EUCHNER CES-AH-C03-AH-SM User guide

More than safety.
System Manual
Non-Contact Safety Switch
CES-AH-C03-AH-SM (Unicode)

System Manual Safety Switch CES-AH-C03-AH-SM
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Contents
Correct use 3
Possible combinations for CES components 4
Exclusion of liability and warranty 4
General safety instructions 5
System description 6
Montage 7
Electrical connection 8
General notes 8
Test pulses, pulsing and power control 8
Behavior in case of faults 8
Automatic restart and start button 9
Safety in case of faults 9
Fuse protection for power supply 9
Voltage drop on cable and switch 10
Connection cables and plug connectors 11
Connector assignment 11
Connection example 12
Setup 13
LED indicators 13
Teach-in function for actuator 13
Functional check 14
System status table 15
Technical data 16
Technical data for safety switch CES-AH-C03-AH-SM 16
Technical data for actuator CES-A-BBA/CES-A-BCA 19
Technical data for actuator CES-A-BPA 21
Technical data for actuator CES-A-BRN 23
Ordering information and accessories 25
Inspection and service 25
Service 25
Declaration of conformity 26

System Manual Safety Switch CES-AH-C03-AH-SM
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Correct use
The Coded Electronic Safety switches series CES are safety devices for monitor-
ing movable safety guards.
In combination with a safety guard, this safety component prevents dangerous
machine movements from being performed for as long as the safety guard is
opened. A stop command is triggered if the safety guard is opened during the
dangerous machine function.
Before safety switches are used, a risk assessment must be performed on the
machine, e.g., in accordance with:
EN ISO 13849-1, Safety of machinery. Safety related parts of control systems.
General principles for design
EN ISO 14121-1, Safety of machinery. Risk assessment. Principles
IEC 62061, Safety of machinery. Functional safety of safety-related electrical,
electronic and programmable electronic control systems.
Devices in the system family CES-AH... have special safety outputs that are suitable
for the direct switching of large loads. In appropriate applications it is therefore
not necessary to connect power relays or contactors in between.
The device interrupts the supply of power to the load, if, e.g., the safety guard
is open.
Correct use includes compliance with the relevant requirements for installation
and operation, for example
EN ISO 13849-1, Safety of machinery. Safety related parts of control systems.
General principles for design
EN 1088, Safety of machinery. Interlocking devices associated with guards.
Principles for design and selection
EN 60204-1, Safety of machinery. Electrical equipment of machines. General
requirements
EN 60947-5-3, Specification for low-voltage switchgear and controlgear. Con-
trol circuit devices and switching elements. Requirements for proximity devices
with defined behaviour under fault conditions
The safety switch must be used only in conjunction with the designated CES ac-
tuators from EUCHNER. On the use of different actuators, EUCHNER provides no
warranty for safe function.
Important!
The user is responsible for the integration of the device into a safe overall
system. For this purpose, the overall system must be validated, e.g. in ac-
cordance with EN ISO 13849-2.
Correct use requires observing the permissible operating parameters (see
Technical data).
If a product data sheet is included with the product, the information on the
data sheet applies in case of discrepancies with the operating instructions.
In the estimation of the PL for the overall system, a maximum value of
100 years can be assumed for the MTTFdaccording to the limit value in
EN ISO 13849-1:2008, Section 4.5.2. This corresponds to a minimum value
for the PFHdof 2.47x10-8/h.
It is only allowed to use components that are permissible in accordance with
the table below.
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System Manual Safety Switch CES-AH-C03-AH-SM
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Possible combinations for CES components
Safety Switch
Actuator
CES-A-BBA 071 840 CES-A-BCA 088 786 CES-A-BPA 098 775 CES-A-BRN-100251 100 251
CES-AH-C03-... 20 20 22 27
Key to symbols
15 Combination possible, typ. switch-on distance 15 mm
Combination possible, guard locking for process protection
Combination possible, guard locking for personal protection
Combination not permissible
Exclusion of liability and warranty
In case of failure to comply with the conditions for correct use stated above, or
if the safety instructions are not followed, or if any servicing is not performed as
required, liability will be excluded and the warranty void.

System Manual Safety Switch CES-AH-C03-AH-SM
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General safety instructions
Safety switches fulfill personal protection functions. Incorrect installation or tamper-
ing can lead to fatal injuries to personnel.
Check the safe function of the safety guard particularly
after any setup work
after the replacement of a CES component
after an extended period without use
after every fault
Independent of these checks, the safe function of the safety guard should be
checked at suitable intervals as part of the maintenance schedule.
Warning!
Danger of fatal injury in the event of incorrect connection or incorrect use.
Safety switches must not be bypassed (bridging of contacts), turned away,
removed or otherwise rendered ineffective.
On this topic pay attention in particular to the measures for reducing the pos-
sibility of bypassing from EN 1088:1995+A2:2008, Section 5.7.
The device is only allowed to be installed and placed in operation by authorized
personnel
who are familiar with the correct handling of safety components
who are familiar with the applicable EMC regulations
who are familiar with the applicable regulations on health and safety and ac-
cident prevention
who have read and understood the operating instructions and the system
manual
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Important!
Prior to use, read the operating instructions and the system manual and keep
these in a safe place. Ensure the operating instructions and the system manual
are always available during mounting, setup and servicing. EUCHNER cannot
provide any warranty in relation to the readability of the CD for the storage pe-
riod required. For this reason you should archive a printed copy of the system
manual. If you should lose the operating instructions or the system manual, you
can download these documents from www. EUCHNER.de.
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System Manual Safety Switch CES-AH-C03-AH-SM
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System description
The safety switch CES-AH-C03-AH-SM complies with the following safety require-
ments:
Category 3 according to DIN EN ISO 13849-1
Proximity device with self-monitoring type PDF-S according to EN 60947-5-3.
Redundant design of the circuit in the unit with self-monitoring
This means that the safety system still functions even if an internal component
fails
The switch state of the semiconductor outputs is continuously monitored inter-
nally
The CES non-contact safety switch consists of three components: coded actuator,
evaluation unit and read head.
The evaluation unit is integrated into a housing with the read head.
Each actuator possesses a unique electronic coding and so is a unique element in
the system used. The code in an actuator cannot be reprogrammed.
The actuator must be assigned to the safety switch by a teach-in process so that
it is detected by the system. This unambiguous assignment ensures a particularly
high level of protection against tampering.
The safety switch with integrated evaluation unit and read head is fastened to the
fixed part of the safety guard.
Within the device, the operation of the two safety outputs is dual-channel.
The actuator attached to the movable part of the safety guard is moved towards
the read head fitted in the safety switch by closing the door. When the switch-on
distance is reached, power is supplied to the actuator by the inductive read head
and data can be transferred.
The bit pattern read is compared with the code saved in the safety switch, if the
data match the safety outputs are enabled.
Due to the combination of dynamic polling of the actuator and the redundant,
diverse design of the safety electronics with the two feedback switching elements
for each safety output, the safety switch will enter the safe state with every detect-
able fault.
The safety outputs shut down the safety circuits if the safety guard is opened. The
state of the safety outputs is monitored internally by two microprocessors.
For the safety outputs to switch on, there must be a voltage of UBon the START
input. This voltage can be supplied either using a jumper (automatic start) or using
a start button.
The safety switch has a redundant circuit design with self-monitoring. This means
that the safety system is still effective even if a component fails.
The system is designed so that a failure will not result in the loss of the safety
function. The occurrence of failures is detected by cyclic self-monitoring at the
latest on the next demand to close the safety contacts (e.g. on starting).
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System Manual Safety Switch CES-AH-C03-AH-SM
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Montage
Caution!
Risk of damage to equipment as a result of incorrect installation. Safety switches
must not be used as a mechanical end stop.
Fit an additional end stop for the movable part of the safety guard.
Important!
From the assured switch-off distance Sar, the safety outputs are safely shut
down.
When mounting several safety switches, observe the stipulated minimum dis-
tance to avoid mutual interference.
min. 80mm
If the actuator is installed flush, the switching distance changes as a function
of the installation depth and the safety guard material.
Operating
distance
Actuator
Operating
distance
Actuator
Flush mounting Surface maounting
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Note the following points:
Actuator and safety switch must be easily accessible for inspection and re-
placement.
Actuator and safety switch must be fitted so that
the front faces are at the minimum switch-on distance 0.8 x Sao or closer
when the safety guard is closed (see section Operating distances). For a side
approach direction for the actuator a minimum distance must be maintained
so that the operating distance of the side lobes is not entered (see operating
distance for the actuator).
when the safety guard is open up to the distance Sar (assured switch-off dis-
tance), a hazard is excluded.
the actuator is positively mounted on the safety guard, e.g. by using the
safety screws included.
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System Manual Safety Switch CES-AH-C03-AH-SM
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Electrical connection
General notes
Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connec-
tion.
To avoid faults, the cable must be laid with protection.
The power for the operating voltage and for the inputs +LA and +LB must be
provided from a common power supply.
All the electrical connections must either be isolated from the mains supply
by a safety transformer according IEC 61558-2-6 with limited output voltage
in the event of a fault, or by other equivalent isolation measures.
With inductive loads there can be voltage spikes of up to -50 V lasting sev-
eral milliseconds on switching off the outputs.
To prevent overvoltages on the inputs and outputs for the safety circuits,
inductive loads must be connected with free-wheeling diodes (see Connec-
tion examples page 12.
Power devices which are a powerful source of interference must be installed
in a separate location away from the input and output circuits for signal pro-
cessing. The cable routing for safety circuits should be as far away as pos-
sible from the cables of the power circuits.
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Test pulses, pulsing and power control
Important!
In operation the device regularly switches off the safety outputs for approx.
6 ms to check the safe switching function. The loads connected must toler-
ate this behavior.
A load connected is controlled using the safety paths +LA/LA and +LB/LB.
The control voltage can be pulsed for power control.
Do not use a control system with pulsing to test the output cables or switch
off the pulsing function in your control system.
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Behavior in case of faults
Attention!
In the event of a fault in the safety switch, the safety circuit is switched off
and the DIA LED illuminates red.
After approx. 5 s. the device performs a re-start.
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Important!
If the device does not appear to function when operating voltage is applied (e.g.
green STATE LED does not flash), the safety switch must be returned unopened
to the manufacturer.

System Manual Safety Switch CES-AH-C03-AH-SM
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Automatic restart and start button
Pay attention to the notes for the following applications:
Automatic start, with a jumper (+24 V are continuously present at the START
input)
The device restarts automatically after faults.
Manual start (start via a start button)
Prior to each restart the start button must be pressed
A sticking start button (fault due to welding etc.) is not detected by the device
and results in an automatic restart.
Attention!
Danger due to automatic start / restart.
An automatic start / restart can occur:
On closing the safety guard
On switching on the power supply
On automatic restart after the detection of a fault
Check carefully which start mode is suitable for your application.
Check whether additional measures are necessary to prevent an automatic
restart.
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Safety in case of faults
The operating voltage UBis reverse polarity protected.
The contacts +LA/LA and +LB/LB are short circuit-proof and protected against
reverse polarization.
To prevent switching on of the load connected in the case of a short circuit
between LA or LB and the operating voltage UB, the cables must be laid rigidly
and with protection.
Fuse protection for power supply
The power supply must be provided with fuse protection depending on the current
required for the outputs. If both outputs (LA and LB) are used, protect with max.
10 A fuse.
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System Manual Safety Switch CES-AH-C03-AH-SM
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Voltage drop on cable and switch
If a load is applied to the outputs, voltage drops will occur on the supply cables
and on the switch.
The voltage drops are to be taken into account during the calculation of the power
available in the load connected.
Parameter Value Unit
Maximum resistance of an output path 250 mW
Resistance for further connection cable (e.g. 7 x 1 mm², supply
and return wire) 25 mW/m
Other connection resistances are to be taken into account as necessary.
Calculation example
10 m cable from the switch to the supply / load
Supply voltage on the 24 V connection
Load on channel A: 1 A
Load on channel B: 4 A
For channel A:
Voltage drop on the switch
DU1= R x I = 250 mWx 1 A = 250 mV
Voltage drop on the cable
DU2= Rlx l x I = 25 mW/m x 10 m x 1 A = 250 mV
Voltage at the load
U = UB- DU1- DU2= 24 V - 0.25 V - 0.25 V = 23.5 V
For channel B:
Voltage drop on the switch
DU1= R x I = 250 mWx 4 A = 1 V
Voltage drop on the cable
DU2= Rlx l x I = 25 mW/m x 10 m x 4 A = 1 V
Voltage at the load
U = UB- DU1- DU2= 24 V - 1 V - 1 V = 22 V
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