EUCHNER CES-AP-CR2-CH User guide

More than safety.
System Manual
Non-Contact Safety Switch
CES-AP-CR2-CH (Multicode)
CES-AP-CL2-CH (Multicode)

System Manual Safety Switch CES-AP-C.2-CH
2
Contents
About this manual 3
Correct use 3
Possible combinations for CES components 4
Exclusion of liability and warranty 4
General safety instructions 5
Function 6
Mounting 8
Electrical connection 9
Safety in case of faults 10
Fuse protection for power supply 10
Requirements for connection cables 10
Connector assignment and wire color for safety switch CES-AP-C.2-CH 11
Connection 12
Setup 14
LED indicators 14
Initial setup 14
Functional check 14
System status table 15
Technical data 16
Technical data for safety switch CES-AP-CR2-CH/CES-AP-CL2-CH 16
Technical data for actuator CES-A-BLN-... 18
Technical data for actuator CES-A-BDN 20
Ordering information and accessories 21
Inspection and service 22
Service 22
Declaration of conformity 23

System Manual Safety Switch CES-AP-C.2-CH
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About this manual
This manual is valid for all safety switches CES-AP-C.2-CH with version number
V 1.1.2 or higher.
Correct use
The Coded Electronic Safety switches series CES are safety devices for monitor-
ing movable safety guards.
In combination with a separating 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.
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.
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.
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.
Only components may be used that are permissible in accordance with the
table below.
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System Manual Safety Switch CES-AP-C.2-CH
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Possible combinations for CES components
Safety switch
Actuator
Door hinge right
CES-A-BLN-R2-100776
100776
Door hinge left
CES-A-BLN-L2-104510
104510
Usage independent of
position of door hinge
CES-A-BLN-U2-103450
103450
Usage independent of
position of door hinge
CES-A-BDN-104730
104730
Door hinge right
CES-AP-CR2-CH
Door hinge left
CES-AP-CL2-CH
Key to symbols Combination possible
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-AP-C.2-CH
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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-AP-C.2-CH
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Function
The safety switch CES-AP-CR2-CH/CES-AP-CL2-CH complies with the following
safety requirements:
Safety category 4, PLe according to EN ISO 13849-1
Proximity device with self-monitoring type PDF-M 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
Short circuit detection at the safety outputs by pulse signals
The following switch-on condition applies to safety outputs OA and OB (see also
System status table and the section Typical system times):
Safety guard closed
The non-contact safety switch CES consists of three components: coded actuator
(transponder), evaluation unit and read head.
The evaluation unit is integrated together with the read head in a housing compat-
ible with EN IEC 60947-5-2.
Every EUCHNER actuator supplied has an electronic coding (unique coding) that is
read by the read head. Only if a correct coding is detected does the system accept
the actuator. The code in an actuator cannot be reprogrammed.
Unlike systems with unique code detection, on the CES-AP-C.2-CH a specific code
is not polled but instead it is only checked whether the actuator is of a type that
can be detected by the system (multicode detection). There is no exact compari-
son of the actuator code with the code defined in the safety switch (unique code
detection).
The safety switch is fastened to the fixed part of the safety guard.
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 read head by induc-
tion and data can be transferred.
If a permissible code is detected, the safety outputs are released.
Due to the combination of dynamic polling of the actuator and the redundant,
diverse design of the safety electronics with the two feedback safety outputs, the
safety switch will enter the safe state with every detectable fault.
When the safety guard is opened, the safety outputs switch off the safety circuit
and the monitoring output OUT is switched to high-resistance. The state of the
safety outputs is monitored internally by two microprocessors.
If faults are detected, the safety circuit is switched off and the DIA LED illuminates.
In case of devices with a DIA monitoring output, the output is set to HIGH.
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 failures will not result in the loss of the safety func-
tion. 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-AP-C.2-CH
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If the safety door with the actuator should settle over time, the actuator can drift
out off the read head operating distance. The device recognizes this and indicates
that the actuator is in the boundary area (function available for V 1.1.2 and higher).
This allows the safety door to be readjusted in time.

System Manual Safety Switch CES-AP-C.2-CH
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Mounting
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
distance to avoid mutual interference.
min. 400 mm
The operating distance changes during the mounting of the actuator as a
function of the material used for the safety guard.
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Note the following points:
Actuator and safety switch must be easily accessible for inspection and re-
placement.
The switching operation must only be triggered by the specific actuator desig-
nated for this purpose. For permissible combinations please see the table of
possible combinations on page 4.
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). A mini-
mum distance dependent on the actuator must be maintained for a side ap-
proach direction: - For CES-A-BLN-R2 6 mm
- For CES-A-BLN-L2 6 mm
- For CES-A-BLN-U2 6 mm
- For CES-A-BDN 10 mm
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.
Pay attention to the maximum tightening torque for the safety switch and
actuator mountings of 1 Nm.
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Installation options
Installation options

System Manual Safety Switch CES-AP-C.2-CH
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Electrical connection
Warning!
In case of an error, loss of the safety function through incorrect connection.
To ensure safety, both safety outputs (OA and OB) must always be evaluated.
The monitoring output OUT must not be used as a safety output.
Lay the connection cables with protection to prevent the risk of short cir-
cuits.
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Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connec-
tion.
Do not use a control system with pulsing or switch off the pulsing function in
your control system. The device generates its own clock signal on the output
lines OA/OB. A downstream control system must tolerate these test pulses,
which may have a length of up to 0.4 ms.
No pulses are present when the safety outputs are switched off.
The inputs on an evaluation unit connected must be positive-switching, as the
two outputs on the safety switch deliver a level of +24 V in the switched-on
state.
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.
For use and operation as per the requirements, a power supply with the
feature "for use in class 2 circuits" must be used. The same requirement ap-
plies to the safety outputs.
Alternative solutions must comply with the following requirements:
a) Electrically isolated power supply unit with a max. open-circuit voltage of 30
V/DC and a limited current of max. 8 A.
b) Electrically isolated power supply unit in combination with fuse as per UL248.
This fuse should be designed for max. 3.3 A and should be integrated into
the 30 V/DC voltage section.
All electrical outputs must have an adequate protective circuit for inductive
loads. The outputs must be protected with a free-wheeling diode for this pur-
pose.
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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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-AP-C.2-CH
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Safety in case of faults
The operating voltage UBis reverse polarity protected.
The contacts OA/OB are short circuit proof.
A short circuit between OA and OB is detected by the switch.
A short circuit in the cable can be excluded by laying the cable with protection.
Fuse protection for power supply
The power supply must be provided with fuse protection depending on the current
required for the outputs. The following rules apply:
Max. current consumption of a switch Imax
Imax = IUB + IOUT + IOA+OB
IUB = Switch operating current (30 mA)
IOUT = Monitoring output load current (max. 50 mA)
IOA+OB = Load current safety outputs OA + OB (2 x max. 150 mA)
Requirements for connection cables
Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connec-
tion cables.
Use connection components and connection cables from EUCHNER
On the usage of other connection components, the requirements in the fol-
lowing table apply. EUCHNER provides no warranty for safe function in case
of failure to comply with these requirements.
The connection cable must not be longer than 180 m in total.
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Observe the following requirements with respect to the connection cables:
Parameter Value Unit
Wire cross-section min. 0.14 mm²
R max. 150 W/km
C max. 120 nF/km
L max. 0.65 mH/km
Recommended cable type LIYY 8x or 5x0.14 mm²
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System Manual Safety Switch CES-AP-C.2-CH
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Connector assignment and wire color for safety switch
CES-AP-C.2-CH
Plug connector with latching connection, 6-pin
Figure 1: Connector assignment, plug connector with latching connection
Pin Designation Description Wire color
1 UB Power supply, DC 24 V BN
2 OA Safety output, channel 1 WH
3 0V Ground, DC 0 V BU
4 OB Safety output, channel 2 BK
5 OUT Monitoring output GY
6 - Not used PK
Connection cable with M12 plug connector, 5-pin
Figure 2: Connector assignment, connection cable with M12 plug connector
Pin
Designation Description Wire color
5-pin
5-pin
Pin 5
not
used
1 1 UB Power supply, DC 24 V BN
2 2 OA Safety output, channel 1 WH
3 3 0V Ground, DC 0 V BU
4 4 OB Safety output, channel 2 BK
5 - OUT Monitoring output GY
View on the connection side of the safety switch
S1.1
S1.3
S1.6
S1.2
S1.4
S1.5
+UB
0V
NC
OA
OB
OUT
5
1
4
6
2
3
Coding lug
View on the connection side of the safety switch
S1.1
S1.3
S1.2
S1.4
S1.5
+UB
0V
OA
OB
n.c.
4
1
5
2
3
S1.1
S1.3
S1.2
S1.4
S1.5
+UB
0V
OA
OB
OUT
Coding lug
5-pin 5-pin,
pin 5 not used

System Manual Safety Switch CES-AP-C.2-CH
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Connection
Connect the device as shown in Figure 3. The OUT output can be connected to a
control system as a monitoring output.
Important!
The subsystem CES-AP complies with PL e in accordance with EN 13849-1. To
integrate the subsystem in a category 3 or 4 structure, it is necessary to monitor
the downstream load (the feedback loop must be monitored).
These examples show only an excerpt that is relevant for connection of the CES
system. The example illustrated here does not show complete system planning.
The user is responsible for safe integration in the overall system.
GND
DC 24 V
-F1
CES-AP-C.2-...
UB1
OA2
OB4 NC6
M8 plug-connector
(6-pin)
OUT5
0V3
-V1 -K1
-V2 -K2
L1
M
3~
-M1
L2 L3
Figure 3: Connection example CES-AP-CR2-CH/CES-AP-CL2-CH

System Manual Safety Switch CES-AP-C.2-CH
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Warning!
In case of an error, loss of the safety function through incorrect connection.
To ensure safety, both safety outputs (OA and OB) must always be evaluated.
Single-channel use of the safety outputs leads to a reduction of the category
in accordance with EN ISO 13849-1.
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GND
DC 24 V
CES-AP-C.2-...
UB1
OA2 OB4 NC6
M8 plug-connector
(6-pin)
OUT5
0V3
-K1
-K2
-M1 -M2
M M
A1
A2
A1
A2
13
14
13
14
Figure 4: Example of incorrect connection.

System Manual Safety Switch CES-AP-C.2-CH
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Setup
LED indicators
LED Color State Significance
STATE green
illumi-
nated Normal operation: Door closed
flashing
- Door open
- Actuator in boundary area
(refer to the status table for further signal functions)
DIA red illumi-
nated
- Internal electronics fault
- Fault at the inputs/outputs
Initial setup
Apply operating voltage to the safety switch.
The green LED flashes quickly
A self-test is performed during this time. After this, the LED flashes cyclically
one time and signals that it is in standby state.
Move actuator to the read head (observe distance < Sao).
The green LED illuminates continuously and indicates the detection of the
actuator.
If the green LED is flashing at approx. 2 Hz, the actuator is in the boundary area.
In this case the safety guard must be re-adjusted such that the actuator is com-
pletely in the read area.
Functional check
After installation and any fault, the safety function must be fully checked. Proceed
as follows:
Warning!
Danger of fatal injury as a result of faults in installation and functional check.
Before carrying out the functional check, make sure that there are no per-
sons in the danger area.
Observe the valid accident prevention regulations.
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Switch on operating voltage.
The green LED STATE then flashes at regular intervals.
Close all safety guards.
The machine must not start automatically.
The green STATE LED illuminates continuously.
Enable operation in the control system.
Open the safety guard.
The machine must switch off and it must not be possible to start it as long as
the safety guard is open.
The green LED STATE flashes at regular intervals.
Repeat steps 2-4 for each safety guard.
1.
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2.
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1.
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2.
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3.
4.
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System Manual Safety Switch CES-AP-C.2-CH
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System status table
Operating mode
Actuator/door posi- tion Safety outputs OA and OB
LED indicator
output
State
STATE (green) DIA (red)
Normal operation
closed on Normal operation, door closed
closed on
flashes
quickly
2 Hz
Normal operation, door closed, actuator in the boundary area Re-adjust door
open off 1 x Normal operation, door open
Fault display
closed off 3 x Defective actuator (e.g. fault in code or code not readable)
X off 4 x Output fault (e.g. short-circuit, loss of switching capability)
X off 5 x Internal fault (e.g. component faulty, data fault)
Key to symbols
LED not illuminated
LED illuminated
10 Hz (8 s) LED flashes for 8 seconds at 10 Hz
3 x LED flashes three times, and this is then repeated
X Any state
After the cause has been remedied, faults can generally be reset by opening and
closing the door. If the fault is still displayed afterward, use the reset function or
briefly interrupt the power supply. Please contact the manufacturer if the fault could
not be reset after restarting.
Important!
If you do not find the displayed device state in the System status table, this
indicates an internal device fault. In this case, you should contact the manufac-
turer.

System Manual Safety Switch CES-AP-C.2-CH
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Technical data
Note!
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.
Technical data for safety switch
CES-AP-CR2-CH/CES-AP-CL2-CH
Parameter Value Unit
min. typ. max.
Housing material Plastic PBT
Dimensions 95 x 30 x 12 mm
Weight 0.04 kg
Ambient temperature at UB= DC
24 V
°C
- Plug connector with latching
connection - 30 - + 65
- With connection cable with M12
plug connector
- Connection cable laid rigidly - 40 - + 65
- Connection cable movable 0 - + 65
Storage temperature - 40 - + 70
Degree of protection IP 69K
(IP 67 for version with M12 plug connector)
Safety class III
Degree of contamination 3
Installation position Any
Connection Plug connector or connection cable
Operating voltage UB(reverse polar-
ity protected, regulated, residual
ripple < 5%)
24 ± 15% V DC
For the approval according to
the following applies
Operation only with UL Class 2 power supply, or equivalent
measure
Current consumption 30 mA
Switching load according to DC 24 V, class 2
External fuse
(operating voltage) 0.25 - 1.5 A
Safety outputs OA/OB Semiconductor outputs, p-switching, short circuit-proof
- Output voltage U(OA)/U(OB) 1)
HIGH U(OA)
UB-1.5 - UBV DC
HIGH U(OB)
LOW U(OA)/U(OB) 0 1
Switching current per safety output 1 - 150 mA
Utilization category according to
EN IEC 60947- 5-2
DC-13 24 V 150 mA
Caution: outputs must be protected with a freewheeling diode in
case of inductive loads.
Off-state current Ir≤0.25 mA
Classification
acc. to EN IEC 60947-5-3 PDF-M
Monitoring output OUT 1) Semiconductor output p-switching, short circuit-proof
- Output voltage 0.8 x UB- UBV DC
- Max. load - - 50 mA
Rated insulation voltage Ui- - 75 V
Rated impulse withstand voltage
Uimp
- - 1.5 kV
Resilience to vibration As per EN IEC 60947-5-2
Switching frequency - - 1 Hz
Repeat accuracy R ≤10 %
EMC protection requirements As per EN IEC 60947-5-3
Reliability values according to EN ISO 13849-1
Category 4
Performance Level PL e
PFHd1.8 x 10 -9 / h
Mission time 20 years
1) Values at a switching current of 50 mA without taking into account the cable lengths.

System Manual Safety Switch CES-AP-C.2-CH
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Typical system times
Ready delay: After switching on, the unit carries out a self-test. The system is
ready for operation only after this time.
Switch-on time of safety outputs: The max. reaction time from the moment
when the actuator is at the operating distance (safety door closed) to moment
when the safety outputs switch on Ton is 400 ms.
Risk time according to EN 60947-5-3: If an actuator moves outside the op-
erating distance, the safety outputs OA and OB are deactivated after a maximum
of 260 ms.
Difference time: The safety outputs OA and OB switch with a slight time offset.
They have the same signal state at the latest after a difference time of 10 ms.
Dimension drawings and connector assignments
5,5
95
85 +0,5
75,5
19,5
11
30
4,4
6,9
4,25
6
12
3
Ø
STATE
DIA
23
Safety switch CES-AP-CR2-CH...
Active face
Active face
LEDs
with connection
cable
5,5
95
85 +0,5
75,5
19,5
11
30
4,4
4,25
6
12
3
6,9Ø
STATE
DIA
23
Safety switch CES-AP-CL2-CH...
Active face
Active face
LEDs
with connection
cable
Connection cable with
M12 plug connector
Length of cable piece:
200 mm
Connection cable with M12
plug connector
Length of cable piece:
200 mm
Fastening lug with
reinforcement plate
Fastening lug with
reinforcement plate

System Manual Safety Switch CES-AP-C.2-CH
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Technical data for actuator CES-A-BLN-...
Parameter Value Unit
min. typ. max.
Housing material Plastic PBT
Dimensions
- CES-A-BLN-R2/CES-A-BLN-L2
- CES-A-BLN-U2
95 x 30 x 12
55 x 30 x 12
mm
Weight
- CES-A-BLN-R2/CES-A-BLN-L2
- CES-A-BLN-U2
0.04
0.02
kg
Ambient temperature - 40 - + 70 °C
Degree of protection acc. to EN
IEC 60529 IP 69K
Installation position Active face opposite read head
Power supply Inductive via read head
Dimension drawing
95
85 +0,5
75,5
19,5
11
30
4,4
4,25
12
3
4,4
30
45
55
35
11 4,25
19,5
12
3,5
Active face
Active face
Active face
Active
face
CES-A-BLN-R2 CES-A-BLN-U2
95
85 +0,5
75,5
19,5
11
30
4,4
4,25
12
3
Active face
Active face
CES-A-BLN-L2
Fastening lug with
reinforcement plate
Fastening lug with
reinforcement plate
Fastening lug with
reinforcement plate

System Manual Safety Switch CES-AP-C.2-CH
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Switching distances
Operating distance for center offset m = 0
(only in combination with actuator CES-A-BLN-...)
Parameter Value Unit
min. typ. max.
Switch-on distance - 15 -
mm
Assured switch-on distance sao
1) 10 - -
Switching hysteresis 1) 1 2 -
Assured switch-off distance sar
- in x/z direction
- in y direction
-
-
-
-
40
60
Typical operating distance
(only in combination with actuator CES-A-BLN-...)
Figure 5: Typical operating distance
For a side approach direction for the actuator and safety switch, a minimum distance of s = 6 mm
must be maintained so that the operating distance of the side lobes is not entered.
Z
-25
-30
X
10
5
15
20
-20
-25
-30
-40
-35
-15
-10
-5
-10
20
25
30
15
10
40
35
5
Y
15 20 25
5
-5
-15
30
10
-20

System Manual Safety Switch CES-AP-C.2-CH
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Technical data for actuator CES-A-BDN
Parameter Value Unit
min. typ. max.
Housing material Macromelt PA-based plastic
Dimensions 26 x ∅6 mm
Weight 0.005 kg
Ambient temperature - 40 - + 70 °C
Degree of protection acc. to EN
IEC 60529 IP 67 / IP 69K 1)
Installation position Active face opposite read head
Power supply Inductive via read head
1) With flush installation
Dimension drawing
Caution!
Do not mount at temperatures below 0 °C.
The actuator can be damaged during mounting.
Switching distances
Operating distance for center offset m = 0
(only in combination with actuator CES-A-BDN-...)
Parameter Value Unit
min. typ. max.
Switch-on distance - 19 -
mm
Assured switch-on distance sao
1) 14 - -
Switching hysteresis 1) - 2 -
Assured switch-off distance sar
- in x/z direction
- in y direction
-
-
-
-
40
60
Installation options
26
0
+ 0,5
Ø
30
* min.
30 * 30 *
6,1
0
+ 0,1
z
y
x
6
* metal-free zone
operating distance