Leuze electronic ERS200-M0C3-M20-HLR User manual

ERS200
Safety Command Devices
Original operating instructions
EN 2011/07 - 607330 We reserve the right to make technical changes
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Leuze electronic ERS200 3
TNT 35/7-24V
1 About this document............................................................................................ 5
1.1 Other applicable documents.................................................................................................5
1.2 Used symbols and signal words...........................................................................................6
2 Safety................................................................................................................... 7
2.1 Approved purpose and foreseeable improper operation......................................................8
2.1.1 Proper use..................................................................................................................................... 8
2.1.2 Foreseeable misuse.................................................................................................................... 10
2.2 Competent personnel .........................................................................................................10
2.3 Responsibility for safety......................................................................................................10
2.4 Exemption of liability...........................................................................................................11
3 Device description ............................................................................................. 12
4 Functions........................................................................................................... 17
5 Applications ....................................................................................................... 18
6 Mounting............................................................................................................ 19
6.1 Setting the actuator head ...................................................................................................23
6.2 Mounting the E-STOP Rope Switch...................................................................................24
6.3 Mounting the rope...............................................................................................................25
7 Electrical connection.......................................................................................... 30
7.1 Connecting the contact block .............................................................................................30
8 Setting the device into service........................................................................... 33
9 Testing............................................................................................................... 34
9.1 To be performed prior to the initial start-up by competent personnel.................................34
9.2 To be performed periodically by competent personnel.......................................................34
9.3 To be performed daily by the operating personnel.............................................................35
10 Cleaning............................................................................................................. 36
11 Disposing........................................................................................................... 37
12 Service and support........................................................................................... 38
13 Accessories ....................................................................................................... 39
14 Technical data ................................................................................................... 41
15 EC Declaration of Conformity............................................................................ 44
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

4 ERS200 Leuze electronic
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

About this document
Leuze electronic ERS200 5
TNT 35/7-24V
1 About this document
1.1 Other applicable documents
The information on the ERS200 E-Stop Rope Switch is divided into two docu-
ments. Document "ERS200 Application information" contains only the most
important safety notices.
ªFor the safe implementation, testing and operation, download document
ERS200 Safe implementation and operation from Lueze website.
Table 1.1: Documents on the ERS200 E-Stop Rope Switch
Purpose and target group Title Source
Detailed information for all users ERS200 Safe imple-
mentation and opera-
tion
On the Internet, download
from Leuze website.
Basic information for technicians
and operating company ERS200 Application information Print document part no. 607248 included in the
delivery contents of the product
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

About this document
6 ERS200 Leuze electronic
1.2 Used symbols and signal words
Table 1.2: Warning symbols and signal words
Table 1.3: Other symbols
Symbol for dangers
NOTICE Signal word for property damage
Indicates dangers that may result in property damage if the measures for
danger avoidance are not followed.
CAUTION Signal word for minor injury
Indicates dangers that may result in minor injury if the measures for dan-
ger avoidance are not followed.
WARNING Signal word for severe injury
Indicates dangers that may result in severe or fatal injury if the measures
for danger avoidance are not followed.
DANGER Signal word for life-threatening danger
Indicates dangers that will result in severe or fatal injury if the measures
for danger avoidance are not followed.
Symbol for tips
Text passages with this symbol provide you with further information.
ªSymbols for action steps
Text passages with this symbol instruct you to perform actions.
xxx Placeholder in the product description for all variants
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Safety
Leuze electronic ERS200 7
TNT 35/7-24V
2 Safety
Before using the E-Stop Rope Switch, a risk evaluation must be performed
according to valid standards (e.g. EN ISO 12100-1, EN ISO 13849-1,
EN ISO 14121). For mounting, operating and testing, document ERS200 Safe
implementation and operation, application information as well as all applicable
national and international standards, regulations, rules and directives must be
observed. Observe and print out relevant and supplied documents and distribute
to the affected personnel.
The following standards apply for the risk evaluation at the protective device prior
to using the E-Stop Rope Switch:
• EN ISO 14121, Safety of machinery, risk evaluation
• EN ISO 12100-1, Safety of machinery
• EN ISO 13849-1, Safety-related parts of control systems
The realizable category of the integration in control circuits according to
EN ISO 13849-1 is dependent on the used contact block and wiring.
In particular, the following national and international legal regulations apply for the
start-up, technical inspections and work with Safety Switch:
• Machinery directive 2006/42/EC
• Low voltage directive 2006/95/EC
• Use of work equipment directive 89/655 EEC
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and Labor Protection Act
• Device Safety Act
For safety-related information you may also contact the local authorities (e.g.,
industrial inspectorate, employer's liability insurance association, labor inspec-
torate, occupational safety and health authority).
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Safety
8 ERS200 Leuze electronic
2.1 Approved purpose and foreseeable improper operation
2.1.1 Proper use
• The E-Stop Rope Switch must only be used after it has been selected in
accordance with the respectively applicable instructions and relevant stan-
dards, rules and regulations regarding labor protection and occupational
safety, and after it has been installed on the machine, connected, commis-
sioned, and checked by a competent person.
• When selecting the E-Stop Rope Switch it must be ensured that its safety-
related capability meets or exceeds the required performance level PLr
ascertained in the risk assessment.
• It must be in perfect condition and inspected regularly.
• The switching process must only be triggered by an actuator approved for
this E-Stop Rope Switch that is connected to the moveable guard in a non-
detachable and tamperproof manner.
An E-Stop Rope Switch isa supplementary protective measure for shutting down
in the event of an emergency and must not be used as a replacement for other
protective devices.
ERS200 E-Stop Rope Switches are actuated via a rope. They must be connected
so that the switching function is actuated by moving the rope in any direction and
the dangerous state is stopped immediately.
WARNING
A running machine can cause severe injuries!
ªMake certain that, during allconversions, maintenance work and inspections,
the system is securely shut down and protected against being restarted
again.
WARNING
Severe accidents may result if an E-Stop command device is not used
properly!
ªDo not use as a replacement for other protective devices.
ªInvestigate the cause of each release of an E-Stop Rope Switch along the
entire length of the rope.
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Safety
Leuze electronic ERS200 9
TNT 35/7-24V
Connection conditions:
• rope is easily accessible
• E-Stop is possible at any time while the machine is running
• dangerous state is ended immediately, taking into consideration the appro-
priate Stop category
• danger zone and occupied area along the entire length of the rope are visi-
ble from the E-Stop Rope Switch
• start commands that result in dangerous states are only possible if the
Reset button is manually unlocked
• can be easily accessed by qualified personnel for testing and replacement
Furthermore, the ERS200 E-Stop Rope Switch must not be used under the
following conditions:
• rapidly changing ambient temperature (leads to condensation)
• in the event of strong physical shocks
• in explosive or easily flammable atmospheres
• the mounting locations for E-Stop Rope Switches, stud bolts and deflection
rollers are sufficiently stable
• the safety of multiple persons is dependent on the function of this Safety
Switch (e.g. nuclear power plants, trains, aircraft, motor vehicles, incinera-
tors, medical devices)
Handling the E-Stop Rope Switch:
ªObserve mounting conditions (see chapter 6).
ªThe maximum permissible rope length must not be exceeded.
ªObserve the permissible environmental conditions for storage and operation
(see chapter 14).
ªImmediately replace damaged E-Stop Rope Switches according to these
instructions.
ªUse cable gland, insulation materials and connecting wires of the appropriate
protection rating.
ªProtect E-Stop Rope Switches from strong physical shocks and vibrations.
ªProtect E-Stop Rope Switches from penetrating foreign bodies (e.g. shavings,
sand and blasting agent).
ªBefore performing painting work, cover all moving parts, indicators and the
name plate.
ªImmediately clean any contamination from the E-Stop Rope Switch and deflec-
tion rollers that impacts the function according to these instructions.
ªUse only suitable original accessories (see chapter 13).
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Safety
10 ERS200 Leuze electronic
ªMake no structural changes to the E-Stop Rope Switch.
ªThe E-Stop Rope Switch must be exchanged after a maximum of 20 years.
2.1.2 Foreseeable misuse
Any use other than that defined under the "approved purpose" or which goes
beyond that use of the E-Stop Rope Switch is considered improper use!
E.g. - using without non-detachably mounted actuator
• looping into the safety circuit parts that are not relevant to safety
• using the switch as a limit stop
2.2 Competent personnel
Prerequisites for competent personnel:
• suitable technical training
• knows the rules and regulations for occupational safety, safety at work and
safety technology and can assess the safety of the machine
• knows the instructions for the E-Stop command device and the machine
• has been instructed by the responsible individuals on the mounting and
operation of the machine and of the E-Stop command device
2.3 Responsibility for safety
Manufacturer and operating company must ensure that the machine and imple-
mented E-Stop Rope Switch function properly and that all affected persons are
adequately informed and trained.
The type and content of all imparted information must not lead to unsafe actions
by users.
The manufacturer of the machine is responsible for:
• safe machine construction
• safe implementation of the E-Stop command device
• imparting all relevant information to the operating company
• adhering to all regulations and directives for the safe starting-up of the
machine
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Safety
Leuze electronic ERS200 11
TNT 35/7-24V
The operating company is responsible for:
• instructing the operating personnel
• maintaining the safe operation of the machine
• adhering to all regulations and directives for occupational safety and safety
at work
• regular testing by competent personnel
2.4 Exemption of liability
Leuze electronic GmbH & Co. KG is not liable in the following cases:
• E-Stop Rope Switch is not used as intended
• safety notices are not adhered to
• mounting and electrical connection are not properly performed
• reasonably foreseeable misuse is not taken into account
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Device description
12 ERS200 Leuze electronic
3 Device description
The E-Stop Rope Switch of the ERS200 series is an E-Stop command device in
accordance with EN 60947-5 and satisfies protection rating IP 67. The housing is
made of metal, and the actuator head is made of glass-fiber-reinforced, non-
combustible plastic or metal. An adjustment indicator aids in correctly setting the
rope tension. The actuator head, which can be turned in 90° increments, ensures
that the Reset button—the position of which is likewise displayed by means of an
indicator—is easily accessible. With deflection rollers, the course of the rope can
be adjusted to many danger zones. Various contact sets, housing sizes and rope
exit directions fulfill the most diverse requirements.
1 Actuator head
2 Adjustment indicator
3 Fastening for rope
4 Reset button
5 Housing cover
6 Name plate (connection data, production code and year of manufacture)
1
2
3
4
5
6
1
23
4
6
5
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Device description
Leuze electronic ERS200 13
TNT 35/7-24V
Table 3.1: ERS200 E-Stop Rope Switch
Article Part No. Description
ERS200-M0C3-M20-HLR 63000500 1NC + 1NO, 3 cable entries, exit lengthwise
ERS200-M1C3-M20-HLR 63000501 2NC, 3 cable entries, exit lengthwise
ERS200-M4C3-M20-HLR 63000502 2NC+1NO, 3 cable entries, exit lengthwise
ERS200-M4C1-M20-HLR 63000503 2NC+1NO, 1 cable entry, exit lengthwise
ERS200-M4C1-M12-HLR 63000504 2NC+1NO, 1 cable entry, exit lengthwise, M12 plug
ERS200-M4C3-M20-HAR 63000520 2NC+1NO, 3 cable entries, exit to the right
ERS200-M0C3-M20-HAR 63000522 2NC+1NO, 3 cable entries, exit to the right
ERS200-M1C1-M20-HAR 63000523 2NC, 1 cable entry, exit to the right
ERS200-M4C3-M20-HAL 63000521 2NC+1NO, 3 cable entries, exit to the left
ERS200-M0C3-M20-HAL 63000524 1NC+1NO, 3 cable entries, exit to the left
ERS200-M1C1-M20-HAL 63000525 2NC, 1 cable entry, exit to the left
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Device description
14 ERS200 Leuze electronic
Figure 3.1: Dimensions ERS-MxC3x-HLR in mm
Figure 3.2: Dimensions ERS200-MxC3x-HAR in mm
E
E
T
R
S
P
U
L
L
T
O
28
28
56
57
18
40
33
72
129
6
14.5
14.5
19.5
5.2x6.2
E
E
T
R
S
P
U
L
L
T
O
57
18
40
6
56 33
22
32
20
84
14.5
14.5
89
47.8
5.2x6.2
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Device description
Leuze electronic ERS200 15
TNT 35/7-24V
Figure 3.3: Dimensions ERS200-MxC3x-HAL in mm
Figure 3.4: Dimensions ERS200-MxC1x-HLR in mm
E
E
T
R
S
P
U
L
L
T
O
40 6
56
33
20
84
14.5
22
32
47.8
14.5
18
57
89
5.2X6.2
E
E
T
R
S
P
U
L
L
T
O
60
15
30
30
40
726.5 138.5
38
28
16
5.3
19.5
5.3x7.3
28
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Device description
16 ERS200 Leuze electronic
Figure 3.5: Dimensions ERS200-MxC1x-HAR in mm
Figure 3.6: Dimensions ERS200-MxC1x-HAL in mm
E
E
T
R
S
P
U
L
L
T
O
22
98.5
20 84 16
1530 30
40
6.5 60
5.3
38
49.5
5.3x7.3
E
E
T
R
S
P
U
L
L
T
O
20
84 16
1530 30
40
6.5 60
5.3
38
22
49.5
98.5
5.3x7.3
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Functions
Leuze electronic ERS200 17
TNT 35/7-24V
4 Functions
If the rope is pulled or if it breaks, an E-Stop command is triggered. The contact
block remains in the Stop state until the rope tension is restored to the correct
value (see adjustment indicator) and the Reset button ismanually pulled out to the
notch position.
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Applications
18 ERS200 Leuze electronic
5 Applications
The E-Stop Rope Switch is suitable as a device for the position-independent E-
Stop command output at extended points of operation or danger zones.
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Mounting
Leuze electronic ERS200 19
TNT 35/7-24V
6 Mounting
1 E-Stop Rope Switch (ERS200-Mxxx-HLR)
2 Rope clamp with hook and lock nut, clamping sleeve
3 Rope clamp with eyelet and clamping sleeve
4 Safety spiral spring (AC-SL-ERS)
5 Deflection roller (AC-AP-ERS)
Figure 6.1: Mounting examples A–E
WARNING
Severe accidents may result if the E-Stop Rope Switch is not mounted
properly!
The protective function of the E-Stop Rope Switch is only ensured if it is appro-
priately and professionally mounted for the respective, intended area of applica-
tion.
ªMounting may only be performed by competent personnel.
ªObserve standards, regulations and environmental conditions.
ªProtect the housing from penetrating soiling.
ªTest to ensure proper function.
18 m MAX
2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m
24 m MAX
2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m
6 m MAX
12 m MAX
2 ÷ 3 m 2 ÷ 3 m 2 ÷ 3 m
3 m max 3 m max
1
1
1
12
2
2
2
3
3
34
31
5
2
31
A
B
C
D
E
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Mounting
20 ERS200 Leuze electronic
X-axis Temperature fluctuation in °C
Y-axis Maximum rope length in m
Figure 6.2: Maximum rope length as a function of temperature fluctuation for
mounting examples A–E
Example: If mounting example C is subject to temperature fluctuations of 30°C,
the maximum length of the rope is 10m.
0
5
10
15
20
25
30
A
010 20 30 40 50 60 70 80 90 100
y
x
B
C / E
D
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]

Mounting
Leuze electronic ERS200 21
TNT 35/7-24V
1 E-Stop Rope Switch (ERS200-Mxxx-HAR)
2 E-Stop Rope Switch (ERS200-Mxxx-HAL)
3 Rope clamp with hook and lock nut, clamping sleeve
4 Rope clamp with eyelet and clamping sleeve
5 Safety spiral spring (AC-SL-ERS)
6 Deflection roller (AC-AP-ERS)
Figure 6.3: Mounting examples F–J
5mmax 5mmax
50 m MAX
3÷5m 3÷5m 3÷5m 3÷5m 3÷5m 3÷5m
70 m MAX
3÷5m 3÷5m 3÷5m 3÷5m 3÷5m 3÷5m 3÷5m
16 m MAX
35 m MAX
3÷5m 3÷5m 3÷5m
F
G
H
I
J
3
3
3
4
4
3
4
4
4
4
5
6
12
2
Buy: www.ValinOnline.com | Phone [phone] | Email: [email protected]