Mechan F Series User manual

Keep this guide for future reference
Description
Applications
Declaration of Conformity
This information is designed to help suitably qualied
personnel install and operate Mechan Safety equipment.
Before using this product, read this guide thoroughly along
with any relevant European and/or National standards e.g.
Machinery Directive 2006/42/EC and it’s amendments,
Provision and Use of Work Equipment Regulations.
Further information can be obtained from Mechan Controls
Tel [phone]
The F-Series safety system is a complete electronic safety
switch and emergency stop button monitoring system for
machine guarding applications.
The control unit can monitor up to 30 inputs (F-Series
safety switches and emergency stop buttons), maintaining
CAT 4 SIL 3 and PL e.
FM1 Safety Control Module contains the power supply
regulation, dual safety contact outputs, external reset/moni-
toring circuit, system & gate indication, and the input for
one safety switch sensor and it’s volt free indicator output.
The FM1 and a safety switch sensor are all that is required
for a system that is monitoring one guard.
FX1/FX2 Safety Extender Modules connect to the FM1
to build systems monitoring more than 1 guard. By simply
connecting the required number of FX1’s (one guard switch
input) or FX2’s (two guard switch inputs) to the FM1 sys-
tems can be built to monitor up to 30 guards. The extender
modules provide connections for the safety switches along
with LED and volt free indicator outputs for each safety
switch input.
ESM Emergency Stop Monitor allows the connection of
dual channel Emergency stop buttons or other dual chan-
nel safety devices with volt free contact outputs. Giving
indication for each input channel and overall output indica-
tion.
F-Series Safety Switches are solid state electronic
devices with no contacts or moving parts. This provides a
tamper proof safety system that can only be activated by
the Mechan actuator. When energized the safety switches
are continuously monitored whether the guard is opened or
not.
The Safety switches are resin encapsulated into an ABS
case, to provide a fully sealed, IP67 & IP69K, sensor which
can withstand the most arduous of conditions. Water, dust,
oil, machine vibration and even steam cleaning have little
or no e󰀨ect on their performance, and with a 7-10 mm
switching distance they are easy to install and provide a
long and reliable working life span.
Interlocked guards where additional security required.
Door locking is not required. Harsh environments where
vibration, water or dust are problems.
Food and Beverage packing/lling systems Dairy Pharma-
ceutical Paper Industry, Can Forming and Filling, (Alumini-
um, Steel, Plastic) Semi conductor Manufacture/Assembly.
APPROVALS
CE Complies with all relevant sections of the
CE marking directive
TUV CAT 4 SIL 3 PLe
INTERNATIONAL DIRECTIVES
Machinery Directive 2006/42/EC
Low Voltage Directive 2014/35/EU
Electromagnetic Compatibility Directive 2014/30/EU
INTERNATIONAL STANDARDS
EN ISO
13849-1
Safety of Machinery
Safety related parts of control systems
EN ISO
62061
Safety of Machinery - Functional safety
of safety related electrical, electronic and
programmable electronic control systems
EN 60204 Safety of Machinery
Electrical equipment for machines
EN
60947-5-1
Low voltage switchgear and controlgear
EN 14119 Interlocking devices associated with
guards
EN
60947-5-3
Safety of Machinery
Specication for low voltage switchgear
and controlgear
Please contact Mechan Controls.
CAT 4
SIL 3 PLe
MECHAN CONTROLS
Installation Guide : F-SERIES Safety system

SAFETY CONTROL UNIT
Mounting on 35mm DIN Rail Removal from 35mm DIN Rail
System Assembly
Control Modules Connections & Indication
The control modules are designed to be
mounted in an IP55 (minimum) control
cabinet.
The modules clip on to standard 35 mm
symmetric (top hat) DIN-Rail
To remove the modules, gently lever
out the DIN clip with a small screw-
driver as shown (1).
Tilt the unit in the direction (2) and slip
the unit o󰀨 the DIN Rail (3)
Assemble the required number of modules on the
DIN-Rail, starting with the FM1 and clipping the
FX1, FX2 and, if required, ESM modules, to the
left of the FM1.
The FM1 and FX1 monitor one safety switch
each, whilst the FX2 must have 2 safety switches
connected to it.
The ESM requires 2 x N/O inputs from an Emer-
gency stop button, or other mechanical safety
rated switch.
The maximum number of inputs that can be
monitored by a DC supplied F-SERIES safety
system is 30. The maximum number inputs that
can be monitored by an AC supplied F-SERIES
safety system is 10.
The ‘Control Bus’ straps on each extender unit connect to the adjacent
(right hand side) module as shown.
The ‘Control Bus’ terminator, CT1 (supplied with the FM1), must be
plugged into the last extender module in the system.
23 13
X3 X1X2
14 24
BL
BLUE
DRAIN
BROWN
BR DR
BL BL
BR DR
S23 S13
S14
S24
FM1 FX2 ESM
Power
Ind 1Ind 1 Ind 2 Run Fault
Ch1Ch2
Fault
Run
BL
BR DR
FX1
Ind 1
Indication
Contact
Power
Input
Re-Set
Circuit
Indication
Contact
Indication
Contact
Indication
Contact
Indication
Contact
Safety
Switch
Input
E'Stop
Channel
2
E'Stop
Channel
1
Safety
Switch
Input
Safety
Contact
2
Safety
Contact
1
BLUE
DRAIN
BROWN DRAIN
BROWN
BLUE
Safety
Switch
Input
BROWN
DRAIN
BLUE
Safety
Switch
Input

SAFETY SWITCHES
Mounting
Operation
Mount the switch on to the machine frame and the Actuator on to the
opening edge of the door. Always try to mount the switch on non-ferrous
material. (Ferrous materials may reduce the switching distance.)
Use tamper proof screws to ensure additional security
Leave a minimum of 50 mm between any adjacent switches.
Do not use the safety switch as a door stop.
EN 14119 Provides some mounting suggestions, see example opposite.
When xing the safety switch to a sliding door (A), ensure that when
the door is opened (B) it is not easily accessible, helping prevent the
system being overridden
All Mechan electronic safety switches can only be operated by the mechan actuator. They can approach each other from
most angles, but when in place the targets shown in the diagrams below must be aligned and facing each other.
The R-SERIES safety switch & actuator are UNIQUELY CODED (up to 4 Billion codes) The R-SERIES Safety switch and
actuator are supplied as a pair and the switch will only operate with the correct actuator. Both switch and actuator are
marked with a unique code.
A
B

CONNECTIONS
CONNECTION FOR A SINGLE SWITCH
FX1 FX2 ESM
Note :
1) When the unit is powered, the safety switch
is closed and the re-set circuit is made the N/O
safety outputs will close and the N/C indicator
output will be open.
2) When the safety switch is opened, ( the actua-
tor moved away from the switch) the N/O safety
outputs will open and the N/C indicator output will
be close.
The Mechan xed safety switch is supplied pre-wired with 5, 10 or
15 metres of cable encapsulated into it when manufactured. This
ensures a completely water-tight seal to the electronics within the
switch. Longer cables can be supplied up to maximum of 100 me-
tres and this will not signicantly a󰀨ect performance.
Run the cable back to the control unit through cable protection (if
required) and terminate into the appropriate input channel, following
the colour coding of the wires to the label on the input terminals.
TREAT AS INSTRUMENT CABLES AND KEEP SEPARATE FROM
POWER CABLES (150 mm separation is normally adequate)
If extending Mechan safety switch cables it is important to use the
same type of cable, twisted pair with drain and screen. Multi-way
versions of individually screened, twisted pair and drain cable may
be used to run a number of sensors back to the control unit. Cable
joints should be moisture proof and NOT EARTHED. The only earth
connection must be via the drain terminal.
NOTE: The FX2 requires the commoning of the supply and drain wires (BROWN / DRAIN) from the two switches at the
extender module as shown above.
SEE ‘RESET CIRCUIT
OPTION’ TABLE

CONNECTION FOR MULTI-GATE SYSTEM AND E’STOP
Note :
1) When the unit is powered, safety switches closed, e’stop’s released and the re-set circuit is made the N/O safety out-
puts will close and the N/C indicator output will be open.
2) When a safety switch is opened, ( the actuator moved away from the switch) or one of the e’stops actuated, the N/O
safety outputs will open and the N/C indicator output will be close. LED’s on the input module will indicate which safety
switch / e’stop is operated.
SEE ‘RESET CIRCUIT
OPTION’ TABLE

DIMENSIONS
FM1
DNK1
FMA/SFMA/CMA
FM6
DNK2 BMS
FMG/SFMG
FM7
BMR
FMT/SFMT
FX1 / FX2 ESM
90
[3.53]
17.5
[0.69]
90
[3.53]
17.5
[0.69]
105
[4.12]
90
[3.53]
34
[1.34]
23
[0.91]
23
[0.91]
34
[1.34]
61
[2.40]
16
[0.63]
7
[0.27] 7
[0.27]
26.4
[1.03]
75
[2.95]
52
[2.05]
27
[1.06]
19
[0.75]
36
[1.42]
45
[1.77]
22
[0.86]
4.2 [0.16] dia.
8.1 [0.32] dia.
14 [0.55]
SIDE VIEW
3[ 0.11]
28
[1.1]
28
[1.1]
52 [2.04]
36
[1.42]
22
[0.86]
6.4 [0.25]
52 [2.04]
52
[2.05]
27
[1.06]
19
[0.75]
45
[1.77]
36
[1.42]
34
[1.34]
34
[1.34]
23
[0.91]
23
[0.91]
61
[2.40]
75
[2.95]
16
[0.63]
14.5
[0.57]
7
[0.27]
7
[0.27]
34
[1.34]
34
[1.34]
23
[0.91]
23
[0.91]
61
[2.40]
16
[0.63]
17
[0.65]
7
[0.27]
7
[0.27]
75
[2.95]
6.6
[0.26]
78.0
[3.07]
9.8
[0.37]
9.8
[0.37]
78.0
[3.07]
87.5
[3.44]
27.2
[1.07]
27.2
[1.07]
13.5
[0.53]
13.5
[0.53]
82.5
[3.25]
19
[0.75]
73
[2.87]
7.2
[0.28]
7.2
[0.28]
11
[0.43] 54
[2.13]
19
[0.75]
19
[0.75]
17
[0.67]
82.5
[3.25]

SAFETY SWITCHES F-Type B-Type R-Type Dinky F6 F7
Pre-wired cables Pre-wired 3 / 5 or 10 Metre
Cables
Pre-wired 3 / 5 or 10
Metre Cables
Pre-wired 3 / 5 or 10
Metre Cables
Pre-wired 3 / 5 or 10
Metre Cables
Pre-wired 3 / 5 or 10
Metre Cables
Pre-wired 3 / 5 or 10
Metre Cables
Quick Disconnect M8 Quick Disconnect
5 or 15 Metre Cable
Cable Gland FMA Anaconda
FMG Cord Grip
FMT Brass 20mm Thread
BMS Side Exit
BMR Rear Exit
RMA Anaconda
Unique Coding R-Series - 4 Billion
Unique codes
Operation Electronic
Safety Contact Operating Distance 7mm ON / 10mm OFF
Optimum Gap 1mm
Dimensions See page 6
IP Rating IP67 / IP69K
Cable Length 100 Metres max
Operating temperature -20 to +50C
Mounting Target to target
Construction Blue ABS Resin Filled Orange
ABS Resin Filled Blue ABS Resin Filled
TECHNICAL SPECIFICATIONS
SAFETY CONTROL UNIT FM1 FX1/FX2 ESM
Supply nominal voltage 24Vdc 24Vac 110Vac 230Vac
Nominal power consumption 6VA 3VA 3VA
Safety contacts 2 x N/O
Output contact rating (max) 4A/230Vac; 2A/24Vdc(Res.)@Cos=1
Output contact rating (min) 10V/10mA
Output contact fuse rating AC=5A; DC=2.5A; Quick blow
Drop out time Deactivation by sensor, 13ms
Internal fuse 500mA Resetable
Internal fuse recovery time >2 Seconds
Indication LED’s - Power, Fault, and Run
LED & Volt Free Contact for Safety Switch LED & Volt Free Contact For each input LED for each Channel & Volt Free Contact
Indication Contact rating 500mA/30VDC 500mA/30VDC 500mA/30VDC
Max conductor size 2 x 1.5mm stranded with sleeves,
2 x 2.5mm solid
2 x 1.5mm stranded with sleeves,
2 x 2.5mm solid
2 x 1.5mm stranded with sleeves,
2 x 2.5mm solid
Installation group (Control unit) C in accordance with VDE0110
Enclosure protection Housing IP30, Terminals IP20
Operating temperature 0C to +45C (85% Humidity max) 0C to +45C (85% Humidity max) 0C to +45C (85% Humidity max)
Storage temperature -20C to +60C -20C to +60C -20C to +60C
Housing material PC-GF, Light Grey (RAL 7035) PC-GF, Light Grey (RAL 7035) PC-GF, Light Grey (RAL 7035)
Mounting / Fixing 35mm Symmetric DIN Rail 35mm Symmetric DIN Rail 35mm Symmetric DIN Rail
Utilisation category in accordance with EN 60947-4-1
Safety contacts : AC1 at 230 V Imin:10mA.Imax:4A
Safety contacts : DC1 at 24 V Imin:10mA.Imax:2A
Air gap creepage in accordance with EN 60947-1
Pollution Degree 2
Overvoltage Category III
Rated Insulation Voltage 250V
Rated Impulse Withstand Voltage 4.0KV
Vibration In Accordance With EN 60068-2-6
Weight (AC/DC) 420g/290g FX1 65g / FX2 75g
Frequency 10-55Hz
Amplitude 0.35mm
Safety Related Data
PL In accordance with EN ISO 13849-1 PL-e, CAT 4
SIL CL in accordance with EN IEC 62061 SIL 3
PFHd in accordance with EN IEC 62061 6.0 x 10-9
PFH 6.52 x 10-9
B10d 2000000
MTTFd High > 100 Years (Based on usage rate of 360 days/year, 24 Hours/Day, 10 Operations/Hour)
TM(mission time) 20 Years
DC 99%
SFF 99.5%

Document Number : 327-400-Iss5
MECHAN CONTROLS LTD
14/16 SEDDON PLACE, STANLEY INDUSTRIAL ESTATE
SKELMERSDALE , LANCASHIRE WN8 8EB
UNITED KINGDOM
Telephone :[phone]
web : www.mechancontrols.co.uk
NOTES
In the interest of product development specications are
subject to change without notice.
It is the responsibility of the user to ensure compliance with
any acts or by-laws in place.
All information regarding Mechan equipment is believed to
be accurate at the time of printing. Responsibility cannot be
accepted for errors or omissions. All information regarding
Mechan equipment is believed to be accurate at the time
of printing. Responsibility cannot be accepted for errors or
omissions.
Maintenance
It is recommended to check the safe operation of the of the
switches and look for signs of damage or excessive wear
on a weekly basis. Damaged units should be replaced or
returned to the manufacturer for repair where practical.
Declaration of Conformity
Please contact Mechan Controls.
ATEX – Declaration of Conformity
1) SUBJECT
Equipment and protective F-Series safety switches and Actuators intended for use in potentially Explosive
Atmospheres complies with relevant requirements of ATEX - Directive 2014/34/EU” Encapsulation ’m’ / ’tc’
electrical apparatus for explosive gas and dust atmospheres”, incorporating EN 60079-0 and EN 60079-18
compliant equipment according to the intended Zones:
Category 3G/Zone 2
Category 3D/Zone 22
2) DESCRIPTION
2.1 GENERAL The safety switch, Type FMA from the “F” series, manufactured by Mechan Controls Ltd. It is a
type of Machine Guard safety switch and Actuator used for machine interlocking. The switch consisted of the sen-
sor head and the Actuator target block both consist of solid-state electronic circuits, encapsulated into an ABS
polymer casing with approximate dimensions 74mm x 33mm x 30mm to provide a fully sealed, IP67 & IP69K,
sensor which can withstand the most arduous of conditions. Water, dust, oil, machine vibration and even steam
cleaning have no e󰀨ect on their performance. The encapsulant is a 50:50 mixture of epoxy resin and micron glass
beads. Two through holes were provided for clamping/Fixing into machine guards. The sensor head was provided
with 100m maximum of moulded-in, PVC insulated, sheathed three-core cable. A gland is tted into the enclosure
to allow the attachment of exible metal conduit for protection of the cable.
The safety switch is operated by a control module which supplied 24 V dc at 2 mA to the switch. This Control
module FM1/FX1/FX2/EM1/ESM must be installed in a safe area.
Types FMG and FMT di󰀨er only in terms of the type of connection gland tted.
2.2 IDENTIFICATION The enclosures were marked as follows:
Mechan Controls
Safety Sensor EX-Series
Part Number : FMA, FMG, FMT
We hereby declare that the products identied above conform to the relevant ATEX – Directive 2014/34/EU
Requirements and to the following EC Directive(s) Machinery Directive (2006/42/EC), EMC Directive (2004/108/
EC), Low Voltage Directive(2006/95/EC).