IFM AC903S User manual

7390915/03 01/2017
Original operating instructions
Safety switch with guard locking
AC903S
AC904S
UK

2
Contents
1 Preliminary note���������������������������������������������������������������������������������������������������4
1�1 Explanation of symbols ���������������������������������������������������������������������������������4
2 Safety instructions �����������������������������������������������������������������������������������������������4
3 Items supplied������������������������������������������������������������������������������������������������������5
4 Functions and features ����������������������������������������������������������������������������������������5
5 Structure and operating principle�������������������������������������������������������������������������6
5�1 Actuator version���������������������������������������������������������������������������������������������7
5�2 Version AC903S (guard locking by spring force) �������������������������������������������7
5�3 Version AC904S (guard locking by solenoid force) ���������������������������������������7
5�4 Mechanical release����������������������������������������������������������������������������������������9
6 Installation������������������������������������������������������������������������������������������������������������9
6�1 Installation instructions ����������������������������������������������������������������������������������9
6�1�1 Changing the actuating direction��������������������������������������������������������10
6�2 Protection against environmental influences �����������������������������������������������10
7 Electrical connection������������������������������������������������������������������������������������������ 11
7�1 Wiring����������������������������������������������������������������������������������������������������������� 11
8 Set-up ���������������������������������������������������������������������������������������������������������������� 11
8�1 Setting of the AS-Interface address������������������������������������������������������������� 11
8�2 Configuration in the AS-Interface safety monitor ����������������������������������������� 11
8�2�1 Monitor with extended functions���������������������������������������������������������12
9 Operation�����������������������������������������������������������������������������������������������������������13
9�1 LED indicators / AS-Interface status messages ������������������������������������������13
10 Function check and troubleshooting����������������������������������������������������������������14
10�1 Mechanical function check ������������������������������������������������������������������������14
10�2 Electrical function check ����������������������������������������������������������������������������14
10�3 Troubleshooting �����������������������������������������������������������������������������������������14
11 Scale drawing ��������������������������������������������������������������������������������������������������16
12 Technical data��������������������������������������������������������������������������������������������������17
13 Terms and abbreviations����������������������������������������������������������������������������������18
14 Data bit table����������������������������������������������������������������������������������������������������19

3
UK
15 Standards and approvals���������������������������������������������������������������������������������22
15�1 Directives and standards ���������������������������������������������������������������������������22
15�2 Approvals���������������������������������������������������������������������������������������������������22

4
1 Preliminary note
Technical data, approvals, accessories and further information at
www�ifm�com�
1.1 Explanation of symbols
►Instructions
> Reaction, result
→Cross-reference
Important note
Non-compliance may result in malfunction or interference�
Information
Supplementary note�
WARNING
Warning of serious personal injury�
Death or serious irreversible injuries may result�
2 Safety instructions
• Follow the operating instructions�
• Improper use may result in malfunctions of the unit� This can lead to personal
injury and/or damage to property during operation of the machine� For this
reason note all remarks on installation and handling given in this document�
Also adhere to the safety instructions for the operation of the whole installation�
• In case of non-observance of notes or standards, especially when tampering
with and/or modifying the unit, any liability and warranty is excluded�
• The unit must be installed, connected and put into operation by a qualified
electrician trained in safety technology�
• The applicable technical standards for the corresponding application must be
complied with�
• For installation the requirements according to EN 60204-1 must be observed�
• In case of malfunction of the unit please contact the manufacturer� Tampering
with the unit is not allowed�

5
UK
• Disconnect the unit externally before handling it� Also disconnect any
independently supplied relay load circuits�
• After installation of the system perform a complete function check�
• Only use the unit under the specified operating conditions (→ 12 Technical
data)� In case of special operating conditions please contact the manufacturer�
• Use only as described below (→ 4).
• Safety switches fulfil a personal protection function� Incorrect installation or
tampering can lead to serious injury�
• Safety components must not be bypassed (bridging of contacts), turned away,
removed or otherwise rendered ineffective�
• On this point, take particular note of the measures to reduce the possibilities of
bypassing in EN ISO 14119: 2013�
• The switching operation must only be triggered by actuators specially provided
for this purpose which are permanently connected to the safety guard�
• A complete safety-related system normally consists of several signalling
devices, sensors, evaluation units and concepts for a safe shut-down� The
manufacturer of a machine or installation is responsible for a correct and safe
overall function�
• All safety instructions and specifications in the operating instructions of the
AS-Interface safety monitor must be adhered to�
3 Items supplied
• 1 AS-Interface safety switch type AC90xS
• 1 operating instructions safety switch with guard locking, ident no� 7390915�
If one of the above-mentioned components is missing or damaged, please contact
one of the ifm branch offices�
4 Functions and features
AS-Interface safety switches type AC903S/AC904S operate as slaves on the
safety bus AS-Interface Safety at Work and function as electromagnetic interlock
devices with guard locking� The actuator has a low coding level�
In combination with a guard and the machine control system this safety
component prevents the safety guard from being opened while there is potential of

6
exposure to a mechanical hazard�
For the control system this means the following:
- Switch-on commands which cause hazardous situations must become active
only when the safety guard is in a protective position and the guard locking in
locked position�
- The locked position of the guard locking must be released only when the
hazardous situation is no longer present�
Before safety switches are used, a risk assessment must be performed on the
machine, e�g� according to
- EN ISO 13849, Safety of machinery - Safety-related parts of control systems
- EN 12100-1, Safety of machinery - General principles for design - Risk
assessment and risk reduction
Correct use includes compliance with the relevant requirements for installation
and operation, in particular
- IEC 62061, Safety of machinery - Functional safety of safety-related electrical,
electronic and programmable electronic control systems
- EN ISO 13849, Safety of machinery - Safety-related parts of control systems
- EN 14119, Interlocking devices associated with guards
- EN 60204-1, Electrical equipment of machines
The user is responsible for a safe integration of the device into a safe
overall system�
►Validate the whole system, e�g� to EN ISO 13849-2�
If the simplified procedure to EN ISO 13849-1:2016 (section 6�3) is used for
validation, the performance level (PL) may be reduced in the event of several
units being connected in series� If a data sheet is supplied with the product, the
specifications of the data sheet apply in case of deviations from the operating
instructions�
5 Structure and operating principle
AS-Interface safety switches, type AC903S/AC904S feature a slave interface to
the safety bus AS-Interface Safety at Work� They enable locking of movable safety
guards�

7
UK
There is a rotatable camshaft in the head of the switch that is blocked/released
via the locking bolt� When the actuator is inserted/removed or when the guard
locking is activated/released the locking bolt is moved� The switching contacts are
activated�
When the camshaft is blocked (guard locking active) the actuator cannot be
drawn out of the switch head� For reasons of design, the guard locking can only
be activated if the protective equipment is closed (protected against incorrect
locking)�
Position monitoring of the safety guard and monitoring of interlocking are
performed via two separate contact elements (door monitoring contact SK and
solenoid monitoring contact ÜK)�
When the safety guard is closed and the guard locking is active, each AS-i safety
switch transmits a switch-specific unique safety code sequence comprising 8x4
bits via the AS-Interface bus� This code sequence is evaluated by an AS-Interface
safety monitor� The positively driven contact SK for door monitoring is represented
by the AS-Interface input bits D0 and D1� The solenoid monitoring contact ÜK is
represented by the AS-Interface input bits D2 and D3�
►Configure the safety switch in the AS-Interface safety monitor accordingly (refer
to the operating instructions of the AS-Interface safety monitor and the data bit
table)�
5.1 Actuator version
Actuator S for the AS-i safety switches AC903S/AC904S without insertion funnel�
5.2 Version AC903S (guard locking by spring force)
The locking bolt is held in locked position by spring force and is
electromagnetically released� The spring-interlocked guard locking operates
normally closed� In the event of interruption of the solenoid power supply the
safety guard cannot be opened immediately�
For process protection the interlocking solenoid can be switched by software via
the AS-Interface output bit D0�

8
5.3 Version AC904S (guard locking by solenoid force)
Use only in special cases after a strict assessment of the risk of accident�
In the event of interruption of the solenoid power supply the safety guard can be
opened immediately!
The locking bolt is electromagnetically held in locked position and released by
spring force� The guard locking operates normally open�
►For process protection switch the interlocking solenoid by software via the
AS-Interface output bit D0�
►Close the safety guard and activate the guard locking�
►Insert the actuator into the safety switch�
> The locking bolt is released�
> The door monitoring contact closes�
- AC903S: The locking bolt passes into the locked position by spring force�
- AC904S: The locking bolt passes into the locked position by applying the
operating voltage of the solenoid�
> The safety contacts close�
> The whole safety code sequence (8 x 4 bits) is transmitted via the AS-Interface
input bits D0 to D3�
►Deactivate the guard locking and open the safety guard�
AC903S
►Apply the operating voltage of the solenoid and release the guard locking via
the AS-Interface output bit D0�
> The guard locking is deactivated, the solenoid monitoring contact ÜK opens�
The value pair 0, 0 is transmitted in every bus cycle via the AS-Interface input
bits D2 and D3�
►Remove the actuator�
> The door monitoring contact SK is positively opened and the guard locking is
blocked in this position (protection against unintentional closing)� The values 0,
0, 0, 0 are continuously transmitted via the AS-Interface input bits D0 to D3�

9
UK
AC904S
►Switch off the operating voltage of the solenoid and release the guard locking
via the AS-Interface output bit D0�
> The guard locking is deactivated, the solenoid monitoring contact ÜK opens�
The value pair 0, 0 is transmitted in every bus cycle via the AS-Interface input
bits D2 and D3�
►Remove the actuator�
> The door monitoring contact SK is positively opened and the guard locking is
blocked in this position (protection against unintentional closing)� The values 0,
0, 0, 0 are continuously transmitted via the AS-Interface input bits D0 to D3�
5.4 Mechanical release
In the event of malfunction the guard locking can be released with the mechanical
release irrespective of the state of the solenoid (→ 6.1.1).
►Remove the locking screw�
►Using a screwdriver, turn the mechanical release by approx� 180° in direction
of the arrow�
►The locking screw must be returned to its original position and sealed after use
(for example with sealing lacquer)�
►Carry out a function check after releasing the guard locking� For further
information please refer to the standard EN ISO 14119:2013, section 5�7�5�1�
6 Installation
Do not use safety switches and actuators as an end stop and only mount in
assembled condition�
►At ambient temperatures higher than 40 °C protect the switch against contact
with inflammable material or personnel�
6.1 Installation instructions
►Mount the safety switch so that
- access to the switch is difficult for operators when the safety guard is open
and the operation of the mechDanical release is still possible�
- address programming, inspection and replacement by authorised personnel
is possible�
►Insert the actuator in the actuating head�

10
►Mount the safety switch positively�
►Permanently connect the actuator to the safety guard so that it cannot be
detached (e�g� using the enclosed non-removable screws), alternatively rivet
or weld�
►Fit an additional end stop for the movable part of the safety guard�
Observe EN ISO 14119:2013, sections 5�2 and 5�3, on mounting of a safety
switch and an actuator�
Observe EN ISO 14119:2013, section 7, on measures to reduce the
possibilities of bypassing�
6.1.1 Changing the actuating direction
A
D
B
C
►Remove the screws from the actuating head�
►Set the required direction�
►Tighten the screws with 0�6 Nm�
►Close the unused actuating slots with the supplied slot covers�

11
UK
6.2 Protection against environmental influences
A lasting and correct safety function requires that the actuating head must be
protected against the penetration of foreign bodies such as swarf, sand, blasting
shot etc�
►Cover the actuating slot, the actuator and the type label during paint work�
7 Electrical connection
►For use and operation as per the UL requirements use an isolating transformer
or a power supply with secondary overcurrent protection (3 A)�
7.1 Wiring
The safety switch is connected to the bus system with an M12 connector and
a 4-pole cable� Additionally, via a passive AS-Interface splitter with a yellow
AS-Interface cable�
2
43
1
1� AS-Interface +
2� not used
3� AS-Interface -
4� not used
Observe the total current consumption from AS-i (→ chapter 12)
8 Set-up
8.1 Setting of the AS-Interface address
The address can be set before or after installation�
►Set the AS-Interface address of the safety switch using an AS-Interface
programming device� Addresses 1 to 31 are valid�
►Connect the programming device to the M12 connector of the safety switch
using a programming cable�
Address 0 is the default setting on delivery� During operation the AS-Interface LED
red Fault is lit and the AS-Interface LED green Power flashes�

12
8.2 Configuration in the AS-Interface safety monitor
Refer to the operating instructions of the AS-Interface safety monitor and the data
bit table�
Configure the safety switch in the AS-Interface safety monitor with the set
AS-Interface address, for example, as follows:
Dual-channel dependent
- synchronisation time = infinite (∞)
In this operating mode, the safety guard must be opened each time prior to
restarting in order to perform the start-up test�
Dual-channel independent
The guard locking is opened or closed via the output D0� When the guard locking
is open, the safety circuit shuts down� It is not necessary to open the door� Safety
is provided again when the guard locking is closed�
The dual-channel feature and the door contact are not tested in this configuration�
Take additional measures for testing outside the monitor�
8.2.1 Monitor with extended functions
For the monitor with extended functions the following configuration is possible:
- dual-channel conditionally dependent
- independent: In-1
The guard locking is opened or closed via the output D0� When the guard locking
is open, the safety circuit shuts down� It is not necessary to open the door� Safety
is provided again when the guard locking is closed�
The switch is monitored for malfunction, the door contact (SK) must not switch
before the guard locking contact (ÜK)�
Status signals (not relevant to safety)
The status of the AS-Interface input bits D0 and D1 for door monitoring and the
AS-Interface input bits D2 and D3 for solenoid monitoring can also be requested
via the controller (PLC) (see operating instructions AS-Interface safety monitor)�

13
UK
9 Operation
9.1 LED indicators / AS-Interface status messages
Status
LED 3 Fault
and
LED 4 Power
Device status
green is lit normal operation
red and green are lit No data exchange between
master and slave�
Possible causes:
- master in the STOP mode
- slave not in LAS
- slave with wrong IO ID
- reset active at slave
red is lit
green is flashing
No data exchange between
master and slave�
Cause:
- slave address = 0
red and green flashing device error in the slave
red is flashing
green is lit
1: LED green
2: LED red
3: LED red Fault
4: LED green Power
Two additional function LEDs 1 + 2 can be connected via the AS-Interface bus,
e�g� to indicate the door status� The red LED 2 is connected via the bit D1 as
output to the AS-Interface bus, the green LED 1 via the bit D2�

14
10 Function check and troubleshooting
WARNING
Errors during installation and function check can lead to fatal injury�
►Before the function check ensure that there are no persons in the hazardous
area�
►Adhere to the applicable accident prevention regulations�
►After installation and each error carry out a complete check of the safety
function�
10.1 Mechanical function check
The actuator must slide easily into the actuating head�
►Close the safety guard several times to check the function�
10.2 Electrical function check
►1� Switch the operating voltage on�
►2� Close all safety guards�
►In case of guard locking by means of solenoid force activate the guard locking�
The machine must not start automatically� It must not be possible to open the
safety guard�
►3� Activate operation in the controller
It must not be possible to deactivate the guard locking as long as the operation is
active�
►4� Switch off the operation in the controller and deactivate the guard locking�
The safety guard must remain locked until there is no longer a risk of injury� It must
not be possible to start the machine as long as the guard locking is deactivated�
►Repeat steps 2 - 4 for every safety guard individually�
10.3 Troubleshooting
►In case of damage or wear replace the complete switch and actuator assembly�
Replacement of individual parts or assemblies, especially of the actuating head, is
not permitted!
The production year is indicated in the bottom right corner of the type label�

15
UK
Maintenance is not necessary�
To ensure a trouble-free long-term operation regular inspections are necessary�
►Check the unit for the following points:
- correct switching function
- secure mounting of the components
- dirt and wear
- loose connectors
Exclusion of liability under the following circumstances:
- if the unit is not used for its intended purpose
- non-compliance with the safety regulations
- installation and electrical connection by non-authorised personnel
- failure to perform function checks

16
11 Scale drawing
55
25 144
190
41,4
240
154
M12x1
30
38,5
44
50
46,4

17
UK
12 Technical data
AC903S, AC904S
Safety switch with guard locking
The unit can be used in applications to PL d according to EN ISO 13849-1: 2016�
Mechanical data
Housing material
reinforced glass-fibre thermoplastic
Degree of protection to IEC 529
IP 67, mating connector plugged in
Life
1 x 10
6
operating cycles
Ambient temperature
-20���55 °C
Installation position
freely selectable
Max� approach speed
20 m/min
Actuation frequency
1200 / h
Actuation force
35 N
Extraction force
30 N (not locked)
Retention force
20 N
Locking force Fmax
2500 N
Locking force FZh
in accordance with the test
principles GS-ET-19
FZh = (Fmax / 1�3) = 2000 N
Weight
approx� 0�5 kg
Switching principle SK, ÜK
positively driven, slow-action switching element
Minimum travel and overtravel
Approach direction
horizontal (h) and vertical (v)
actuator S (standard)
24�5 + 5
AS-Interface specifications
AS-Interface operating voltage
22�5 ��� 31�6 V DC
Max� total current consumption
400 mA
AS-Interface / _extended
addressing mode possible
version 3�0 /
no
AS-i profile
S-7�B�E
Valid AS-Interface addresses
1���31
AS-i certificate
96201
AS-Interface inputs
Door monitoring contact SK
D0, D1

18
Solenoid monitoring contact ÜK
D2, D3
AS-Interface outputs
D0
interlocking solenoid, 1 = solenoid energised
D1
LED red, 1 = LED on
D2
LED green, 1 = LED on
AS-Interface LED Power
green, AS-Interface voltage applied
AS-Interface LED Fault
red, offline phase or address "0"
Reliability values to EN ISO 13849-1
B10d
5 x 10
6
13 Terms and abbreviations
PL Performance level Capability of safety-related
parts to perform a safety function under
predictable conditions to fulfil the
expected risk reduction�
B10d Number of cycles at which 10 % of the
components
have failed and caused danger�

19
UK
14 Data bit table
3
12
1: Protective equipment closed and locked
2: Protective equipment closed but not locked
3: Protective equipment open
Programming Status D0, D1 D2, D3 Monitor
diagnostics
dual-channel
conditionally
dependent
protective equipment
closed and locked
code sequence green
protective equipment
closed but not locked
half-
sequence
00 yellow, flashing
invalid state
(protective equipment
open, guard locking
active)
00 half-
sequence
flashing red
(monitoring of the
invalid state)
protective equipment
open
00 00 red
address 0 or
communication
disturbed
— grey

20
Programming Status D0, D1 D2, D3 Monitor
diagnostics
dual-channel
independent
protective equipment
closed and locked
code sequence green
protective equipment
closed but not locked
half-
sequence
00 red
invalid state
(protective equipment
open, guard locking
active)
00 half-
sequence
red
protective equipment
open
00 00 red
address 0 or
communication
disturbed
— grey
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