break and earth leakages in the monitoring circuit. F1 = Glass fuse S = Feedback circuit Relay outputs: Suitable for 2 channel control, for increase in capacity or number of contacts by means of contactors or relays with positive-guided contacts. For 1-channel control, connect NC contact to S11/S12 and bridge S12/S22 Connect potential p-type outputs of safety light grids/curtains to S12/S22. The devices must have the same reference potential. Automatic start: The automatic start is programmed by connecting the feedback circuit to terminals S12/X3. If no feedback circuit is required, establish a bridge. SLC/SLG E SLC/SLG R A1 AC/ DC A2 F1 S12 S11 S21 S22 Control logic X3 X2 13 UB Ui K2 K1 K2 SRB 301 LCB J K1 KB L1 KA N 3 M S LED Function display: The integrated LEDs indicate the following operational states. Position relay K1 Position relay K2 Supply voltage UB Internal operating voltage Ui Note The wiring diagram is shown with guard doors closed and in de-energised condition. 299

300 Safety monitoring modules for optoelectronic safety systems AST LC ST-AS Technical data Note Input module for 2 monitored PNP semiconductor outputs for safety light curtains and light grids AS-Interface LED status display AS-Interface M12 connector Thermoplastic enclosure Long life Protection class IP 67 Approvals Standards: EN 50295, EN , EN 954-1, EN Enclosure: glass-fibre reinforced thermoplastic, self-extinguishing AS-Interface connection type: connector M12 Protection class: IP 67 to EN AS-Interface operating voltage: VDC, via AS-Interface, reverse-polarity proof AS-Interface operating current: 50 ma AS-Interface specification: (V 2.1) Profile: S-0.B IO-Code: 0x0 ID-Code: 0xB ID-Code1: 0xF ID-Code2: 0xE Inputs: Contact Status Data bits 1 on D0/D1 = dynamic code transmission 1 off D0/D1 = static code 00 2 on D2/D3 = dynamic code transmission 2 off D2/D3 = static code 00 Outputs: A0... A3 not used Parameter bits: P0.. P3 not used Input module address: default on address 0, programmable via the AS-Interface Master or Hand-held programming device Indications: AS-Interface: voltage LED green, communication LED red, OSSD1/2; Enabling status: LED yellow Power supply for AOPD: PELV power supply to IEC Reaction time: 20 ms EMC rating: conforming to EMC Directive Ambient temperature: 25 C + 60 ºC Storage and transport temperature: 25 C + 85 ºC Connector ST Connector ST1 Connector ST2 1: AS-i + 2: spare 3: AS-i 4: spare 1: + 24 VDC 2: spare 3: GND 4: spare 5: FE (functional earth) 1: + 24 VDC 2: OSSD 1 3: GND 4: OSSD 2 5: FE (functional earth) Ordering details AST LC ST-AS Note A separate address jack is not available as an option. The addressing must take place via the cable end or the M12 connector. 300

301 Safety monitoring modules for optoelectronic safety systems Note The wiring diagram shows an active optoelectronic device (AOPD) (type SLC/SLG) with a safety input module AST LC ST-AS (Opto-Tube) connected to the AS-i Safety at Work system. Wiring diagrame Emitter The Opto-Tube is directly connected to the receiver module (ST2). The AOPD receives its 24 VDC power supply via the second M12-cable connection (ST1). Receiver The Opto-Tube itself is connected via the M12 connector (ST) to the AS-i network. Before hand the module has to be programmed with an individual address (1-31). See note The emitter module has be wired up separately as described in its mounting and wiring instruction. 301

302 302 Safer by Design

303 Safety light barriers System features: Control Category 2 and 4 acc. to EN or acc. to EN 61496, Type 2 and Type 4 Up to 4 pairs of one-way light barriers can be connected Different functions Start/Restart interlock Contactor monitoring Cyclic testing Integrated soiling check Status and error indication Signalling outputs for external indications Free of maintenance Extremely compact design Simple and flexible mounting and adjustment 7

304 Safety light barriers SLB 200 Control Category 2 to EN only in combination with safety monitoring module SLB 200-C04-1R Extremely compact design Range to 4 m Protection class IP 67 Maintenance free Integral soiling check LEDs visible from both sides Simple flexible mounting and adjustment Technical data Comprising: emitter SLB 200-E31-21 receiver SLB 200-R31-21 Standards: IEC/EN Control Category: 2 (only in combination with SLB 200-C) Enclosure: ABS 10 % GF Enclosure dimensions: 31 x 50.5 x 19 mm Connection: emitter: 10 cm conductor, M 8 x 1, 3-pole coupler socket receiver: 10 cm conductor, M 8 x 1, 4-pole coupler socket Max. cable length: 50 m Protection class: IP 67 to EN Response time: 30 ms (only in combination with SLB 200-C) Range: 4 m Start/Restart interlock: only in combination with safety monitoring module Contactor control: only in combination with safety monitoring module Light emission wavelength: 880 nm Ue: 24 VDC ± 20% Safety outputs: only in combination with safety monitoring module Angle of radiation: ± 4 Min. size of object: 9 mm Ø LED status indication: soiling, switching condition and power on Ambient temperature: 10 C C Storage and transport temperature: 20 C + 80 ºC System components SLB 200-C04-1R Connector plug M 8 x 1 (with cable) Mounting angle BF 31 Approvals Mounting angle BF UNI 1 Ordering details SLB 200-➀31-21 No. Replace Description ➀ E/R Emitter / receiver 304 Note The system components (safety monitoring module, connector plug, cable, etc.) are not included in delivery. Ordering details Monitoring of safety light barriers SLB 200-C04-1R refer to page 4-6 Connector plug M 8 x 1 emitter: KDE M8-3 (without cable) KDE M8-3-2m KDE M8-3-5m receiver: KDR M8-4 (without cable) KDR M8-4-2m KDR M8-4-5m Mounting angles BF 31 Mounting angles universal BF UNI 1

305 Safety light barriers SLB 400 Control Category 4 to EN only in combination with safety monitoring module SLB 400-C10-1R Very compact design Range to 15 m Protection class IP 67 Connecting plug can be rotated Maintenance free Integral soiling check LED switching conditions display Simple flexible mounting and adjustment Technical data Comprising: emitter SLB 400-E 50-21P receiver SLB 400-R 50-21P Standards: IEC/EN Control Category: 4 (only in combination with SLB 400-C) Enclosure: ABS Enclosure dimensions: 50 x 50 x 17 mm Connection: M 12 x 1, 4-pole coupler socket, can be rotated Max. cable length: 100 m Protection class: IP 67 to EN Response time: 25 ms (only in combination with SLB 400-C) Range: 15 m Start/Restart interlock: only in combination with safety monitoring module Contactor control: only in combination with safety monitoring module Light emission wavelength: 880 nm Ue: 24 VDC ± 20% Safety outputs: only in combination with safety monitoring module Angle of radiation: ± 2 Min. size of object: 13 mm Ø LED status indication: soiling, switching condition and power on Ambient temperature: 0 C C Storage and transport temperature: 20 C + 80 ºC System components SLB 400-C10-1R Connector plug M 12 x 1 (with cable) Mounting angle BF 50 Approvals H Ordering details SLB 400-➀50-21P No. Replace Description ➀ E/R Emitter / receiver Note The system components (safety monitoring module, connector plug, cable, etc.) are not included in delivery. Mounting angle BF UNI 1 Ordering details Monitoring of safety light barriers SLB 400-C10-1R refer to page 4-8 Connector plug M 12 x 1 emitter/receiver: KD M12-4 (without cable) KD M12-4-2m KD M12-4-5m Mounting angles BF 50 Mounting angles universal BF UNI 1 305

306 Safety light barriers SLB 200-C To IEC Control Category 2 to EN 954-1, BWS-T Up to two pairs of light barrier devices can be connected 1 enabling path 1 signalling output Operating voltage 24 VDC Test input LED display of switching conditions Response time 30 ms Start/Restart interlock can be switched active or inactive Contactor monitoring can be switched active or inactive Additional cyclic testing Co-ordinated for use with SLB 200 R/E safety light barriers Technical data Standards: IEC/EN /-2, EN Control category: 2 Start-up test: yes Start conditions: Test button, start-reset button, on/off coding Feedback circuit: yes Enclosure: polycarbonate Mounting: snaps onto standard DIN rail to EN Connection: screw terminals Cable section: max. 4 mm 2 (incl. conductor ferrules) Protection class: IP 20 to EN Ue: 24 VDC ± 20% Ie: 180 ma Power consumption: Inputs: test input: command device: NC contact release start/restart interlock (start/reset): enable via command device (NO contact), contactor monitoring (NC contacts) Monitored inputs max. 2 pairs of light barriers Input resistance: Max. cable length: Test and feedback: potential-free contact Outputs: 1 enabling path Enabling contacts: 1 enabling path Utilisation category: AC-15, DC-13 Ie/Ue: 2 A / 250 VAC, 2 A / 24 VDC Contact load capacity: max. 250 VAC, max. 2 A (cos ϕ = 1) Switching voltage: max. 250 VAC Load current: 8 A Max. fuse rating: 4 A gg D-fuse Signalling output: 1 transistor output Switch-on conditions: test duration: 150 ms (without relay control) 450 ms (with relay control) Switch-off time: response time (complete sy.): 30 ms Indications: red LED for light barrier interrupted green LED for light barrier free soiling: flashing red/green Function display: 4 LEDs EMC rating: conforming to EMC Directive Max. switching frequency: 10 Hz Overvoltage category: II to DIN VDE 0110 Degree of pollution: 3 to DIN VDE 0110 Resistance to vibration: Hz / amplitude 0.35 mm Resistance to shock: 10 g / 16 ms Ambient temperature: 0 C + 50 ºC Storage and transport temperature: 20 C + 80 ºC Dimensions: 45 x 84 x 118 mm Note: Inductive loads (e.g. contactors, relays, etc.) are to be suppressed by means of a suitable circuit. Approvals Ordering details SLB 200-C04-1R 306

307 Safety light barriers Note For protection in Control Category 2 to EN Monitoring two pairs of light barrier devices and the power contactor using the SLB 200-C safety monitoring module Test push button I The test push button is connected to X13 and X14 in order to carry out a check of the light barrier monitoring function. The terminals X15 and X16 must be bridged. The wiring diagram is shown for the de-energised condition. Contactor check To monitor an external contactor, the feedback circuit is connected to X17 and X18. The terminals X19 and X20 must be bridged. Start push button H The start push button can be used to start the monitoring of the light barriers for a new start or after an interruption. The terminals X3 and X4 must be bridged. It is also possible to connect only one pair of light barrier devices. Wiring diagram Note In order to set for the desired mode of operation and number of light barriers connected, remove the front cover of the safety monitoring module. As supplied all switches are in Position 1. Note The required functions can be selected by means of the internal DIP switches. DIP switch 1 DIP switch 2 DIP switch 3 Position 1 With contactor check With start/restart interlock Connection of two light barriers Position 2 Without contactor check Without start/restart interlock Connection of one light barrier 307

308 Safety light barriers SLB 400-C To IEC Control Category 4 to EN 954-1, BWS-S Cross-wire monitoring ISD Integral System Diagnostics Operating voltage 24 VDC Feedback circuit to monitor external contactors Two short-circuit proof additional transistor outputs Response time 30 ms Start/Restart interlock can be switched active or inactive Contactor monitoring can be switched active or inactive Can be coded Up to 4 light barrier pairs SLB 400 can be connected Technical data Standards: IEC/EN /-2, EN Control category: 4 Start-up test: yes Start conditions: Start-reset button, on/off coding Feedback circuit: yes Enclosure: glass-fibre reinforced thermoplastic Mounting: snaps onto standard DIN rail to EN Connection: screw terminals Cable section: max. 4 mm 2 (incl. conductor ferrules) Protection class: terminals IP 20, enclosure IP 40 to EN Ue: 24 VDC ± 15% Ie: 0.3 A without additional transistor outputs Power consumption: Inputs: S1, S2 Monitored inputs max. 4 pairs of light barriers Input resistance: approx. 2 kω to ground Input signal 1 : VDC Input signal 0 : VDC Max. cable length: 100 m of 0.75 mm 2 conductor Outputs: 2 enabling paths Enabling contacts: 2 enabling paths Utilisation category: AC-15, DC-13 Ie/Ue: 2 A / 250 VAC, 2 A / 24 VDC Contact load capacity: max. 250 VAC, max. 2 A (cos ϕ = 1) Switching voltage: max. 250 VAC Load current: max. 2 A Switching capacity: max. 500 VA Max. fuse rating: 2 A gg D-fuse Additional outputs: additional transistor outputs Y1, Y2, Ue 4 V, 100 ma total, short-circuit proof, p-type Signalling output: 2 transistor outputs, Y1 + Y2 = max. 100 ma, p-type, short-circuit proof Switch-on time: Response time: 25 ms Monitoring for synchronism of muting sensors: Indications: ISD Function display: 9 LEDs (ISD*) EMC rating: conforming to EMC Directive Max. switching frequency: 10 Hz Overvoltage category: II to DIN VDE 0110 Degree of pollution: 3 to DIN VDE 0110 Resistance to vibration: Hz / amplitude 0.35 mm, ± 15 % Resistance to shock: 30 g / 11 ms Ambient temperature: 0 C + 55 ºC Storage and transport temperature: 25 C + 70 ºC Dimensions: 99.7 x 75 x 110 mm Note: Inductive loads (e.g. contactors, relays, etc.) are to be suppressed by means of a suitable circuit. Approvals H Ordering details SLB 400-C10-1R 308

309 Safety light barriers Note Wiring diagram For protection in Control Category 4 to EN Monitoring up to four pairs of light barrier devices and the power contactors using the SLB 400-C safety monitoring module The wiring diagram is shown for the de-energised condition. Connection of two pairs of safety light barrier devices When two pairs of safety light barriers are connected, the terminals X9-X10 and X11-X12 must be bridged. Restart push button J The restart function can be selected by means of the DIP switches. When a start push button is connected to X5 and X6, it must be operated for min. 250 ms and max. 5 s after an interruption of the safety light barriers. ISD The following faults are registered by the safety monitoring modules and indicated by ISD Short-circuit on the connecting leads Interruption of the connecting leads Failure of the safety relay to pull-in or drop-out Fault on the input circuits or the relay control circuits of the safety monitoring module Mutual influence between the connected pairs of light barrier device and others on neighbouring systems Note The ISD tables (Intergral System Diagnostics) for analysis of the fault indications and their causes are shown in the appendix. 309

310 Safety light barriers accessories SLB 200 and SLB 400 System components System components Mirror SLB 200/400 SMA 80 Mounting post ST 1250 Mounting angle BF SMA 80-1 Floor-stand base STB 1 Mounting angle BF SMA 80-2 T-slot nut NST 20-8 Ordering details Mirror SMA 80 Mounting angles for mirror BF SMA 80-1 BF SMA 80-2 T-slot nut NST 20-8 Ordering details Mounting post ST 1250 Floor-stand base STB 1 310

311 SAFETY CATEGORY 3 PRESSURE MATS GENERAL PRODUCT FEATURES SCHMERSAL s Series SMS Safety Pressure Mats feature a 100% active area, low actuating force, rugged cable termination, durable unibody construction cable entry, IP67 submersible rating, highly chemical resistant mat material, CEcompliance, and a 3-year warranty. When properly installed with a compatible safety controller (described herein) they meet the stringent requirements of EN954-1 safety category

312 SERIES SMS 3 Safety Pressure Mats Features & Benefits 100% active mat area ramp edge trim and insulating strip-contact design ensure actuation over entire mat surface High chemical resistance mat material is tolerant to most acids, alcohols, aldehydes, caustics, solvents and oils found in an industrial environment Non-slip surface profile unique surface geometry designed to enhance traction and minimize slippage Meets safety category 3 requirements of EN suitable for most industrial applications Modular design permits protection over a diversity of hazardous area shapes/sizes Easy-to-install simple 4-wire connection (without need of a terminal resistor or additional base plate) Integral 6m cable satisfies wiring requirements for a wide variety of applications Rugged IP67 design with mechanical life expectancy of more than 5 million actuations Fully CE-compliant third-party certified to EN Extended warranty mats are warranteed for 3 years from date of shipment Description The maintenance-free series SMS 3 safety mat system is designed to safeguard personnel when entering a hazardous area around dangerous machinery. A person s presence is detected upon their stepping/walking on the mat. The interconnected safety controller (such as the AZR 31 R2, AZR 31 T2, or AZR 11 RT2) continuously monitors the integrity of the safety mat system, sending a stop signal to the machinery in the event of a system fault or pressure mat actuation. When properly installed with the ramp edge profiles, a 100% mat actuation area is achieved thus complying with the stringent requirements of EN safety category 3 Operation The series SMS 3 safety mat consists of two electrodes (steel plates) separated by an internal layer of compressible elastomeric insulating strips. The insulating strips are capped by a conductive u-shaped strip whose edges overhang the compressible insulator. Upon the application of pressure (e.g. walking/stepping on the mat), the insulating strips compress allowing the conductive strip to close the normally-open circuit between the steel electrodes. This closure signal is detected by the system s safety controller whose safety output(s) sends a stop signal to the machinery being approached. Model SMS SMS SMS SMS SMS SMS SMS SMS SMS SMS SMS SMS AVAILABLE STANDARD MODELS Length x Width of Mat without Trim Kit Ramp Edge Trim Kit (Must be ordered separatley)* 250 mm x 250 mm SMS PF mm x 500 mm SMS PF mm x 1000 mm SMS PF mm x 500 mm SMS PF mm x 1000 mm SMS PF mm x 1500 mm SMS PF mm x 750 mm SMS PF mm x 1000 mm SMS PF mm x 1500 mm SMS PF mm x 1000 mm SMS PF mm x 1500 mm SMS PF mm x 1200 mm SMS PF SMS mm x 1500 mm SMS PF Other sizes and non-rectangular shapes available. Please consult factory. *SMS 3 Safety Mats and Trim Kits must be ordered with a compatible safety controller module. Active Edge trim is also available. Please consult factory. 312

313 SERIES SMS 3 SAFETY PRESSURE MAT TECHNICAL SPECIFICATIONS Conformance to Standards EN Degree of Ingress Protection IP67 per IEC Response Time 30ms (single mat only) Mechanical Life Expectancy > 5 million operations Maximum Load 2000 N/cm 2 (2,900 lbs/sq. in) Material Mat: Plastisol; Ramp Edge: Aluminum Mat Thickness 12mm (.05 in.) Mat Weight 18 kg/m 2 (3.7 lbs/sq. ft) Standard Cable Length 6 meters (19.7 ft) (Other lengths available. Please consult factory.) Ambient Operating +5 C to +50 C Temperature Range (+41 F to +122 F) Warranty Period 3 Years (from date of shipment) Agency Approvals CE-Compliant Chemical Resistance Water: Excellent Mineral Acids: Good Excellent Organic Acids: Good Excellent Alcohols: Good Aldehydes: Good Excellent Caustics: Good Excellent Petroleum Solvents: Fair Good Oils: Good TRIM KIT DETAILS Mat installation with 2-1/2" ramp edge trim for perimeter finishing and active threshold joining trim for interior multiple-mat bridging. Ramp edge trim installation detail. Place ramp edge trim flush against edge of mat as shown. Active Threshold joiner trim installation detail

314 SERIES SMS 3 COMPATIBLE SAFETY CONTROLLERS The SMS 3 safety mat system includes a choice of three compatible safety controllers one of which is required for each installation. These choices are summarized in the chart below with complete technical specifications shown at the right. Model Number Type Reset (See Note 1) Number of Safety Outputs Available Signaling Output Safety Controller Input Voltage AZR3IT2-24VAC Automatic 3 1 N.C. (Voltage-free) 24VAC AZR3IT2-24VDC Automatic 3 1 N.C. (Voltage-free) 24VDC AZR3IT2-110VAC Automatic 3 1 N.C. (Voltage-free) 110VAC AZR3IR2-24VAC Manual 3 1 N.C. (Voltage-free) 24VAC AZR3IR2-24VDC Manual 3 1 N.C. (Voltage-free) 24VDC AZR3IR2-110VAC Manual 3 1 N.C. (Voltage-free) 110VAC AZR11RT2-24VDC Automatic (user selectable) 1 1 N.O. (PNP-output) 24VDC Note 1: Manual reset units require the presence of a discrete trailing edge signal (24V to 0V) to activate (reset) the safety outputs. A reset button must be provided. Automatic reset units do not require a reset signal. These units automatically re-activate (reset) the safety outputs when pressure is removed from the mat and no other safety circuit faults exist. A discrete reset button may be used for increased safety. Each of these DIN-rail mountable safety controllers are designed to monitor the integrity of the SMS 3 safety mat circuit. In the event of mat actuation or the occurrence of a fault in the circuit, the safety output(s) will be activated to stop the hazardous machinery. Detectable faults include: Open circuit in interconnection wiring Short in the interconnection wiring Fault in one or more of the controller s safety relays Welded contact in the controlled positive-guided motor contactor or control relay In addition, each unit features LED system status indicators to aid in installation and trouble shooting. 314

315 SERIES SMS 3 COMPATIBLE SAFETY CONTROLLERS TECHNICAL SPECIFICATIONS Conformance to Standards EN , IEC , EN954-1, EN292-1, EN292-2, DIN VDE , VDE 0113 Part 1 Housing Material Polycarbonate Mounting Arrangement DIN-rail mounting according to DIN EN Housing Dimensions AZR31: 73.2mm x 45mm x 121mm AZR11: 82mm x 22.5mm x 98.8mm Degree of Ingress Protection Terminals: IP20 Housing: IP40 (per IEC 60529) Operating Voltage 24VAC ± 15% (AZR31) 24VDC ± 15% (AZR31 & AZR11) 110VAC ± 15% (AZR31) 230VAC ± 15% (AZR31 available on request) Power Consumption AZR31: <3W AZR11: <0.5W Inputs Channel A, B: Voltage-free contacts Output Signals AZR31: 3 enabling (safety) outputs (Two N.O. relay contacts in series) 1 signaling contact (Two N.C. relay contacts in parallel) AZR11: 1 enabling (safety) output (Two N.O. relay contacts in series) 1 signalling contact (PNP output, 15mA) Switching Voltage/ Switching Power Response Time Signalling Ambient Operating Temperature Range Storage Temperature Range Weight Agency Approvals AZR31: Max. 440 VAC, 1500 VA Max. 30VDC, 60W AZR11: Max. 250 VAC, 1000VA 15 ms AZR31: Green LEDs for control voltage, Channel A, channel B, Output AZR11: Green LEDs for control voltage, Output 0 C to +50 C (+32 F to +122 F) -25 C to +70 C (-13 F to +158 F) AZR31: Approx. 465 gm (1 lb) AZR11: Approx. 150 gm (0.35 lb) UL, CSA, CE-Compliant 7 315

316 OPTIONAL JUNCTION BOX FOR MULTIPLE MATS SPECIFICATIONS 7.10 in. (180,3 mm) 6.29 in. (159,8 mm) 5.87 in. (149,1 mm) Mounting Holes in. (280,9 mm) 9.44 in. (239,8 mm) 9.02 in. (229,1 mm) Mounting Holes 3.5 in. (88,9 mm) 0.61 in. (15,5 mm) 5.13 in. (130,3 mm) 0.58 in. (14,7 mm) 4.72 in. (119,9 mm) 6.29 in. (159,8 mm) 6.35 in. (161,3 mm) 7.10 in. (180,3 mm) 316 Up to 5 Mats Up to 10 Mats Part Number SMS JB 5 Part Number SMS JB 10 Weight 1.9 lbs Weight 2.7 lbs Material Acylonitrile Butadine Styrene (ABS) Material Acylonitrile Butadine Styrene (ABS) Temp. Range -40 F to +180 F with standard Neoprene gasket Temp. Range -40 F to +180 F with standard Neoprene gasket (-4 C to +82 C) (-4 C to +82 C) -40 F to +266 F with optional silicone gasket -40 F to +266 F with optional silicone gasket (-4 C to +130 C) (-4 C to +130 C) Protection Class NEMA Types 1, 2, 3, 3R, 4, 4X, 5, 12 and 13 Protection Class NEMA Types 1, 2, 3, 3R, 4, 4X, 5, 12 and 13 IP65 IP65 DIN DIN Capacity 6 integral cable grips will accept up to 5 Larco Capacity 12 integral cable grips will accept up to 10 Larco Safety mat cables. 4 plugs provided to seal Safety mat cables. 9 plugs provided to seal unused positions unused positions Control Cable 18/4 SVT Black 20' cable.245" OD Control Cable 18/4 SVT Black 20' cable.245" OD Wires are designated as black-#1, white-#2, Wires are designated as black -#1, black-#3 and white-#4. white-#2, black-#3 and white-#4. (Maximum cable length: 300') (Maximum cable length: 300') Terminal Strips 24-position tubular contacts. (No wire lugs Terminal Strips 48-position tubular contacts. (No wire lugs required.) Captive screws and dead front required.) Captive screws and dead front construction eliminate short circuits. construction eliminate short circuits.

317 FAIL-TO-SAFE SAFETY EDGES SELECTION GUIDE SCHMERSAL s Series SE Safety Edges/Bumpers are available as sub-assembly components or as custom assemblies produced to user specifications. The following pages provide details regarding operation, construction and ordering details. Among the user options are safety edge profile, mounting frame profile and length. Please contact us if you have any questions, special needs or require assistance with properly specifying the safety edge which meets your requirements

318 SERIES SE Optical Safety Edges/Bumpers Features & Benefits Can be cut & mounted in the field easy to fit and adjust length when placing the edge on the door Safety controller SE 100 handles up to 2 safety edges reduced cost in multiple door applications Rugged corrosion & abrasion resistance rubber profiles tolerant to most industrial environments Watertight design meets IP 68 environmental requirements. Low operating force assures reliable operation Automatic gain control tolerates slight bending Simple field installation low cost & easy to repair Meets rigid safety agency standards BG, UL and CSA Description The series SE Safety edge consists of a rugged high tear resistant rubber profile, an aluminum mounting rail, a plug-in optoelectronic transmitter and receiver pair and a compatible safety controller. The design features a high reflective internal rubber surface and a self-adjusting gain optical pair whose performance is uncompromised by slight bending and predictable over the specified operating range. Units can be quickly and easily assembled (without special skills or use of adhesives) for lengths of 400 mm to 10 m. The self adjusting optical pair assure the same sensitivity and performance independent of chosen length. The mechanical design assures encapsulation of the transmitter and receiver ensuring reliable operation unaffected by environmental soiling. Operation In operation the transmitted IR beam is detected, by the receiver resulting in enabling of the safety controllers safety output(s). Deformation of the rubber profile interrupts/weakens the signal between the transmitter and receiver. This is sensed by the safety controller disabling the outputs allowing the hazardous movement to be stopped. Depending upon the choice of safety controller the system meets the requirements of EN Safety control category 1 or 4. Typical Applications Ideal wherever crushing or shearing points are to be safeguarded, such as on guard doors, elevating platforms, rising stages, moving stock shelving, operating process tables, loading ramps, hoists or tipping equipment. Note: Not recommended for use on overhead doors. Please consult factory for such applications. 318 is a trademark of SCHMERSAL

319 SERIES SE ORDERING & ASSEMBLY INFORMATION AVAILABLE SUBASSEMBLY COMPONENTS Parts required for a system are: Aluminum profile, rubber profile, sensor set and safety controller Aluminum Profile SE-AL SE-AL SE-AL SE-AL SE-AL SE-AL SE-AL SE-AL Safety Controller SE- 100C (2 Bumpers) SE- 400C SE- 304C (4 Bumpers) Description 1.25 m 2.50 m 1.25 m 2.50 m 1.25 m 2.50 m 1.25 m 2.50 m Rubber Profile Description SE- P mm SE-P SE- P mm SE-P SE- P mm SE-P SE- P mm SE-P Sensor Set Description SE- SET SE - T Transmitter & SE - R Receiver Description Safety Control Category 1 Safety Control Category 4 Safety Control Category 3 (Please contact factory for details) Description Accessories SE- EC 40 (2 required) End Cap for SE - P 40 SE- EC 70 (2 required) End Cap for SE - P 70 SE- SC Rubber profile shears SE- WA Wiring aid SE- J1 Junction Box } } } P70 } } AL 10 & AL 12 for use with P40 rubber profile. AL 20 & AL 22 for use with P70 rubber profile P40 Rubber profile for use with AL 10 & AL 12 mounting rail. Rubber profile for use with AL 20 & AL 22 mounting rail. 1 Cut Six steps to install the safety edge aluminum rail to desired length and fasten in place 4 Press the transmitter and receiver units into the ends of the rubber profile 2 Cut the rubber profile to desired length 5 Thread emitter or receiver cable through profile to desired cable exit end of rubber profile. 3 Clip the rubber profile into the aluminum rail 6 Connect to the desired safety controller It is ready! 7 319

320 SERIES SE TECHNICAL DATA Aluminum Mounting Rail Profiles & Dimensions (mm) ,5 2 centering groove 9 centering groove SE AL 10 SE AL 20 1, centering groove 9 centering groove SE AL 12 SE AL 22 Rubber Mounting Rail Profiles & Dimensions (mm) Table of Properties Rubber Profile SE - P 40, SE - P 70 Rubber Material EPDM, shore hardness 60 Temperature Range - 40 C to C ( short term) - 30 C to C ( long term) Resistance good against ozone, moderate against oils, acids, solvents, fuels Ø13,4 Ø 13,4 Ø10,9 Ø10, ,5 31 SE P SE P 70

321 SERIES SE TECHNICAL DATA Force/Travel diagram for the rubber profiles with SE 100 C controller unit Force/Travel diagram for the rubber profiles with SE 400 C controller unit Force/Travel table of rubber profiles with SE-100 C Force/Travel Fa [N] Sa [mm] Fn [N] Sn [mm] Testing Speed 100 mm/s 10 mm/s SE-P SE-P Force/Travel table of rubber profiles with SE-400 C Force/Travel Fa [N] Sa [mm] Fn [N] Sn [mm] Testing Speed 100 mm/s10 mm/s SE-P SE-P Legend Fa Actuating force Sa Actuating travel Fn Overtravel force Sn Overtravel Sg Total deformation travel with the above test data. The measurements are carried out according to EN * Sg = Sa + Sn The complete system is suitable for finger recognition in accordance Test conditions Measurement parameters Temperature: T = 20 C Mounting position B (to EN *) Place of measurement C 3 (to EN *) * preliminary 7 321

322 SERIES SE TECHNICAL DATA Transmitter and Receiver Pair Technical Data for SE - T / SE - R Technical Data SE - T, SE - R Material Polyurethane Protection class IP 68 Dimensions 11.5 mm dia., 37 mm long Connecting cable 3 x 0.14 mm2 stranded wire Cable length Transmitter 6.6 m Receiver 3 m Permissible Max. 200 m cable length Operating -25 C to +75 C temperature Fitting the rubber profile in a light bend Light bends in the profile reduce the maximum possible length of safety edge. The infrared signal between the transmitter and receiver overcomes light bends by reflection in the inner wall of the profile and self adjusting gain to increase transmission power. Large radii offer less resistance in this case than smaller ones. The reflective properties of the individual batches supplied are not absolutely constant and affect the reproducibility within certain limits. The reflective characteristics of the SE-P40 and SE-P70 profiles are the same. The SE-P40 profile allows tighter radii to be used than the SE-P70 because of its smaller dimensions. When formed into tight bends, rubber profiles tend to buckle, thus leading to total blockage of the light channel. a r l Maximum Bend Bend Radius (r) Angle (a) Length (l) 0 m 0 10,0 m 1 m 15 4,5 m 0,5 m 63 2,5 m 0,3 m 90 1,25 m Note: Maximum edge length is a function of both bend angle and bend radius.the above values are guidelines only. 322

323 SERIES SE TECHNICAL DATA SE Series Safety Controllers Electrical Specification SE C SE C Standards EN , EN , VDE 0660 Part 200 EN1760-2, EN ,VDE 0660 Part 200 Safety Control Category 1 to EN to EN Enclosure PE (black), Crastin (grey) PE (black), Crastin (grey) Fixing DIN rail EN DIN rail EN Screw terminals max. 2 x 2.5 mm 2 solid wire max. 2 x 2.5 mm 2 solid wire max. 2 x 1.5 mm 2 stranded wire with end thimble max. 2 x 1.5 mm 2 stranded wire with end thimble Protection class (terminals) (IP 20) Enclosure IP 40 IEC/EN 60529/ VDE (IP20) Enclosure IP40 IEC/EN 60529/ VDE Operational voltage 24VDC (+ 20 % / 10 %) 24VDC (+ 20 % / 10 %) Fuse rating (supply) 1A (surge-resistant) 1A (surge-resistant) Inputs 1 or 2 pairs SE-T/R Transmitter/Receiver 1 pair SE-T/R Transmitter/Receiver Outputs Changeover contacts Normally open contacts Safety contacts 11/14 13/14, 23/24 Signalling contacts 21/22/24 Semiconductor X1, Connection to internal ground Umax. 36 V, Imax. 50 ma Max. switching capacity max VA max VA Utilization category AC-15; DC-13 AC-15; DC-13 Rated operational current/voltage Ie / Ue 2 A/230VAC; 2 A/24VDC 2 A/230VAC; 3 A/24VDC Switching voltage 250V AC/DC 250V AC/DC Max. switching current 6A (resistive load) 4A (resistive load) Contact fuse rating 6A surge-resistant 4A surge-resistant Mechanical life 2 x 10 7 switching cycles 3 x 10 7 switching cycles Readiness time Max. 300ms Approx. 32ms Switch-on delay Max. 300ms Approx. 32ms Switch-off delay Typically 15ms Typically 15ms Ambient temperature +5 C to +55 C +5 C to +55 C Shock resistant < 5g / 33Hz (VDE 0160) < 5g / 33Hz (VDE 0160) Interference According to EMC Directive According to EMC Directive Weight Approx. 0.18kg Approx. 0.2kg Clearance and creepage distances Degree of soiling 2 to VDE 0160 Degree of soiling 2 to VDE 0160 Overvoltage category III / 4kV to VDE 0160 Overvoltage category III / 4kV to VDE 0160 Power consumption < 4 W < 4 W Note: Maximum distance to controller: 200m. Use 20AWG to extend bumper leads to safety controller

324 SERIES SE TECHNICAL DATA SE 304C Electrical Specification Standards Safety Control Category Enclosure Mounting Screwterminals Protection class (terminals) Operating voltage Fuse rating (supply) Inputs Outputs Safety contacts Signalling contacts Max. switching capacity Utilization category Rated operational current/voltage Switching voltage Max. switching current Mechanical life Switch-off delay Ambient temperature Shock resistant Interference Weight Power consumption SE - 304C EN to EN954-1 Thermoplastic DIN rail EN Max. 2x2.5mm 2 solid wire Max. 2x1.5mm 2 stranded with end thimble (IP20) Enclosure IP40 IEC/EN 60529/VDE VDC (+20%/-10%) 24VAC (+10%/-10%) 1A (Slow-blow) 1 to 4 pairs SE-T/R Transmitter/Receiver NO contact 13/14 Semi-conductor XI, Imax. 50 ma Max. 1500VA AC-15, DC-13 2A/230VAC, 2A/24VDC 250VAC/60VDC 2A >10 7 switching cycles Typically 17ms +5 C to +55 C <5g/33Hz (VDE 0160) According to EMC Directive kg <4W 324

325 SERIES SE TECHNICAL DATA Typical Wiring Diagram Example with SE C Example with SE C SE1 S E 2 SE-R SE-T SE-R SE-T bn bn gn gn wh wh +24V L1 +24V- +24V- SE-R gn br SE-T L1 S A1(+) A4(-) S12 S22 A3(+) A1(+) A4(-) S12 A3(+) X1 X2 X K1 K1 U- sensors input relay output K2 K1 U- K2 K2 K1 sensors input relay output K1 K2 K2 K1 K2 A2(-) SE-100C A2(-) SE-400C V N M 3 N M 3 SE-R gn bn wh Example with SE C SE1 SE-T wh gnbn SE-R SE4 SE-T SE-R gn bn wh SE2 SE-T SE-R gn bn wh SE3 SE-T gn1 S12 gn2 S22 wh bn gn3 gn4 A4(-) A3(+) S32 S

326 326 Safer by Design

327 GENERAL & SPECIFIC-PURPOSE SAFETY CONTROLLERS GENERAL PRODUCT FEATURES SCHMERSAL s PROTECT Series Safety Controllers have been designed to satisfy a wide range of application requirements. Features include: Removable, plug-in screw terminals Compact size Electronic fuses Feedback monitoring Convection-cooled housings PNP and/or dry contact monitoring capability Stop category 0 and Stop category 1 models Cross short monitoring Multiple-voltage operation Safety Category 3 and 4 models Monitored manual reset 7 327

328 328 SERIES SAFETY CONTROLLERS *Suitable for use in systems designed for up to Safety Control Category 3 per EN All others are suitable for use in systems up to Safety Control Category 4 per EN DIFFERENTIATED-INPUT SAFETY CONTROLLERS SRB 202 C 24VDC Dry Contacts N.C. Yes Depends Depends upon model* upon model* SRB 400 C 24VDC Dry Contacts 2 4 None Yes Depends Depends upon model* upon model* *Please see selection chart on Page 282. SELECTION GUIDE Model Operating Types of Number of Number of Number of Feedback Type of Cross-short Voltage (UB) Inputs Input Devices Safety Auxiliary Monitoring Reset Monitoring Monitored Monitored Outputs Outputs SRB 201 ZH 24VDC Two-hand control N.C. Yes Automatic Yes (dry contacts) SRB 206 ST* 24VAC/DC Dry contacts Yes Monitored- No or (Semi- manual VAC conductor) or Automatic SRB 206 SQ* 24VAC/DC Dry contacts Yes Monitored- Yes or (Semi- manual VAC conductor) or Automatic SRB 211 AN 24VAC/DC Dry contacts 1 2 (stop category 0) 1 Yes Monitored- Yes 1 (stop category 1) (Semi- manual (selectable) conductor) or Automatic New! SRB 211 ST 24VAC/DC Dry contacts 1 2 (stop category 0) 1 Yes Monitored- Yes or 1 (stop category 1) (Semi- manual (selectable) PNP-type outputs conductor) or Automatic SRB 301 LC 24VAC/DC Dry contacts N.C. Yes Manual Yes & or or Automatic (selectable) SRB 301 LCI PNP-type outputs SRB 301 ST 24VAC/DC Dry contacts N.C. Yes Monitored- Yes or manual (selectable) PNP-type outputs or Automatic SRB 301 ST- 48V-230VAC Dry contacts N.C. Yes Monitored- No 230V manual or Automatic SRB 301 SQ- 48V-230VAC Dry contacts N.C. Yes Monitored- Yes 230V manual or Automatic SRB 324ST 24VAC/DC Dry contacts 1 3 (stop category 0) 1 N.C. plus Yes Monitored- Yes or 2 (stop category 1) 3 semi- manual PNP-type outputs conductors or Automatic New! SAFETY OUTPUT EXPANSION MODULE SRB 402 EM 24VAC/DC N/A N/A 4 2 N.C. Yes Automatic N/A

329 SAFETY CONTROLLER SELECTION CRITERIA It helps the selection process to view a safety controller as having four basic characteristics, each determined by the application requirements. This approach can be applied to any safety controller. FOUR BASIC SAFETY CONTROLLER CHARACTERISTICS Supply Voltage Input Monitoring Feedback & Reset Circuit Output SUPPLY VOLTAGE REQUIREMENTS Select your supply voltage. While many voltages are possible (24VDC, 24VAC, 24VAC/DC, 115VAC and 230VAC), 24 VDC gives the most flexibility since virtually all controllers are available in this voltage. Also, since a transformer and rectifier are not required, this unit generally is less expensive and smaller than a 115VAC model. It is important to recognize that the safety controller supply voltage is always converted by the controller electronics to 24VDC for internal operation and for powering monitored input devices. Hence monitored input devices need only be rated for 24VDC. INPUT MONITORING REQUIREMENTS The first step is to determine whether you need single channel (up to Safety Control Category 2) or dual-channel (Control Category 3 & 4) operation. Single-channel systems must monitor one N.C. positivebreak contact. Dual-channel systems can monitor 1 N.O./1 N.C. or 2 N.C. contacts. Generally, these need to be isolated dry contacts since most controllers will view C-form contacts as a short circuit. Remember that 24VDC is supplied by the safety controller for monitoring these contacts. Safety controllers are also available for monitoring non-potential free contacts (such as PNP outputs from light curtains). Models are also available that allow users to field select the monitored contact configuration. Another consideration is crossed wire detection (a short between channels). This requires special circuitry in the safety controllers and is required for Safety Control Category 4 safety control systems. FEEDBACK & RESET CIRCUIT REQUIREMENTS Safety controllers with feedback capability can also monitor control relays and motor contactors with positiveguided contacts. Such feedback is required for Safety Control Category 3 & 4 systems. A NC auxiliary contact is wired into the feedback loop (with or without a reset (start) button) to detect welded contacts in these external control devices. The safety controller detects the existence of a weld when the relay shuts down due to a power loss or open machine guard and prevents a restart. In order to reset the controller, the feedback loop must be closed (at least temporarily). If the NC auxiliary contact stays open due to a contact weld, the controller cannot be reset. Safety Control reset can be automatic or be achieved using the edge of a 24VDC reset signal. With automatic reset the controller will automatically reset (outputs close) when the machine guard is closed. Alternately, a reset or start button (manual reset) can be added to the feedback loop if desired. The controller only needs to momentarily see a 24VDC signal at the feedback terminals to reset. With a monitored-manual reset, some type of pushbutton is required. For monitored-manual resets, the feedback loop circuitry is designed so that it needs to see a 24V to 0V transition (trailing edge) in order to reset. This method of reset is generally required when a person can actually get inside a machine guard (where they would be at risk if the equipment should automatically restart when the guard closes). OUTPUT REQUIREMENTS Determine the number and type of safety controller outputs required for machine control elements and signaling. Following are the typical types of safety controller outputs: A. N.O. safety enable circuits either instantaneous or timed. B. N.O. or N.C. auxiliary relay contacts these are not to be used for safety functions, but only for annunciation/signaling. C. Semiconductor outputs for annunciation

330 SERIES SRB 201 ZH Two-Hand Control Safety Controller TECHNICAL FEATURES Description The Model SRB 201 ZH is designed expressly for use with two-hand control units. It is equipped for connection to two actuators each with 1Normally-Open (N.O.) and 1 Normally-Closed (N.C.) dry contacts. Both actuators (inputs) must be operated simultaneously (that is, within 500ms as required by EN574 type III/C requirements for machine operation to be enabled. Should the input actuators not be simultaneously operated within this specific 500ms period, both must be released before a start cycle can be initiated. Input Voltage 24 VDC # Discrete Input 2 Devices Monitored Compatible Input Device 1 N.O. & 1 N.C. Contact Configuration (Dry Contacts) Number & Type Safety Outputs 2 N.O. (Dry Contacts) Number & Type Auxiliary 1 N.C. (Dry Contact) (Non-Safety or Signalling Output) Typical Input Devices Monitored Two-hand control Type of Reset Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category Rating 4 Per EN Selected Features Plug-in screw terminals Electronic fuse Cross-short recognition Automatic reset AVAILABLE MODELS Front View Model Number SRB 201ZH Operating Input Voltage 24 VDC 330

331 SERIES SRB 201 ZH MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) 10 7 switching cycles 200 gm DIN rail ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% Power Consumption 1.2 W (max.) Fuse (Input Power) Internal electronic fuse* F1, F2 : tripping current >.02 A F3 : tripping current >.06 A (Hybrid) Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable suppressor circuit) Switching Capacity 24 VDC, 2 A (Auxiliary Contacts) Application Category AC 15 / DC 13 : EN Pick-up Delay 50 ms Drop-out Delay 30 ms Contact Type & Materials AgSnO self cleaning, positively driven Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Plug-in self-lifting screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN *Resets automatically after a short time-delay. TERMINAL CONNECTIONS Supply Voltage (24VDC) Monitored Input #1 (N.O. Contact) Monitored Input #1 (N.C. Contact) Monitored Input #2 (N.O. Contact) A1 A2 A2.1 S12 A1.1 S11 A1.1 S22 Monitored Input #2 (N.C. Contact) Safety Output #1 (N.O.) Safety Output #2 (N.O.) Feedback Monitoring with Automatic Reset A2.1 S X1 X2 Auxiliary Output (N.C.)

332 SERIES SRB 206 & SRB 206 SQ General Purpose Safety Controllers (for dry contact input monitoring) TECHNICAL FEATURES Input Voltage Description The Model SRB 206 ST/SQ family are general purpose units designed for use with safety devices having Normally-Closed (N.C.) dry contacts. Each is equipped for connection with up to six input devices such as E-stop push button and safety interlock switches. In addition it features user-selectable monitored-manual or automatic reset, six (non-safety) semiconductor outputs for signalling/annunciation, and two safety outputs. SRB 206 SQ and SRB 206 SQ-230 also feature cross-short recognition. Front View SRB 206 ST (SQ) 24 VAC / DC SRB 206 ST (SQ) V V AC # Discrete Input Devices 6 (Single or Dual-Channel) Monitored Compatible Input Device N.C. (Dry Contacts) Contact Configuration Number & Type 2 N.O. (Dry Contacts) Safety Outputs Number & Type Auxiliary 6 - short circuit proof, PNP-type (Non-Safety or semiconductor Y1 - Y6 max 20mA Signalling Outputs) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Type of Reset Monitored-manual (Selectable) (24 VDC trailing edge) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 3 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition (SRB 206 SQ models only) Up to 6 monitored devices Six auxiliary outputs Selectable monitored-manual or automatic reset AVAILABLE MODELS Model Number Operating Input Voltage SRB 206 ST SRB 206 ST - 230V SRB 206 SQ* SRB 206 SQ-230* 24V AC/DC VAC 24V AC/DC VAC *Feature cross-short recognition. 332

333 SERIES SRB 206 & SRB 206 SQ MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM (shown with 1 input) TERMINAL CONNECTIONS (Model SRB 206 ST shown) Supply Voltage 45mm x 100mm x 121mm (1.77" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 300 gm DIN rail Monitored Input #1A ELECTRICAL SPECIFICATIONS Operating Voltage Power Consumption Fuse (Input Power) 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz 48 VAC-240VAC, 50/60 Hz 3.6 W (max.), 3.6 VA 24 V Internal electronic (hybrid) Fuse F1, Tripping current > 1 A (Resets after interruption of supply voltage) 230 V Primary : Fuse (glass), tripping current > 1.0 A Secondary : Internal electronic fuse, tripping current > 0.12 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 24 VDC, 20 ma (Auxiliary Contacts) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable supressor circuit) Application Category AC 15 / DC 13 : EN Pick-up Delay 200 ms Drop-out Delay 40 ms Contact Type & Materials AgCdO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Self-lifting, plug-in screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN Monitored Input #1B Monitored Input #2A A1 A2 S11 S12 S71 S72 S11 S22 Monitored Input #2B Monitored Input #3A Monitored Input #3B Monitored Input #4A S72 S82 S31 S32 S82 S92 S31 S42 Monitored Input #4B Monitored Input #5A Monitored Input #5B Monitored Input #6A S92 S102 S51 S52 S102 S112 S51 S62 Monitored Input #6B S112 S122 Safety Output #1 (N.O.) Safety Output #2 (N.O.) Feedback Monitoring with Monitored-manual Reset X1 X2 7 Feedback Monitoring with Automatic Reset PNP-Semiconductor Outputs #1 through #6 X1 X3 Y1 Y2 Y3 Y4 Y5 Y6 333

334 SERIES SRB 211 AN General Purpose Safety Controller (for dry 1 NO/1 NC contact input monitoring) TECHNICAL FEATURES New! Description The Model SRB 211 AN is a general purpose unit designed for use with safety devices having Normally-Open and Normally-Closed dry contact switching outputs. It is equipped for connection of one monitored input device in dual-channel configuration. In addition it features userselectable monitored-manual or automatic reset, stop category 0 & 1 safety outputs, and feedback monitoring of positive-guided controlled loads. Front View Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Dual-Channel) Monitored Compatible Input Device N.O./N.C (Dry Contacts) Contact Configuration Number & Type 3 N.O. (1 delayed : 1-30 sec.) Safety Outputs (dry contacts) Number & Type Auxiliary PNP (Non-Safety or Signalling Outputs) Typical Input Devices E-stops (N.C./N.O.) Monitored Interlock switches (N.C./N.O.) Type of Reset Monitored-manual (Selectable) (24 VDC trailing edge) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) K3/4 (safety relay 3 & 4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 (2 safety outputs) 1 (1 safety output) Safety Control Category 4 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition Stop category 0 & 1 safety outputs Selectable trailing edge or automatic reset Resetable electronic fuse Feedback monitoring AVAILABLE MODELS Model Number SRB 211 AN Operating Voltage 24 V AC/DC 334

335 SERIES SRB 211 AN MECHANICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 255 gm DIN rail Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 5.2 W, 7.2 VA (max.), plus signaling output Y1 Fuse (Input Power) Internal electronic Fuse F1, Tripping current > 1.5 A (Resets approx. 1 second) Fuse (Safety Outputs) 4 A Slow-blow (Recommended) Switching Capacity 230 VAC, 4 A Resistive (Safety Outputs) (inductive with suitable suppressor circuit) Switching Capacity 24 VDC 100mA (Auxiliary Contacts) Application Category AC 15 / DC 13 : EN Pick-up Delay 40 ms Drop-out Delay 50 ms Contact Type & AgSnOAgNi, self cleaning, positive-guided Materials Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Plug-in, self-lifting, screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN TERMINAL CONNECTIONS Supply Voltage Monitored Input #1 (N.O.) Monitored Input #2 (N.C.) Safety Output #1 (N.O.) A1 A2 S13 S14 S21 S Safety Output #2 (N.O.) Safety Output #3 (Stop Category 1, N.O.) Feedback Monitoring with Automatic Reset Feedback Monitoring with Manually- Monitored (Trailing Edge) Reset X1 X3 X1 X2 Auxiliary Output (PNP-Semiconductor) Y

336 SERIES SRB 211 ST General Purpose Safety Controller (for dry contact and PNP-type input monitoring) TECHNICAL FEATURES Description The Model SRB 211 ST is a general purpose unit designed for use with safety devices having Normally- Closed (N.C.) dry contacts or PNP-type switching outputs. It is equipped for connection of one monitored input device in single- or dual-channel configuration. In addition it features user-selectable monitored-manual or automatic reset, stop category 0 & 1 safety outputs, and feedback monitoring of positive-guided controlled loads. Front View Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual-Channel) Monitored Compatible Input Device N.C. (Dry Contacts) or Contact Configuration PNP-switching Number & Type Safety 3 N.O. (1 delayed: 1-30 sec.) Outputs (dry contacts) Number & Type Auxiliary PNP (Non-Safety or Signalling Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Monitored-manual (Selectable) (24 VDC trailing edge) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) K3/4 (safety relay 3 & 4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 (2 safety outputs) 1 (1 safety output) Safety Control Category 4 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition Stop category 0 & 1 safety outputs Selectable monitored-manual or automatic reset Hybrid fuse Feedback monitoring AVAILABLE MODELS Model Number Operating Voltage SRB 211 ST 24V AC/DC 336

337 SERIES SRB 211 ST MECHANICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting Typical Wiring Diagram 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 255 gm DIN rail Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 5.1 W, 5.7 VA (max.), plus signaling output Y1 Fuse (Input Power) Internal electronic (hybrid) Fuse F1, Tripping current > 1 A (Resets after interruption of supply voltage) Fuse (Safety Outputs) 4 A Slow-blow (Recommended) Switching Capacity 230 VAC, 4 A Resistive (Safety Outputs) (inductive with suitable suppressor circuit) Switching Capacity 24 VDC 100mA (Auxiliary Contacts) Application Category AC 15 / DC 13 : EN Pick-up Delay 40 ms Drop-out Delay 40 ms Contact Type & AgSnO, self cleaning, positive-guided Materials Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Plug-in, self-lifting, screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN Terminal Connections Supply Voltage Monitored Input #1 (N.C. or PNP) Monitored Input #2 (N.C. or PNP) Safety Output #1 (N.O.) A1 A2 S11 S12 S21 S Safety Output #2 (N.O.) Safety Output #3 (Stop Category 1, N.O.) Feedback Monitoring with Automatic Reset Feedback Monitoring with Monitored-manual Reset X1 X3 X1 X2 Auxiliary Output (PNP-Semiconductor) Y

338 SERIES SRB 301 LC & General Purpose Safety Controller SRB 301 LCI (for dry contact and PNP-type input monitoring) TECHNICAL FEATURES Description The Model SRB 301 LC is a lower cost general-purpose unit designed for use with safety devices having Normally- Closed (N.C.) or PNP-type switching outputs. It is equipped for connection of one input device in single- or dual-channel configuration. In addition it features feedback monitoring of positive-guided controlled loads, automatic or manual reset and optional cross-short recognition. Front View Input Voltage 24 V AC/DC # Discrete Input Devices 1 (Single or Dual-Channel) Monitored Monitored Contact N.C. (Dry Contacts) or Configuration PNP-switching Number & Type Safety 3 N.O. (Dry Contacts) Outputs Number & Type Auxiliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs Type of Reset Manual (24 V Leading Edge) (Selectable) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 4 Rating Per EN Selected Features Cross-short recognition (Field-wired option) Screw terminals (LC) Detachable terminals (LCI) Feedback monitoring Electronic fuse (LCI) Glass fuse (LC) AVAILABLE MODELS Model Number Operating Voltage SRB 301 LC SRB 301 LCI 24V AC/DC 24V AC/DC 338

339 SERIES SRB 301 LC & SRB 301 LCI MECHANICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 230 gm (0.5 lbs.) DIN rail (35mm) Operating Voltage Power Consumption Fuse (Input Power) Fuse (Safety Outputs) Switching Capacity (Safety Outputs) 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz 1.7 W (max.), 1.9 VA Internal glass fuse F1: T 1.25 A (SRB 301 LC) Internal electronic fuse* (SRB 301 LCI) 6 A Slow-blow (Recommended) 230 VAC, 6 A Resistive (inductive with suitable supressor circuit) 24 VDC, 2 A Switching Capacity (Auxiliary Contacts) Application Category AC 15 / DC 13, EN Pick-up Delay 30 ms Drop-out Delay 50 ms Contact Type & AgSnO, self cleaning, positive-guided Materials Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Self-lifting, screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN *Resets automatically after a short time-delay. TERMINAL CONNECTIONS Supply Voltage Monitored Input #1 (N.C.) Monitored Input #2 (N.C.) Safety Output #1 (N.O.) A1 A2 S11 S12 S21 S Safety Output #2 (N.O.) Safety Output #3 (N.O.) Feedback Monitoring with Automatic or Manual (Leading Edge) Reset Auxiliary Output (N.C.) X1 X

340 SERIES SRB 301 ST SERIES SRB 301 ST - 230V SERIES SRB 301 SQ - 230V General Purpose Safety Controllers (for dry contact and PNP-type input monitoring) Model SRB 301 ST shown. Description The above general-purpose safety controllers are designed for use with safety devices having Normally- Closed (N.C.) or PNP-type switching outputs. Each is equipped for connection of one input device in singleor dual-channel configuration. In addition they feature plug-in screw terminals, user-selectable monitoredmanual or automatic reset, feedback monitoring of positive-guided controlled loads and cross-short recognition (on selected models). Front View TECHNICAL FEATURES Input Voltage SRB 301 ST 24 VAC / DC SRB 301 ST V V AC SRB 301 SQ V V AC # Discrete Input Devices 1 (Single or Dual-Channel) Monitored Monitored Contact N.C. (Dry Contacts) Configuration Number & Type 3 N.O. (Dry Contacts) Safety Outputs Number & Type Auxiliary 1 N.C. (Dry Contacts) (Non-Safety or Signalling Output) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP semiconductor outputs (SRB 301 ST only) Type of Reset Monitored-manual (Selectable) (24 VDC trailing edge) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) Ui (voltage beyond internal fuse) UB(voltage at input terminals, SRB 301 ST only) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 4 Rating Per EN Type Fuse Hybrid Selected Features Cross-short recognition (SRB 301ST 24 VAC / DC & SRB 301 SQ only) Plug-in screw terminals Selectable monitored-manual or automatic reset Feedback monitoring AVAILABLE MODELS Model Number Operating Voltage SRB 301 ST* 24V AC/DC 340 Model SRB 301 ST shown. SRB 301 ST V VAC SRB 301 SQ V* VAC *Feature cross-short recognition.

341 SERIES SRB 301 ST SERIES SRB 301 ST - 230V SERIES SRB 301 SQ - 230V MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight SRB 301 ST SRB 301 ST - 230V Mounting TYPICAL WIRING DIAGRAM TERMINAL CONNECTIONS (Model SRB 301 ST shown) Supply Voltage 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 240 gm (0.5 lbs.) 250 gm DIN rail (35mm) Monitored Input #1 (N.C.) ELECTRICAL SPECIFICATIONS Operating Voltage SRB 301 ST 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz SRB 301 ST (SQ) - 230V 48 VAC VAC, 50/60 Hz Power Consumption SRB 301 ST 2.4 W (max.), 3.8 VA SRB 301 ST (SQ) - 230V 2.8 VA Fuse (Input Power) 24 V Internal electronic (hybrid) Fuse F1, Tripping current > 0.6 A (Resets after interruption of supply voltage) 230 V F1 : glass bulb, tripping current 0.5 A Secondary : electronic fuse, tripping current 0.12 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable surge supressor) Switching Capacity 24 VDC, 2 A (Auxiliary Contacts) Application Category AC 15 / DC 13, EN Pick-up Delay SRB 301 ST 200 ms SRB 301 ST (SQ) - 230V 30 ms Drop-out Delay SRB 301 ST 20 ms SRB 301 ST (SQ) - 230V 30 ms Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Self-lifting, plug-in screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN Monitored Input #2 (N.C.) Safety Output #1 (N.O.) A1 A2 S11 S12 S21 S Safety Output #2 (N.O.) Safety Output #3 (N.O.) Feedback Monitoring with Automatic Reset X3 S12 Feedback Monitoring with Monitored-manual Reset X2 S12 7 Auxiliary Output (N.C.)

342 SERIES SRB 324 ST General Purpose Safety Controller (for dry contact & PNP-type input monitoring TECHNICAL FEATURES New! Description The Model SRB 324 ST is a general purpose unit designed for use with safety devices having Normally- Closed (N.C.) dry contacts or PNP-type switching outputs. It is equipped for connection of one monitored input device in single- or dual-channel configuration. In addition it features user-selectable monitored-manual or automatic reset, stop category 0 & 1 safety outputs, and feedback monitoring of positive-guided controlled loads. Front View Input Voltage 24V AC/DC # Discrete Input Devices 1 (Single or Dual-Channel) Monitored Compatible Input Device N.C. (Dry Contacts) or Contact Configuration PNP-switching Number & Type 5 N.O. (2 delayed: 1-30 sec.) Safety Outputs (dry contacts) Number & Type Auxiliary 1 N.C. (dry contact) (Non-Safety or 3 - PNP Signalling Outputs) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Devices with PNP outputs Type of Reset (Selectable) Monitored-manual (trailing edge) Automatic Feedback Monitoring Yes LED Displays Green LEDs for: K1-K4 (safety relays 1-4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 (3 safety outputs) 1 (2 safety outputs) Safety Control Category 4 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition Stop category 0 & 1 Selectable monitored-manual or automatic reset Hybrid fuse Feed back monitoring AVAILABLE MODELS Model Number SRB 324 ST Operating Voltage 24 V AC/DC 342

343 SERIES SRB 324 ST MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 45mm x 100mm x 121mm (1.8" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 480 gm DIN rail (35mm) ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz Power Consumption 4.8 W, 7.8 VA max. (Plus signalling contacts Y1-Y3) Fuse (Input Power) Internal electronic Fuse F1, tripping current > 2.5 A (reset approx. 1 second) Internal hybrid fuse F2, tripping current > 1.0 A (reset after interruption of supply voltage) Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs Stop 0) (inductive with suitable supressor circuit) Switching Capacity Y1-Y3: 24 VDC, 100mA (PNP) (Auxiliary Contacts) 61/62: 24 VDC, 2 A max. (Dry) Application Category AC-15 / DC-13 : EN Pick-up Delay 30 ms Drop-out Delay 30 ms (13/14, 23/24, 33/34) Contact Type & Material AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Plug-in, self-lifting, screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN TERMINAL CONNECTIONS Supply Voltage Monitored Input #1 Monitored Input #2 Safety Output #1 (NO) A1 A2 S11 S12 S21 S Safety Output #2 (NO) Safety Output #3 (NO) Safety Output #4 Stop Category 1 (NO) Safety Output #5 Stop Category 1 (NO) Feedback Monitoring Monitored-Manual Reset Automatic Reset Jumper Auxiliary PNP Output X1 X2 X3 X4 X4 X5 S31 S32 Y1 Y2 Y

344 SERIES SRB 202 C & SRB 400 C Differentiated-Input Controllers Description The Series SRB202C and SRB400C are (general purpose) units designed for use with safety devices having two Normally-Closed (N.C.) and/or one Normally-Open (N.O.) and one Normally-Closed (N.C.) dry contacts. Uniquely, they provide for differentiated switching of the safety outputs depending on the input that is actuated. For example, actuating an E-Stop as Input #1 would disable all of the unit s safety outputs. Conversely, actuation of Input #2 (e.g., a safety guard interlock switch) would only disable half of the available safety outputs (safety output #2 on SRB202C units and safety outputs #3 & #4 on SRB400C units). Thus this functionality, which would normally require two discrete safety controllers, can be achieved with a single unit (controller). Front View TECHNICAL FEATURES Input Voltage 24 VDC # Discrete Input Devices 2 Monitored Compatible Input Device Input #1: 2 N.C. (Dry contacts) Contact Configuration Input #2: 2 N.C. or 1 N.O./1 N.C. Number & Type Safety 2 N.O. (SRB202 models) Outputs 4 N.O. (SRB400 models) Number & Type Auxiliary SRB202: 2 N.C. (Non-Safety or SRB400: None Signalling Outputs) Typical Input Devices E-stops (N.C.) Monitored Interlock switches (N.C.) Type of Reset Monitored-manual (Depends on model) (24 VDC trailing edge) Automatic or Manual Feedback Monitoring Yes LED Displays Green LEDs for: K1 (safety relay 1) K2 (safety relay 2) K3 (safety relay 3) K4 (safety relay 4) Ui (voltage beyond internal fuse) UB (voltage at input terminals) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category 4 Rating Per EN Selected Features Plug-in screw terminals Cross-short recognition ( Q models only) Electronic fuse Feedback monitoring Selection Chart Outputs Input #1 Input #2 Cross- Model # Safety Aux Contacts Reset short Contacts Reset SRB202CA N.C. Auto No 1 N.O./1 N.C.* Auto SRB202CS N.C. or No 2 N.C. or Manual Manual SRB202CA/Q N.C. Yes 1 N.O./1 N.C.* SRB202CA/T N.C. No 1 N.O./1 N.C.* Auto SRB202CS/T N.C. Monitoredmanual Manual No 2 N.C. or SRB202CA/QT N.C. Yes 1 N.O./1 N.C.* 344 SRB400CA N.C. Auto No 1 N.O./1 N.C.* SRB400CS N.C. or No 2 N.C. SRB400CA/Q N.C. Manual Yes 1 N.O./1 N.C.* SRB400CA/T N.C. No 1 N.O./1 N.C.* SRB400CS/T N.C. Monitoredmanual No 2 N.C. SRB400CA/QT N.C. Yes 1 N.O./1 N.C.* *Suitable for use with BNS coded-magnet switches. Auto or Manual Auto or Manual

345 SERIES SRB 202 C & SRB 400 C MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 100mm x 121mm (0.9" x 3.9" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 235 gm DIN rail (35mm) ELECTRICAL SPECIFICATIONS Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10% Power Consumption 4.4 W Fuse (Input Power) Internal electronic fuse* F1, Tripping current > 1 A Fuse (Safety Outputs) 6 A Slow-blow (Recommended) Switching Capacity 230 VAC, 6 A Resistive (Safety Outputs) (inductive with suitable suppressor circuit) Switching Capacity 24 VDC 100mA (Auxiliary Contacts) Application Category AC 15 / DC 13 : EN Pick-up Delay 40 ms Drop-out Delay 50 ms Contact Type & AgSnO, self cleaning, positive-guided Materials Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Plug-in, self-lifting, screw terminals for 13 to 20 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN *Resets automatically after a short time-delay. TERMINAL CONNECTIONS Input Power Monitored Input #1A (N.C.) Monitored Input #1B (N.C.) Monitored Input #2A (N.C.) A1 A2 A1 S12 A1 S22 S31 S32 Monitored Input #2B (N.C.) Monitored Input #2B (N.O.)* Feedback and Reset Input #1 Feedback and Reset Input #2 S41 S42 S43 S44 A1 X1 A1 X2 Output #1 Output #2 Output #3 (SRB400 only) Output #4 (SRB400 only) Auxiliary Output #1 (SRB202 only) Auxiliary Output #2 (SRB202 only) *For models having 1 N.O./1 N.C. contacts on Input #2. 345

346 SERIES SRB 402 EM Safety Output Expansion Module TECHNICAL FEATURES Input Voltage 24 V AC/DC Number & Type Safety Outputs 4 N.O. (Dry Contacts) Number & Type Auxiliary 2 N.C. (Dry Contacts) (Non-Safety or Signalling Outputs) LED Displays Green LEDs for: K1/K2 (safety relay 1 & 2) Conformity to Standards UL, CSA, BG (CE-compliant) Stop Category 0 Safety Control Category Rating Function of Master Safety Per EN Controller (mounted in same control cabinet) Selected Features Plug-in screw terminals Compatible with all SRB PROTECT SM Series models AVAILABLE MODELS Description The Model SRB 402 EM is designed for use as an accessory for SCHMERSAL s PROTECT SM Series safety controllers. It provides additional safety (enabling) outputs where required to satisfy the system control requirements. Model Number SRB 402 EM Operating Voltage 24 V AC/DC Front View 346

347 SERIES SRB 402 EM MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting TYPICAL WIRING DIAGRAM 22.5mm x 90mm x 121mm (0.9" x 3.54" x 4.75") -25 C to +45 C (-13 F to +113 F) >10 7 switching cycles 215 gm (0.47 lbs.) DIN rail (35mm) ELECTRICAL SPECIFICATIONS Operating Voltage Power Consumption Fuse (Input Power) 24 VDC -15% / +20%, residual ripple max. 10% 24 VAC -15% / +10%, 50/60 Hz 1.0 VA (max.) Glass fuse F1 : 1.0 A / 250 V (Slow-blow) 6 A Slow-blow (Recommended) 230 VAC, 6 A Resistive (inductive with suitable supressor) 24 VDC, 2 A Fuse (Safety Outputs) Switching Capacity (Safety Outputs) Switching Capacity (Auxiliary Contacts) Application Category AC 15 / DC 13, DIN VDE 660 Teil 200 Pick-up Delay 30 ms Drop-out Delay 35 ms Contact Type & Materials AgSnO, self cleaning, positive-guided Contact Resistance 100 mohm (max. in new state) Air Clearance & DIN VDE (04.97), 4 kv/2 Creepage Distance Cable Connections Self-lifting, screw terminals for 13 to 24 AWG Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN TERMINAL CONNECTIONS Supply Voltage Safety Output #1 (N.O.) Safety Output #2 (N.O.) Safety Output #3 (N.O.) A1 A Safety Output #4 (N.O.) Feedback Monitoring to Main Module Auxiliary Output #1 (N.C.) Auxiliary Output #2 (N.C.) X1 X

348 SERIES PROTECT-IE-02 & PROTECT-IE-11 Input Expansion Module TECHNICAL FEATURES Description The Protect-IE is designed for use as an accessory for Schmersal s Protect Series Safety Controllers. It provides 4 additional sensor inputs where required to satisfy the system control requirements. Depending on the version, the Protect- IE monitors 1 NO/1NC or 2 NC contacts. It is possible to cascade multiple units to monitor up to 80 sensors. Input Voltage 24 VDC Number & Type of 2 N.O. (dry contacts) to master Outputs safety controller Number & Type Auxiliary 4 24 VDC (Y1-Y4) (non-safety or signalling outputs) Reset & Feedback Performed by master controller Monitoring Typical Input Devices E-stops Monitored Interlocks Coded-magnets LED Displays Green LEDs for: UB (voltage at input terminals) Y1-Y4 (signalling output) Conformity to Standards UL, CSA, BG (CE-compliant) (In preparation) Stop Category 0 Safety Control Category A function of the master safety Rating Per EN controller (mounted in same control cabinet), with a maximum of Control Category 3 Selected Features Cage-clamp terminals Cross-short recognition Electronic fuse Compatible with all SRB Protect Series models with 2 N.C. inputs Front View Model Number Protect-IE-02 Protect-IE-11 AVAILABLE MODELS Monitoring Configuration of Sensors 2 NC 1 NO/1 NC Operating Voltage 24 VDC 24 VDC 348

349 SERIES PROTECT-IE-02 & PROTECT-IE-11 MECHANICAL SPECIFICATIONS Dimensions (W x H x D) Ambient Operating Temperature Range Mechanical Life Expectancy Weight Mounting 48mm x 126mm x 61mm (1.89" x 4.96" x 2.4") -25 C to +55 C (-13 F to +131 F) >10 7 switching cycles 140 gm DIN rail Typical Wiring Diagram (Model Protect-IE-02 shown) ELECTRICAL SPECIFICATIONS Operating Voltage Power Consumption Fuse (input power) Fuse (outputs) Switching Capacity (outputs) Switching Capacity (auxiliary contacts) Pick-up Delay Drop-out Delay Contact Resistance Air Clearance & Creepage Distance Cable Connections 24 VDC -15% / +20%, residual ripple max. 10% 1.7 W max.; plus Y1-Y4 Internal electronic fuse, tripping current > 100 ma 2 A slow-blow 24V, 2 A Resistive (inductive with suitable suppressor) 24 VDC, 100 ma (Y1-Y4) 20 ms 20 ms 100 mohm (max. in new state) DIN VDE (04.97), 4 kv/2 Cage-clamp terminals for min. 0.08mm 2 & max. 2.5mm 2 Stranded or multi-core with wire end ferrule Terminal Labeling DIN EN / DIN Terminal Connections (Model Protect-IE-02 shown) Supply Voltage Output #1 (N.O.) Output #2 (N.O.) Signalling Outputs (24 VDC) A1 A Y1 Y2 Y3 Y4 Monitored Input #1A (N.C.) Monitored Input #1B (N.C.) Monitored Input #2A (N.C.) Monitored Input #2B (N.C.) + S1 Monitored Input #3A (N.C.) S2 Monitored Input #3B (N.C.) + S3 Monitored Input #4A (N.C.) S4 Monitored Input #4B (N.C.) 7 + S5 S6 + S7 S8 349

350 350 Safer by Design

351 APPENDICES Topic Page Frequently Asked Questions Regarding Man-Machine Safeguarding Requirements & Techniques Frequently Asked Questions Regarding Safety Light Curtains Selected Machine Safeguarding Terminology Machine Safety Standards Selected Conversion Factors NEMA, UL, CSA & IEC Ingress Protection Ratings

352 352

353 TABLE OF CONTENTS Topic Page I. Man-Machine Safeguarding Principles and Practices II. Control Reliability III. Risk Assessment IV. Safety Standards, CE Marking and the European Machinery Directive V. Safety Controllers VI. Applications and Solutions Positive-Break Contacts Positive-Mode Mounting Positive-Guided Contacts Risk Assessment 353

354 I. Man-Machine Safeguarding Principles & Practices 1 Why should machine guard interlocks be tamper resistant? Safety professionals recognize that, in many factories, workers often override or bypass safeguards intended to protect them from injury. Reported motivation includes real or perceived inconvenience, production incentives, familiarity with the equipment, or simply the challenge presented by the presence of the safeguard to be defeated. Consequently, manufacturers are increasingly recognizing the need for, and their obligation to provide, safety interlocks which are not easily defeated/bypassed by the operator or maintenance personnel. Additionally, safety standards-making groups encourage use of interlocks which are not easily defeated using simple, readily-available means (such as a paper clip, tape, rubber band, piece of rope, screwdriver, etc.). For example, the American National Standards Institute s (ANSI) B , Reference Standard for Safeguarding Machine Tools specifically requires:. Barrier guards that protect against unauthorized adjustment or circumvention.. Interlock devices that are not easily bypassed.. Reduced liability With the growing number of product liability cases, companies are recognizing the benefits of designing safety circuits with interlock devices that are difficult to defeat. To further reduce their liability exposure, firms are selecting only those devices that have been tested and certified for use in safety applications by a recognized, independent third-party agency. Manufacturers are encouraged to surpass safety design expectations. As cited at a recent DESIGN NEWS seminar entitled Product Liability A Survival Kit for the 90 s, jurors expect companies to go beyond mere compliance. They give greater benefit to firms who have designed their products with the latest state-of-the-art machine guarding safety devices. 2 What is meant by the term difficult to defeat when related to safety interlock switches in safety standards such as ANSI B11.19, ANSI B11.20, ANSI-RIA 15.02, OSHA , et al? Difficult to defeat is a subjective term related to workers propensity to override or bypass safety devices intended to protect them from injury. Colloquially it means that the relevant devices or systems cannot be defeated or bypassed using readily available means (such as a piece of wire, tape, simple hand tool, etc.). It implies the basic safety interlock switch design serves as a deterrent to easily overriding or bypassing its intended function. 354

355 3 How is this requirement ( difficult to defeat ) being addressed by safety interlock switch manufacturers? Safety interlock switch manufacturers are addressing this requirement by:. Designing two-piece keyed interlocks which feature a geometrically-unique actuating key and associated operating mechanism which function together to deter bypassing.. Designing coded-magnet sensors whose multiple reed contacts can only be actuated in the presence of a matched magnetic field array.. Encouraging positive-mode mounting of singlepiece interlock switches. 4 What are positive-break safety interlocks? Positive-break safety interlocks are electromechanical switches designed with normally-closed (NC) electrical contacts which, upon switch actuation, are forced to open by a non-resilient mechanical drive mechanism. (Spring actuators are not considered positive-break mechanisms.) One example of a positive-break safety interlock is shown in the photo below. This third-party certified and widely used safety switch features a two-piece construction: an electromechanical switching mechanism and a geometrically-unique actuator key. A simple illustration of this design concept is shown in Figure 2. The actuator key is typically mounted to a movable guard such as an access door, protective grating, equipment hood, or plexiglass safety cover. When the guard is closed, the actuator mates with the electromechanical switching mechanism. Upon opening of the movable guard, the actuator key mechanically rotates a cam mechanism forcing the NC electrical contacts to open the safety circuit. For machine applications with residual motion after shutdown, key actuated interlocks are available with a solenoid latch which, in conjunction with a time-delay, motion detector, position sensor or other machinery status monitor, can delay access to hazardous areas until safe conditions exist. Four optional actuator key entry locations (one on back of unit) Actuator key typically mounted to movable guard Positive-break switch mechanism, typically mounted to guard frame FIGURE 1 355

356 356 FIGURE 2 Conventional versus Positive-Break Contacts

357 5 Are conventional electromechanical limit switches designed with positive-break contacts? Conventional limit switches are typically designed to use a spring force to open normally-closed electrical contacts. Such designs are subject to two potential failure modes:. Spring failure. Inability of the spring force to overcome stuck or welded contacts. When actuated, either situation may result in an unsafe condition due to failure to open normally-closed contacts. Consequently, such designs are not certified or recognized as suitable for safety applications. SCHMERSAL offers several limit switches designed with positive-break contacts in both snap-acting and slow-action models for use in safety applications. 6 How can I recognize positive-break safety interlock switches? Devices which feature a positive-break design carry the following internationally-recognized (IEC) safety symbol: These designs meet the international requirements established for such safety interlock switches. Typically, the positive-break symbol can be found on products as part of product specification identification, as shown below. FIGURE 3 357

358 7 What is meant by a positive linkage switch actuator, and why is it recommended for safety applications? A positive linkage switch actuator is designed to eliminate possible slippage between the actuator and its mounting shaft. Examples of such designs are pinned, square and serrated shafts (see Figure 4, below). Pinned Actuator Square Serrated Positive Linkage FIGURE 4 8 What is positive-mode mounting and why is it essential in safety applications? Positive-mode mounting assures that an electromechanical safety interlock switch is positively-actuated when equipment or machinery shut-down is desired. Safe Positive-Mode Mounting (Figure 5) When mounted in the positive-mode, the non-resilient mechanical mechanism which forces the normally closed (N.C.) contacts to open is directly driven by the safety guard. In this mounting mode, opening the safety guard physically forces the N.C. contacts to open when the guard is open. 358 FIGURE 5 POSITIVE-MODE INSTALLATION

359 Unsafe Negative-Mode Mounting (Figure 6) When mounted in the negative-mode, the force applied to open the normally-closed (N.C.) safety circuit contacts is provided by an internal spring. In this mounting mode the N.C. contacts may not open when the safety guard is Open. (Here welded/stuck contacts, or failure of the contact-opening spring, may result in exposing the machine operator to a hazardous/unsafe area of the machinery.) Positive-mode installation is especially important when using single-piece safety interlock switches. This installation mode takes full advantage of the device s positivebreak design using the external force applied by the safety guard to open the N.C. contacts. FIGURE 6 NEGATIVE-MODE INSTALLATION 9 What are the risks of installing single-piece, safety interlock switches in the negative mode? When mounted in the negative-mode (see Figure 6 above), single-piece safety interlock switches can be easily defeated/circumvented by the operator often simply by taping down the switch actuator when the safety guard is open. In addition, spring-driven, normally-closed contacts can fail to open due to sticking, contact welding, or a spring failure. Under such circumstances the operator or maintenance personnel may be exposed to an unsafe or hazardous condition. Consequently, where possible, two-piece, key-actuated, tamper-resistant safety interlocks are recommended. These devices are designed to be difficult to defeat, while providing the assurance of safety circuit interruption inherent with positive-break interlock switch designs. 359

360 10 What are self-checking, redundancy, and single-fault tolerance? Self-Checking: The performing of periodic self-diagnostics on a safety control circuit to ensure critical individual components are functioning properly. Faults or failures in selected components will result in system shut-down. Redundancy: In safety applications, redundancy is the duplication of control circuits/components such that if one component/circuit should fail, the other (redundant) component/circuit will still be able to generate a stop signal. When coupled with a self-checking feature, a safety circuit component failure, or component failure within the safety circuit monitoring module or safety relay module, will be automatically detected and the machine shut down until the failure is corrected. Single-Fault Tolerance: A safety circuit is considered to be single-fault tolerant if no foreseeable single fault will prevent normal stopping action from taking place. Rugged, fail-to-safe, safety circuit controllers (often called safety relay modules) are also available that incorporate the above features to satisfy the control reliability requirements of existing domestic and international safety standards. 11 Are cable-pull switches acceptable for use in E-Stop circuits? OSHA and the European safety standards permit use of cable-pull switches in E-Stop circuits provided they: (1) Operate whether the cable is pulled or goes slack (e.g. breaks or is cut). (2) Feature positive-break NC contacts. (3) Must be manually reset before the controlled equipment can be restarted. 12 In addition, European Norm EN418 requires that the switch latch at the same time that the contacts change state. SCHMERSAL offers a variety of cable-pull switches that meet both EN418 and the OSHA guidelines. These are complemented by several safety circuit controllers and safety relay modules designed expressly for use in E-Stop circuits. Are reed switches recommended or acceptable in safety circuits and, if so, under what conditions? Reed switches may be used as interlocks in safety circuits provided:. they are designed to be actuated by a specific (coded) magnetic-field array matched to the switch s reed-array pattern.. they are used in combination with a safety controller capable of periodically checking the integrity and performance of the reed switch contacts. One such combination is shown in Figure 8, below. Coded-magnets are required to actuate the sensor, thus making it difficult for the operator or maintenance personnel to defeat or bypass. The safety controller features multiple safety relays with positive-guided contacts, redundant control circuits, and self-diagnostics that check safety system operation. 360

361 In the event of a component or interconnection wiring failure in the safety circuit, or in the safety circuit controller, the unit will shut down the system in a safe state. Note: Reed switches used without an approved safety circuit controller do not satisfy safety requirements. Reed switches are susceptible to sticking due to power surges, shock, or vibration. Additionally, reed switches tend to fail in the closed position. This failure mode cannot be addressed by using a fuse. To ensure reliability of a safety circuit using reed-type switches, use of a safety controller is required. Depending upon the application, it is also recommended that they feature two independent contacts to permit dualchannel monitoring. FIGURE 8 13 What is meant by controlled access? Controlled access generally refers to a movable machine guard that is designed such that it can only be opened under specific conditions. Typically such movable guards restrict access to an area of a machine which continues to present a hazard to the operator immediately upon the removal of power. In these situations opening of the guard is prevented until the hazardous condition has abated. This is usually achieved by a solenoid-latching interlock switch controlled by a motion detector, position sensor, time-delay or other machine-status monitor which releases the interlock (allowing the operator to open the guard) only after safe conditions exist. 14 What is diverse redundancy, and how does it heighten the reliability of a safety circuit? Diverse redundancy is the use of different types of components and software in the construction of redundant circuits/systems performing the same function. Its use is intended to minimize or eliminate failure of redundant circuits and components due to the same cause ( common-cause failure). Such designs serve to increase the functional reliability of the safety circuits and systems. 361

362 15 Why are safety interlock switches and safety controllers required? For machinery builders who export to the European Union, the use of such components designed expressly for machine guarding safety systems is mandated by the requirements of the European Machinery Directive and the need to comply with relevant safety standards. These requirements include:. Use of interlock switches that feature positive-break normally closed contacts.. Use of interlock switches or machine guarding position sensors, which are tamper-resistant/difficult to defeat.. (Where risk level dictates) the need to monitor the integrity of the safety circuit components and its interconnection wiring to ensure the system will function properly when called upon to do so. For machinery builders selling in the U.S., the use of such components is encouraged by the safety guidelines and standards of the Federal government and several industry standards-making groups including:. OSHA (Occupational Health & Safety Administration). ANSI (American National Standards Institute). UL (Underwriters Laboratories). ISA (Instrument Society of America). SAE (Society of Automotive Engineers). 16 As an OEM, what are the benefits of using positive-break and tamper-resistant interlocks in safety applications? Proper selection and installation of safety interlocks which have been tested and certified by an approved, independent safety testing body benefits the equipment manufacturer by:. Providing greater protection from injury for machine operators, maintenance personnel, set-up and other user personnel.. Satisfying international safety regulations a must for U.S. equipment manufacturers who wish to export to the European Economic Community.. Enhancing product marketability.. Satisfying safety standards and guidelines against which manufacturer s responsibility, in the event of an injury, is judged.. Reducing liability risks.. Minimizing insurance claims/costs. 362

363 17 As an in-plant user, what are the benefits of using positive-break, and/or tamper-resistant interlocks in safety applications? Proper selection and installation of such safety interlocks which have been tested and certified by an approved, independent testing body benefit the in-plant user by:. Providing greater protection from injury for machine operators, maintenance personnel, and other employees.. Reducing liability risks.. Minimizing insurance claims/costs.. Satisfying safety standards and guidelines against which employer responsibility, in the event of an injury, is measured.. Reducing the indirect costs associated with worker injury (e.g. lost production, loss of skilled workers, reduced productivity due to employee stress, etc.) 18 What are the benefits of using SCHMERSAL safety interlock switches and related controls? While SCHMERSAL is not the only manufacturer of such devices, there are a number of factors which favor your consideration. These include: (1) All SCHMERSAL safety interlocks have been thirdparty tested and certified to meet relevant directives all are CE-compliant. (2) Each can be provided with a Declaration of Conformity. (3) Each has been designed expressly for safety applications to meet the requirements of ANSI, OSHA and the European Machinery Directive. (4) SCHMERSAL s individually-coded keyed interlocks (AZ16zi, AZ17zi, and AZM170zi) provide the highest level of tamper resistance. (5) SCHMERSAL s safety interlocks and related controllers have been proven in thousands of installations worldwide. (6) SCHMERSAL s microprocessor-based Series AES safety controllers feature integrated systems diagnostics which, using a visual colored LED display pattern, help identify the type of system fault that has occurred and its location (to minimize downtime). (7) SCHMERSAL s safety controllers are easily integrated with their more than 200 positive-break interlock switches and coded-magnet sensors to achieve any desired safety level. And, they are also compatible with other manufacturers safety-approved components. 363

364 II. Control Reliability 19 What is meant by control reliability? Control reliability implies that the safety device or system is designed, constructed and installed such that the failure of a single component within the device or system shall not prevent normal machine stopping action from taking place but shall prevent a successive machine cycle from being initiated. 20 How does this definition of control reliability relate to the European machinery safety requirements? Safety systems which are single component failure control reliable meet the requirements of a Category 3 safety-related control system as defined by the harmonized European machinery safety standard EN

365 21 What are positive-guided or force-guided relays, and why are they preferred over conventional relays when designing safety systems? Positive-guided relays feature N.O. and N.C. contacts which operate interdependently. For such relays, the N.O. and N.C. contacts can never be closed simultaneously. In the event one of the contacts welds closed, the other contacts cannot change state. For example, should one or more of the N.O. contacts weld/stick shut when closed, the N.C. contact(s) will remain open with a minimum gap of 0.5mm. This unique feature is desirable in machine safety circuits where fail- to-safe and/or single component failure control reliability is desired. The positive relationship (interdependent operation) between N.O. and N.C. contacts permit self-checking/monitoring of the performance of these devices. Such relays provide a higher level of safety system integrity and reliability. A simple illustration of the interdependent function of positive-guided contacts is shown in Figure 9. FIGURE 9 POSITIVE-GUIDED VS. CONVENTIONAL CONTACTS 365

366 22 What are redundant logic circuits, and what are their benefits in safety circuit applications? Control reliability implies that the safety device or system is designed, constructed and installed such that the failure of a single component within the device or system shall not prevent normal machine stopping action from taking place but shall prevent a successive machine cycle from being initiated. To achieve this, safety controllers are typically designed with dual logic circuits, each of which can provide safety circuit checking/monitoring. These functionally-equivalent logic circuits crossmonitor each other, as well as checking the safety circuit for component failures, short circuits, open circuits, etc. Since these controllers detect faults in the safety circuit components and interconnection wiring to effect machine shutdown, such redundant self-monitoring circuits enhance safety system reliability. In so doing they provide a higher level of safety for the machine operator and maintenance personnel. To heighten the integrity and reliability of these units, SCHMERSAL engineers have had each of the redundant logic circuit microprocessors programmed by a different software specialist thus reducing the probability of a simultaneous logic-circuit malfunction due to a programming error. Use of such safety controllers, in combination with safety interlock switches, tamper-resistant coded-magnet switches, and emergency cable-pull switches enables control engineers to achieve the single component failure control reliability required by OSHA, ANSI, and international machine guarding safety standards/guidelines. 23 What characterizes fail-to-safe operation? Fail-to-safe safety devices are designed such that a component failure will cause the device to attain rest in a safe condition. This term is generally applied to electronic safety interlock systems using non-mechanical presence or position sensors (such as reed switches, proximity switches, et al) and/or safety controllers. Such controllers are often designed to feature redundancy, self-diagnostics, and positive-guided contacts. 366

367 24 Why should I upgrade or enhance my current safety interlock or safety barrier design? 25 Heightened awareness and concern for worker safety has, and is, precipitating compelling reasons for such upgrades or enhancements. These are embodied in a variety of industrial safety standards and guidelines against which machinery manufacturers and users level of responsibility and degree of liability are measured. Several of these current and emerging standards and guidelines are listed under references at the end of this booklet. The following excerpts are provided simply to illustrate the importance and need to consider providing new or improved safety systems. OSHA Guidelines OSHA General Requirements for all machines : One or more methods of machine guarding shall be provided to protect the operator and other employees from hazards The guarding device shall be in conformity with any appropriate Standards thereof OSHA Applicability of Standards : Any Standard shall apply according to its terms to any employment and place of employment in any industry even though particular Standards are prescribed for the industry OSHA Incorporation by Reference : The Standards of agencies of the U.S. Government, and organizations which are not agencies of the U.S. Government which are incorporated by reference in this part, have the same force and effect as other Standards in this part ANSI B Machine Tool Safeguarding 7.2.6: The user shall ensure that barrier guards are installed, maintained, and operated so as to protect against unauthorized adjustment or circumvention Annex C: Performance of safety-related function(s) Control reliability is not provided by simple redundancy. There must be monitoring to assure that redundancy is maintained. Control reliability uses monitoring and checking to determine that a discernable component, module, device or system has failed and that the hazardous motion (or situation) is stopped, or prevented from starting or restarting. Control reliability ensures that a failure of the control system or device will not result in the loss of the safety-related function(s). What is fault exclusion and how does it affect safety circuit design? In selected situations the occurrence of known possible component failures ( faults ) can be minimized by the safety system design or component selection. Simple examples are: (1) the use of an overrated contactor to preclude the possibility of contact welding. (2) design of a machine guard such that the interlock switch actuator cannot be damaged. (3) use of positive-break safety interlock switches together with a safety controller, such that the possibility of a contact weld resulting in the loss of the safety function is eliminated. The elimination of such faults are a compromise between the technical safety requirements and the theoretical probability of their occurrence. Design engineers are permitted to exclude such faults when constructing the machinery s safety system. However, each fault exclusion must be identified, justified, and documented in the Technical File submitted to satisfy the European Machinery Directive. 367

368 III. Risk Assessment 26 What is risk assessment? Various machines present different types of hazards and risks to the operator and/or maintenance personnel. Risk assessment is a systematic means of quantifying these risk levels in order to determine the scope of the required safety system needed to protect personnel from possible injury. 27 How do I go about assessing the risk level presented by a machine or manufacturing process? Different machines and processes have different levels of relative risk. Determining this relative risk level involves evaluating four major factors. These include: (1) Severity of the potential injury. (2) Frequency of exposure to the potential hazard. (3) Possibility of avoiding the hazard if it occurs. One approach provides guidelines for risk assessment based upon five defined levels of risk. These levels range from the lowest risk (level B) in which the severity of injury is slight and/or there is relatively little likelihood of occurrence, to the highest risk (level 4) in which the likelihood of a severe injury (if the safety system fails) is relatively high. This particular method is depicted in Figure 10, in which the following qualitative definitions apply: S: Severity of potential injury S1: slight injury (bruise) S2: severe injury (amputation or death) F: Frequency of exposure to potential hazard F1: infrequent exposure F2: frequent to continuous exposure P: Possibility of avoiding the hazard if it occurs (generally related to the speed/frequency of movement of hazard point and distance to hazard point) P1: possible P2: less possible For further details of the above, the reader is referred to the EN (Safety of Machinery: Principles for the Design of Related Control Systems). Selection of the Safety Category: A brief overview of these safety categories is provided in Figure 11. Preferred categories Possible categories, which require additional measures Over-dimensioned measures for the relevant risk FIGURE 10 Another methodology is outlined in ANSI s Technical Report B11.TR3. This guideline suggests a task-based review of potential hazards by both the equipment designer and the ultimate end-user. 368

369 28 What are the defined levels of relative risk for machinery within which the safety system should be designed? The European harmonized standard, EN954-1 (Safety of Machinery Design of Safety Related Control Systems), outlines five relative levels of risk associated with the operation/maintenance of machinery. The greater the possibility and/or severity of injury, the greater the requirements are on the design and integrity of the machine safety systems. In general, these levels of risk are defined as follows: º Safety Cat. B General Safety System Requirements Safety system designed to meet operational requirements and withstand expected external influences. (This category is usually satisfied by selecting components compatible with the application conditions e.g. temperature, voltage, load, etc.) 1 Safety system must meet the requirements of Category B, but must use well-tried safety principles and components. Well-tried principles and components include those which:. avoid certain faults e.g. short circuits.. reduce probability of faults e.g. over-rating selected components, over-dimensioning for structural integrity.. detect faults early e.g. ground fault protection.. assure the mode of the fault e.g. ensure an open circuit when it is vital that power be interrupted should an unsafe condition arise.. limit the consequences of the fault. 2 Safety system must meet the requirements of Category B. In addition the machine shall be prevented from starting if a fault is detected upon application of machine power, or upon periodic checking during operation. (This suggests the use of a safety relay module with redundancy and self-checking. Singlechannel operation is permitted provided that the input devices such as machine guard interlocks, E-stop pushbuttons, et al are tested for proper operation on a regular basis.) General Safety System Behavior A single fault or failure in the safety system can lead to the loss of the safety function. A single fault or failure in the safety system can lead to the loss of the safety function. However, the use of well tried safety principles and safety components results in a higher level of safety system reliability. Here, too, a single fault or failure in the safety system can lead to the loss of the safety function between the checking intervals. However, periodic checking may detect faults and permit timely maintenance of the safety system. Safety Cat. General Safety System Requirements 3 Safety system must meet the requirements of Category B. In addition the safety control system must be designed such that a single fault will not lead to the loss of the safety function. And, where practical, the single fault will be detected. (This requires redundancy in the safety circuit monitoring module and the use of dual-channel monitoring of the input and output devices such as machine guard interlock switches, E-stop pushbuttons, safety relays, etc.) 4* Safety system must meet the requirements of Category B. In addition the safety control system must be designed such that a single fault will not lead to the loss of the safety function and will be detected at or before the next demand on the safety system. If this is not possible, then the accumulation of multiple faults must not lead to the loss of the safety function. (This also requires redundancy in the safety circuit and the use of dual-channel monitoring of the input and output devices such as machine guard interlock switches, E-stop pushbuttons, safety relays, etc. Here the number of allowable faults will be determined by the application, technology used, and system structure.) General Safety System Behavior Here a single fault or failure in the safety system will not lead to the loss of the safety function and, where possible, will be detected. Here a single fault or failure in the safety system will not lead to the loss of the safety function, and it will be detected in time to prevent the loss of the safety function. *Category 4 safety requirements are usually associated with extremely high-risk applications. Since general machine design practice respects classic safety hierarchy, in which most machine hazards are either: designed out, guarded against (if they cannot be designed out), and,. (as a last resort) warned against, Category 4 requirements may arise relatively infrequently. FIGURE

370 29 Which of these risk category safety system requirements is consistent with OSHA and ANSI s requirement for a control reliable safety circuit? Within the above defined levels of risk, a Category 3 safety system would satisfy OSHA and ANSI s requirement for a control reliable safety circuit. Here use of an appropriate fail-to-safe, safety controller in combination with one or more safety interlock switches and/or coded-magnet sensors will meet the single component failure detection and system shutdown criteria, while preventing a successive machine cycle from being initiated when a fault is detected. 30 How can the safety system requirements, and the requirement for machine safety system control reliability, be satisfied? Machine safety system control reliability can be achieved through use of:. Safety components which feature fail-to-safe design.. Electromechanical safety interlocks which feature positive-break N.C. contacts.. Use of safety relays which feature positive-guided contacts.. Use of self-checking safety controllers.. Use of redundant monitoring/checking circuits and related safety system components. The selection of these components will, of course, be a function of the application and its level of risk assessment. SCHMERSAL has available an applications and safety circuit wiring handbook to serve as a reference for selecting, designing and wiring the appropriate safety circuit for a given level of risk assessment. 31 Are safety controllers needed when addressing Category 1 or 2 safety system requirements? Category 1 and 2 safety system requirements can be achieved without the use of safety controllers. However, this requires very careful design of the safety control circuit and a thorough understanding of the standards related to the Machinery Directive. Use of a safety circuit controller ensures meeting Category 1 and 2 requirements without a time-consuming study of the machine control system. 370

371 32 How common are Category 4 safety system requirements and how can they be satisfied? Category 4 safety system requirements are typically associated with extremely high-risk applications in which: (a) The severity of a potential injury is extremely high (e.g. amputation or death). (b) The employee/operator is exposed to the hazard highly frequently or continuously. (c) There is little possibility of the employee/operator avoiding the hazard. Classic safety hierarchy states that dangers should be: (1) designed out; (2) guarded against, if they cannot be designed out; and then (3) (as a last resort) warned against. When Category 4 safety requirements are encountered (that is, when the safety control system must be able to detect any single fault, or provide multiple fault tolerance, without loss of the safety function), it is important to remember these define the performance requirements of the overall safety system not of the individual components. (This, of course, is true for all safety categories not only Category 4.) In this system context, it is clear that safety system component selection and design for equipment assessed as a Category 4 risk will be dictated by the number of faults the system can tolerate without loss of the safety function. Hence the appropriate safety system components are application-specific, requiring a thorough understanding of the operation of the machinery and its control system. Use of a safety controller rated at Category 4 does not, in itself, assure the overall safety system meets this level of performance requirements. Since this classic safety hierarchy reflects general machine design practice, few machines present Category 4 risk conditions. 371

372 IV. Safety Standards, Marking and the European Machinery Directive 33 What is the mark and what does it mean? The CE mark (for Conformite Europeene) is a symbol applied to finished products and machinery which meet applicable European Directives. For electrical and electronic finished products, these include the Low Voltage Directive and, where relevant, the Electromagnetic Compatibility (EMC) Directive. 34 No, the CE mark is not a safety mark. It simply serves to advise European customs officials that the product meets all applicable European Directives, allowing it to be placed 35 The CE mark on a machine indicates that the machine as a whole conforms to the requirements of the European Machinery Directive (EMD). The EMD states that the machine must comply with the Essential Health & Safety requirements and the EMC. Does the mark on a safety interlock switch, coded-magnet sensor, safety controller or other finished product intended for use in a safety circuit signify the product is safe? on the European Economic Market Area (The European Union and the countries of Iceland, Liechtenstein and Norway). Are third-party approvals needed to apply the mark to safety components? Third-party examination by an approved, independent testing agency or notified body is required for some safety components. Specific products include light curtains, safety mats, and two-hand controls. In addition some countries, such as Germany, require third-party certification for safety circuit controllers. For most other safety components (such as interlock switches, coded-magnet sensors, limit switches, et al) self-certification by the manufacturer is acceptable. 372 Despite this liberty, as policy SCHMERSAL has all of their safety products certified by an independent third party (such as the BG). Whether third-party or self-certified, all CE-marked components must be documented by a Declaration of Conformity. This document, signed by a highly positioned technical manager (e.g. Director of Engineering, et al), lists all standards and directives to which the product conforms. In addition, component manufacturers must maintain technical files documenting test results, etc.

373 36 Are machine guarding safety interlock switches and related safety control products subject to -marking? SCHMERSAL considers all of their safety interlock switches, sensors and related control accessories as products requiring mandatory CE-marking. Consequently these products are designed to meet the EMC and Low Voltage Directives as required. The CE-marking on SCHMERSAL s products affirms their compliance with these applicable Directives. 37 Since -marking of safety products is (for most items) a self-certification process, how can a user be assured -marked products truly meet relevant European Directives? Users of CE-marked products have three vehicles of assurance at their disposal. These include an EC Declaration of Conformity, EC Type-Examination, and Type-Certification (Technical Report). Each of these is described below. EC Declaration of Conformity The Declaration of Conformity is mandatory for all products that are CE-marked. It is also mandatory for machine components which, if they fail, could lead to a dangerous or hazardous condition on the machine. These mandates are defined in the European Machinery Directive, and must be issued by the manufacturer for all products that are CE-marked. This document, signed by a highly-positioned technical manager (e.g. Director of Product Development, Director of Research, Head of Engineering, et al), lists all the Standards and Directives to which the product conforms. It is a self-certification procedure normally undertaken by the manufacturer. All SCHMERSAL safety products have a Declaration of Conformity document according to the European Machinery Directive mandates. EC Type-Examination This is a third-party examination conducted by an approved, independent testing agency/notified body (such as the BG in Germany), and is compulsory for selected safety equipment. Here the product is investigated to confirm that it conforms to all the Standards and Directives listed in the Declaration of Conformity. The examination procedure, the definition of an approved independent testing agency/notified body, and the types of safety equipment for which this examination is mandatory is defined in the European Machinery Directive. (Specific products for which an EC Type- Examination is mandated include light curtains, safety mats, and two-hand controls. In addition the German authorities include safety circuit controllers as requiring such testing.) This examination may only be conducted once, by one approved body, whose findings are then valid for the entire European Economic Community. All SCHMERSAL safety controllers are so tested and certified. And each can be supplied with an EC Type- Examination Certificate issued by a recognized, approved body/notified body. Type Certification (Technical Report) This is similar to the EC Type-Examination, but is not compulsory. Here the product is investigated by an approved independent testing laboratory (usually by a notified body) to confirm that it conforms to all the Standards and Directives listed in the Declaration of Conformity. This examination may be carried out in as many countries and as often as required. All SCHMERSAL safety products not covered by an EC Type-Examination certificate (such as our electromechanical safety interlock switches) have been so tested and certified. And each can be supplied with a Type Certificate issued by a recognized, notified body (e.g. BG, TÜV). 373

374 38 To what type machines does the European Machinery Directive apply? The European Machinery Directive applies to all machinery that is powered and has moving parts. Excluded are manually-powered equipment, motor vehicles, medical machinery and other special equipment some of which is regulated by other legislation under European Community Directives. 39 Who is responsible for certifying that an affected machine complies with the essential health and safety requirements embodied in the European Machinery Directive? For most classes of machines, the affixing of the CE mark to demonstrate compliance with relevant European Directives is a self-certification process. For the most dangerous types of machines (Schedule 2, Annex IV of the European Union Machinery Directive, such as presses, sawing machines, manually-loaded injection/compression plastics molding machines and others listed in this Schedule), certification must be done by a recognized, independent, third party (known in Europe as a notified body ). A list of notified bodies is available from The Official Journal of the European Communities, U.S. Contact, UNIPUB; Lanham, MD. While self-certification of many machines is legally acceptable, many machinery buyers prefer purchasing machines which have been evaluated and certified by independent, recognized third parties. This preference, in some cases, has been precipitated by sale of self-certified machines which were found to not meet relevant Directives. 40 What are Consensus Standards, and how do they relate to OSHA guidelines? Consensus Standards are those industry standards developed by groups of professionals representing a cross-section of firms within that industry. Examples are standards prepared by ANSI (American National Standards Association), ISA (Instrument Society of America), ASME (American Society of Safety Engineers), SAE (Society of Automatic Engineers) and RIA (Robotics Industry Association). These standards provide safety guidelines for machinery designers and users. OSHA specifically requires that guarding devices at the point-of-operation be in conformity with any appropriate standards (which include any OSHA or industry consensus standards ). Hence OSHA may cite such consensus standards as a basis for their findings and enforcement. 374

375 V. Safety Controllers 41 What are safety controllers and what are their functions? Safety controllers (such as SCHMERSAL s AES and AZR Series) are connected between machine guarding interlock/e-stop switches and the machine s stop control elements (such as a motor contactor or control relay). These controllers contain dual, self-checking safety system monitoring circuits and positive-guided output relays. Each is designed to monitor faults in the safety system s interlock/e-stop switches, the safety circuit interconnection wiring, and their own internal monitoring circuits and output relays. Detection of a fault in the machine s safety circuit or of an open machine guard, disables the module s output signal(s) facilitating machine stoppage, and/or prevents the restarting of the machine until the fault has been corrected. In addition to detecting open guards and/or actuated E- Stop switches, safety controllers are capable of detecting the following types of safety system faults:. Guard monitoring switch/sensor failure. Open-circuit in interconnection wiring. Short-circuit in interconnection wiring. Short-to-ground in interconnection wiring. Welded contact in controlled output device. (such as positive-guided motor contactor). Failure of safety controller s positive-guided relay(s). Fault in safety system monitoring circuit. Insufficient operating voltage. Some microprocessor-based safety controllers, such as SCHMERSAL S AES Series, also feature integrated system diagnostics with visual LED outputs which indicates fault type and location thus minimizing machine downtime. Safety controllers detect and locate system faults. Units are available for use with guard interlock switches, coded-magnet sensors, safety edges, light curtains, E-stops and emergency cable-pull switches to satisfy a broad range of application requirements. 375

376 42 Why should safety controllers be used with safety interlocks/e-stops? Safety controllers increase the reliability of the machine guarding safety system. Their ability to detect safety circuit faults, and shut down the machine until the fault is corrected, greatly heighten the safety level. 43 What is the difference between a single and dual-channel safety controller, and when should each be used? A single-channel safety controller is capable of accepting only one (normally-closed) input. When used in safety circuits they are unable to detect a short-circuit failure in the interconnection wiring, or a failure of the monitored input to change state. A dual-channel safety controller is capable of accepting two inputs; one to each of its two, redundant self-monitoring safety circuits. When used in safety circuits they are typically capable of detecting interconnection wiring faults (such as short-circuits, open circuits, and ground faults) or a failure of one of the monitored input(s) to change state. As such they provide a higher level of safety than single-channel units. Single-channel safety controllers are suitable for relatively low levels of risk assessment (e.g. EN Safety Categories B, 1 and 2). Dual-channel units are appropriate when designing control reliable safety systems that is, systems in which a single component failure will not prevent normal machine stopping action from taking place, but will prevent a successive machine cycle from being initiated. 44 How do I decide which safety controller to use? Safety controller selection is usually based on: (1) the type of inputs being monitored (e.g. E-Stops, interlock switches, light curtains, coded-magnet sensors, et al). (2) the number of inputs being monitored. (3) the number and type of outputs required from the safety controller (e.g. number of parallel outputs from the module s positive-guided relays and the number of auxiliary/signaling outputs). (4) the need/desire to monitor the integrity of the positive-guided contacts in the controlled output device (e.g. motor contactor, control relay, et al). (5) the level of safety desired (this is usually determined by a structured risk assessment). These application parameters will normally narrow, and simplify, the choice of safety controller to one or two units. 376

377 45 When is it necessary to design a safety system tosatisfy the requirements of EN Category 4? Category 4 safety requirements are usually associated with extremely high-risk applications. Consequently the safety system needed to satisfy these conditions can be quite complex and costly. Since general machine design practice respects classic safety hierarchy, most extremely high-risk hazards that is: (a) those which the operator cannot avoid (b) those in which the operator is exposed frequently or continuously, and (c) those which could result in serious injury, amputation or death Consequently for most applications it is generally not necessary to incur the cost/complexity of Category 4 safety system design. Many low-risk situations can be satisfied by safety systems that meet the requirements of Category B, 1 or 2 as defined by EN In most higher-risk situations, a suitable safety system (and one which meets ANSI s requirement for control reliability ) can be achieved with a system designed to meet the Category 3 requirements of EN When needed, Category 4 requirements can be satisfied by proper selection from SCHMERSAL s wide range of CE-compliant safety interlocks and related safety controllers. are designed-out during machine development or are guarded against (if they cannot be designed-out). 377

378 VI. Applications and Solutions 46 What are some of the applications in which positive-break and tamper-resistant safety interlocks are used? Positive-break and tamper-resistant safety interlocks are inherently safer alternatives to conventional industrial components such as:. (Non-safety) electromechanical limit switches. Inductive proximity switches. Snap-acting position switches (without positive-break). Uncoded reed switches. Hall-effect sensors. Magnetic position switches. Photoelectric sensors Such conventional industrial sensors/switches are not recommended for safety applications. For increased safety and reduced liability, only components which have been tested and certified by an independent, recognized safety commission/agency are recommended. Typical applications for these safety interlocks include:. Metal cutting machine tools. Metal forming machine tools. Grinding machines. Woodworking machinery. Packaging equipment. Printing presses. Stamping/punch presses. Textile machinery. Material handling/conveyor lines. Forging equipment. Crushing machines. Sawing systems. Robot work-cell enclosures. Emergency trip-wire systems. Assembly equipment 47 What type safety interlock switches are available that are positive-break, tamper resistant, and certified for safety applications? The examples on the following pages are representative of the growing family of safety switches from SCHMERSAL which satisfy these requirements. 378

379 Safer by Design 379

380 Frequently Asked Questions Selection & Application of Safety Light Barriers 380 With Glossary of Light Curtain Terminology

381 TABLE OF CONTENTS Topic Page I. Selection & Application Characteristics II. Safety Distance Requirements III. Wiring & Installation Considerations IV. Standards & Certifications V. Glossary of Selected Light Curtain Terminology direction of approach reference plane 381

382 I. Selection & Application Characteristics 1 What is meant by protected height? Protected height is the length of the light curtain s active sensing area that is the distance from center of the first beam to the center of the last beam in the light curtain s transmitter/receiver array. 2 What is meant by range of a light curtain? Range is the maximum effective distance that may exist between the light curtain s emitter (transmitter) and its receiver. The effective range is generally reduced by use of reflecting mirrors and environmental contaminants (such as fog, smoke, steam, dust, moisture, etc.) 382

383 3 What is meant by response time of a light curtain? The response time of the light curtain is the time it takes for the light curtain to transmit the output (alarm) signal to the safety interface or machine control element after the protection field has been interrupted. The overall response time of the light curtain safety system includes the response time of the light curtain, the response time of any interposed interface (such as a safety controller or safety PLC), and the response time of the machine primary control elements (e.g. motor contactor or control relay). Response time is one of the important factors that must be considered when calculating the proper minimum safety distance. 4 What is meant by minimum object sensitivity and does it mean the same as optical pitch or beam spacing? Minimum object sensitivity refers to the smallest object (diameter) that the light curtain can detect. It is commonly stated as the resolution of the light curtain and is also referred to as detection capability. Optical or beam spacing refers to the distance from the center line of one beam to the center line of the next beam. It is important to understand that it is possible for an object to be in such a position that it does not block the path of a single beam even though it is the same diameter of the optical pitch. Therefore the resolution of a light curtain is equal to the optical pitch plus one lens diameter. P=Pitch between two lenses D=Diameter of one lens R=Resolution 383

384 5 What light curtain resolutions are commonly used? The most common light curtain resolutions are: 14mm (0.55 inches) for finger protection 30mm (1.25 inches) for hand protection 50mm (2.0 inches) to 500mm (20.0 inches) for body protection. Finger Detection Hand Detection Whole Body Protection 6 What do angle of divergence and angle of acceptance mean and what are the application considerations that they imply? Angle of divergence is the cone angle of the emitted light from the transmitter. Angle of acceptance is the cone angle within which the receiver will detect this emitted light. The wider the angles, the easier it is to align the light curtain. However, one must recognize that a wider angle of acceptance can result in possible interference from another photoelectric device emitting light energy within the receiver s angle of acceptance. Contemporary light curtain standards (IEC 61496) require a maximum angle of divergence of ± 2.5 degrees for Safety Category 4 units. (SCHMERSAL Series SLC/SLG light curtains feature a coded signal, and hence are not affected by interference from other photoelectric devices). 384

385 7 What are two box and three box light curtain systems? A three box light curtain system consists of an emitter, a receiver and a separate safety controller (safety relay module). A two box system consists of an emitter and a receiver with the safety controller functions integral to the emitter-receiver pair. A two box light curtain system generally results in lower wiring and installation cost. 8 9 What is an OSSD? OSSD is the abbreviation for Output Signal Switching Device (also known as the light curtain s safety outputs). For example the SCHMERSAL Series SLC 410 light curtains have two OSSD s (two, 500mA PNP safety outputs). What is fixed blanking and floating blanking? Fixed Blanking is when a fixed set of adjacent light beams are rendered permanently inactive for the purpose of allowing product or part of the process to enter the sensing area without deactivating the light curtain safety outputs. An example would be the blanking of a small segment of the light curtain to allow finished parts to eject from a machining operation through this specific opening in the protected field. Floating blanking is when a set number (one or more) of adjacent beams is allowed to ignore the presence of an object within their portion of the protection field. However, unlike fixed blanking (where the specific set of inactive beams are fixed), floating blanking allows the set number of adjacent beams to float within protected field thus allowing the object to be ignored to move within the protected field without deactivating the light curtain safety outputs. As long as no more than the selected number of adjacent beams is interrupted, the system remains operational and does not stop the machine. If one or more additional beams are interrupted, the light curtain system will provide a signal to initiate machine stoppage. An example would be similar to the ejected parts example above, but where the parts eject through a moving opening that is, at different points through the protected field. 385

386 10 What is muting? Muting is the provisional and automatic overriding of the light curtain safety output function during normal, uninterrupted machine cycle operation. This is an important function in applications in which the light curtain or light grid must be interrupted by some part of the machine or the materials being processed without stopping the operation or process. An example is a palletizing system within which the palletized product must be allowed to pass through the opening protected by the light curtain, while the entry of a person must stop the machine. Muting is typically accomplished using additional sensing devices (such as safety limit switches or photoelectric sensors that can be checked for functionality) in conjunction with a light curtain and a muting controller (such as SCHMERSAL s model SCM 3R) to detect the presence of the material/machine element and override the light curtain s safety function. materials authorized people non-authorized to go through the barrier 386

387 11 12 What is PSDI? PSDI (Presence Sensing Device Initiation) refers to the use of the sensing device (e.g. light curtain) to activate the machine/ manufacturing process once it has been determined that a human is no longer in the hazard area. I want to set up my light curtain so it operates in PSDI mode. What are some of the requirements? Use of a light curtain in the PSDI mode requires that it have a maximum object sensitivity of not less than mm (1.25 inch) and be located at the correct safety distance from the point of the hazard. Blanking of the sensing field is not permitted when operating in this mode. 13 What application characteristics suggest that a light curtain may be a more suitable means of protection than some other alternative safety device? (such as a safety pressure mat, interlocked movable guards, or a laser scanner)? Some of the application characteristics that may suggest use of a light curtain are: The hard guards require frequent (and costly) cleaning such as in a food processing application. The operator is required to gain frequent access to the hazardous area such that hard guards or movable guards are inconvenient and/or compromise efficient process operations. Products of different sizes/shapes are required to pass through the guarded area without interrupting production. A single light curtain might be less costly and may be used without compromising the safety of personnel. Fork lifts or other vehicles must frequently enter the hazardous area. 387

388 14 What questions might I ask to better evaluate if a light curtain is suitable solution for my application? Typical application screening" questions might include: Will the presence of dirt, dust, moisture, oil mist, or other environmental contaminants adversely affect a light curtain s performance? Can the light curtains be installed such that their alignment and performance are maintained? Can the light curtains be installed to respect the required safety distance for the application? Will ambient light conditions (such as welding arcs, AGV or forklift strobe lights) adversely affect the light curtain s performance? 388

389 II. Safety Distance Requirements How do I define the danger zone? The danger zone is that area of a machine or manufacturing cell within which a person will be exposed to a hazard and potential injury. When using safety light curtains it is important to locate them at the proper safety distance such that they initiate the stopping of the machine/process before personnel reach a point-of-hazard. How important are safety distance calculations, and who should assume the responsibility for making this calculation? Safety distance calculations are essential to the effective application and use of safety light curtains. Failure to respect the required safe distance in a given application may place personnel at risk of injury. Since proper safety distance calculations require consideration of ambient conditions, equipment stop times, response times of other interposing light curtain safety system components (such as motor contactors, control relays, safety controllers, etc.), such calculations are best done by the OEM supplying the light curtain as an integral component to their machine or equipment, or alternatively by the end-user in whose facility the light curtain is being installed. 389

390 17 How do I calculate the correct safety distance between the hazard and the location of the light curtain? For the U.S., the safety distance is typically calculated using OSHA s suggested formula: Ds = Hs x (Ts+Tp+Tr+2Tm) Dp Where: Ds = Hs = Ts = Tp = Tr = Minimum safety distance (in inches). Hand Speed constant of 63 inches per second (1.6 m/s). Maximum machine stopping time (in seconds). Maximum response time of the light curtain (in seconds). Maximum response time of all other interposing control elements e.g. safety controller, motor contactor, safety PLC (in seconds). Tm = Increase in the press stopping time allowing for brake wear (in seconds). Dp = Penetration depth factor (using the OSHA Penetration Depth Factor Calculation chart or formula) In addition ANSI (American National Standards Institute) has established a formula that will result in a similar calculation. In Europe, the following formula (adopted from EN 999) should be used and documented in the technical file: S = K (t1+t2+t3) +C Where S = K = t1 = t2 = t3 = C = minimum safety distance (mm) approach speed of object to the hazard (mm/sec) response time of the safety light curtain (in seconds) response time of the safety interface e.g. safety controller, PLC (in seconds) machine response time (in seconds) additional distance (safety factor) 390 Note: C and K will vary depending on application characteristics and light curtain resolution. For further details see SCHMERSAL Safety Light Curtain Catalog-Handbook GK-3.

391 Example: Calculate the safety distance required when using a 14mm resolution light curtain to guard a point-ofoperation hazard for which the response time of the light curtain is 6ms, the response time of the interposing safety controller is 12ms, the machine stop time is 60ms and the safety factor is negligible. S = 1600 mm/sec x ( ) S = 125 mm (5 inches) safety barrier point of danger direction of approach reference plane 18 How do I calculate the Penetration Depth Factor? Penetration Depth Factor can be calculated using OSHA s Penetration Depth Factor Calculation chart or by using the following formula: Dp = 3.4 (S ) Where Dp = Depth penetration factor S = Object Sensitivity or Light Curtain resolution (in inches) 391

392 19 After doing the safety distance calculations, I have found that due to space limitations I cannot locate my light curtain the required distance from the point-of-hazard to stop the machine in time. What can I do to provide a safe situation? Depending upon the application, there are a few possible solutions. These include the following: 1. If the machine presenting the hazard is controlled by an AC motor, one can install a dynamic brake to reduce the stopping time of the machine. 2. If the equipment presenting the hazard is controlled pneumatically or hydraulically, one can install a safety valve that produces equal pressure on both sides of the control cylinder s actuator reducing the stopping time of the equipment. 3. One can install a movable hard guard (in lieu of a light curtain) that allows access to the hazardous area only after the system has stopped or the hazard no longer exists. 392

393 III. Wiring & Installation Considerations How can I guard multiple sides of a machine with one light curtain? Multiple sides of a machine or manufacturing cell can be guarded with a single light curtain using reflecting mirrors to bend the light beams around the corners provided that the performance characteristics of the light curtain and mirrors are adequate to span the sensing distance effectively. Does the use of reflecting mirrors affect the maximum sensing range of the light curtain? Yes. Each mirror typically reduces the maximum sensing range by 10% to 25% depending upon the light curtain and the type of mirror used (e.g. front-surface reflecting, rear-surface reflecting, metal mirror, etc.) 22 What, if any, environmental conditions must be considered when using safety light curtains? Abnormal or unusual environmental conditions can compromise the performance of a safety light curtain system. For example: Sudden changes in temperature may result in condensation on the light curtain lenses or deflecting mirrors. The presence of fog, smoke or dense fumes typically reduce the effective range of a light curtain. 23 The presence of steam or dust also typically reduces the effective range of a light curtain. Must I be concerned about other light sources creating problems with my light curtain? Yes, one must be aware of other light sources (such as sunlight, reflections from nearby surfaces, welding arcs, light energy from other light curtains). Each should be considered when using safety light curtains. 393

394 24 Must light curtains only be used in the vertical position? No, some applications call for light curtains to be used in the horizontal orientation. When using light curtains horizontally, relevant industry standards (such as ANSI-RIA 15.06) should be respected. 25 Some light curtains are matched sets and some are not. Why and what does that mean to a user? A matched set means that the light curtain transmitter and receiver are matched at the factory (during manufacturing) for optimal performance. If during operation of the light curtain, the transmitter or receiver is damaged or fails, both must be replaced and returned to the factory for repair and adjustment. If the light curtain s transmitter and receiver are not matched, and a receiver or transmitter unit fail or become damaged, it can simply be replaced with another unit. SCHMERSAL s light curtain pairs (transmitter and receiver) need not be matched. 26 Does my light curtain have to be hard-wired or may I use quick-disconnects? Both types of terminations are permitted. In either case, disconnecting the receiver or transmitter will result in a shut-down. 27 If I am using a Safety PLC, do I still have to use a safety controller (safety relay module) with my light curtain? A safety PLC may be used without a safety controller (safety relay module) provided that it: Can accept the light curtain s safety output signals, Has the correct diagnostics to meet the control reliability requirements, and 394 Can provide a safety output suitable for initiating stoppage of the machine posing the hazard.

395 28 When using a light curtain with two safety outputs, may I use one for safety and one for annunciation (e.g. to send a signal to my PLC that the light curtain has been interrupted)? The answer depends on the safety category desired, as well as other elements in the safety system. For higher safety categories (Category 3 or 4) dual (redundant) safety outputs are needed to satisfy control reliability requirements. For such applications the answer is no. 29 How does one select the proper light curtain system for a given application? Typical selection factors include: How large is the object/body part that is being detected/protected? (This will determine the minimum required light curtain resolution.) What is the height/length of the area ( protected field ) to be guarded? What is the maximum distance ( range ) that will separate the emitter and the receiver in the application? How quickly must I stop the machine or process after interruption of the light curtain, and will the light curtain safety system have a fast enough response time to do so based on its intended location? What type of load will the light curtain safety outputs control, and are they sufficient for the application? (This will help determine the current capability required of the safety signals e.g. semiconductor outputs for controlling a safety PLC or solid state relay vs. relay outputs for direct control of a motor contactor). What safety level or safety control category does the application s risk assessment indicate is required? 395

396 IV. Standards & Certifications 30 Does OSHA or ANSI certify Safety Light Curtains? No, neither OSHA or ANSI certifies any safety device or system. However, there are many independent third-parties (notified bodies such as UL, CSA, or TUV) that can test and certify safety devices for compliance to industry standards What is IEC and why is it important? IEC is the European standard that defines the performance requirements for electro-optic safety devices. It is important because it addresses both the hardware and software requirements, and must be satisfied if light curtains are to meet the CE requirements of the European Economic Community. Is third-party certification of light curtains required, or may the manufacturer self-certify? Safety light curtains must be certified for their compliance to relevant standards by an independent, recognized third-party. They may not be self-certified by the manufacturer. 396

397 V. Glossary of Selected Light Curtain Terminology AOPD: AOPD is the abbreviation for Active Optoelectronic Protective Device such as a light curtain, light grid, and single light beam. Alignment: Positioning of a light curtain beam so that the maximum amount of emitted light energy reaches the receiver element. Alignment Aid: Typically a built-in light curtain feature that facilitates alignment of the emitter (transmitter) and receiver during installation. For long-range sensing, or when using deflecting mirrors, an external alignment aid (such as a laser aligning tool) may be used during installation. Ambient Conditions: The environmental conditions in the area in which the light curtain is installed (e.g. humidity, temperature, light level, etc.). Angle of Acceptance: The included angle of the field of view within which the receiver will respond to the emitter s (transmitter s) transmitted light energy. Angle of Divergence: The included angle of the field of light energy transmitted by the emitter element of the light curtain. Attenuation: A reduction in the energy level of the emitted light caused by environmental elements such as dirt, moisture, or other contaminants in the ambient. Beam Spacing: The distance between the centerline of each of the beams of light energy transmitted by the emitter. BG: BG is the abbreviation for Berufgenossenschaft an independent German insurance agency whose legislative arm recommends industry safety practices. The BG is one of many independent, recognized test agencies (also known in Europe as notified bodies ) authorized to certify that safety products comply with all relevant standards. 397

398 Blanking (Fixed Blanking): Fixed Blanking is when a fixed set of adjacent light beams are rendered permanently inactive for the purpose of allowing product or part of the process to enter the sensing area without deactivating the light curtain safety outputs. An example would be the blanking of a small segment of the light curtain to allow finished parts to eject from a machining operation through this specific opening in the protected field. Blanking (Floating Blanking): Floating blanking is when a set number (one or more) of adjacent beams is allowed to ignore the presence of an object within their portion of the protection field. However, unlike fixed blanking (where the inactive beams are fixed), floating blanking allows the set number of adjacent beams to float within protected field thus allowing the object to be ignored to move within the protected field without deactivating the light curtain safety outputs. As long as no more than the selected number of adjacent beams is interrupted, the system remains operational and does not initiate stoppage of the machine. If one or more additional beams are interrupted, the light curtain system will initiate machine stoppage. An example would be similar to the ejected parts example above, but where the parts eject through a moving opening that is, at different points through the protected field. CE Mark: The CE mark (for Conformite Europeene) is a symbol applied to finished products (including components such as light curtains, safety mats, safety interlock switches, safety controllers and machinery) which meet all applicable European Directives. CSA: Abbreviation for Canadian Standards Association. An independent testing agency similar to Underwriters Laboratories, Inc. (UL) in the United States. A product that is CSA certified has been type-tested and approved by the Canadian Standards Association as meeting relevant electrical and safety codes. Emitter (photoelectric): The light generating member of a light curtain pair. Also called the transmitter. IEC: The International Electrotechnical Commission, headquartered in Europe. This organization writes and distributes recommended safety and product performance standards for electrical products and components many of which become reference models for U.S. standards. IP Rating: A rating system established by the IEC. The IP rating defines the environmental suitability of light curtains and other component/system enclosures for various ambient conditions. Similar to NEMA ratings for electrical enclosures. 398

399 LED (Light Emitting Diode): A semiconductor that emits a small amount of light energy when current flows through it in the forward direction. Light Curtain (light screen): An array of photoelectric sensing beams configured to sense objects present in their sensing area. Safety light curtains are used to detect personnel who enter into an unsafe area around or within a machine or work cell. Minimum Object Sensitivity: Minimum object sensitivity refers to the smallest object (diameter) that the light curtain can detect. It is commonly stated as the resolution of the light curtain, and is also called the detection capability. MPCE: MPCE is an abbreviation for Machine Primary Control Element. An MPCE is the final device controlling the power to a machine (e.g. a control relay or motor contactor). MSCE: MSCE is the abbreviation for Machine Secondary Control Element. An MSCE is a control element other than the MPCE capable of removing power from a machine (e.g. a safety controller, safety PLC). Modulation (photoelectric): Modulation of a light source refers to the repeated turning of it on and off at a high frequency (typically several kilohertz). The secret of a modulated photoelectric sensor s superior performance is that the emitter and receiver are tuned to the frequency of modulation. Only the modulated light is amplified, with all other light reaching the receiver ignored. Muting: Muting is the provisional and automatic overriding of the light curtain safety output function during normal, uninterrupted machine cycle operation. This is an important function in applications in which the light curtain or light grid must be interrupted by some part of the machine or the materials being processed without stopping the operation or process. Nanometer (nm): Unit of measurement used to specify the wavelength of light energy. 1 nm = meter (10-9 meter). Optical Pitch: Optical pitch is the distance from the centerline of one beam to the centerline of the next beam in a transmitter-receiver beam array. It is also known as beam spacing. 399

400 OSSD: OSSD is the abbreviation for Output Signal Switching Device (also known as the light curtain s safety outputs). Protected Height: Protected height is the length of the light curtain s active sensing area that is the distance from the center of the first beam to the center of the last beam in the light curtains transmitter-receiver beam array. PSDI: PSDI (Presence Sensing Device Initiation) refers to the use of the sensing device (e.g. light curtain) to activate the machine and/or manufacturing process once it has been determined that a human is no longer in the hazard area. Range (sensing range): The specified maximum operating distance between the light curtain emitter (transmitter) and receiver (without use of deflecting mirrors). Use of deflecting mirrors typically reduces the maximum range of a light curtain. Receiver: The light curtain element that responds to the emitted light energy. Resolution: The smallest object profile dimension that will be reliably sensed or detected by a given light curtain transmitter-receiver pair. Response Time (response speed): The time required for the output (OSSD) of the light curtain/beam to change state in response to a change of the input signal (e.g. sensing event). Response time of a sensor becomes extremely important when calculating a suitable safety distance for a given light curtain pair. Safety Distance: Safety distance is the minimum distance from the safety light curtain to the point-ofhazard that must be respected to insure that a person will not be exposed to the hazard. It is a function of the speed of approach, and the cumulative response times of the safety light curtain, any interposing safety interfaces (such as a safety controller or safety PLC), the machine primary control element (such as a motor contactor or control relay), and the stop time of the machine. Transmitter (photoelectric): The light generating member of a light curtain pair. Also called the emitter. UL: Abbreviation for Underwriters Laboratories Inc. An independent testing agency for products sold in the United States. A device that is UL listed has been type-tested and certified to meet required electrical and/or safety standards. 400

401 GLOSSARY OF MACHINE SAFEGUARDING TERMINOLOGY 401