Reer Aus X Series User guide

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CONTROL UNIT SERIES AUS X
8540643 - 26/08/2016 Rev.13
1
INDEX
INTRODUCTION............................................................................................... 3
NEW SAFETY PARAMETERS FOR TYPE 2 BARRIERS AND MANDATORY LABELLING ...... 4
AUS X CONTROL UNIT ..................................................................................... 5
OPERATING MODES DESCRIPTION .................................................................................. 5
AUTOMATIC............................................................................................................................... 5
MANUAL..................................................................................................................................... 6
CONNECTION OF EXTERNAL CONTACTORS K1 and K2........................................................... 6
CONNECTON EXAMPLES .................................................................................................. 7
CONNECTION OF AUS X WITH 2 COUPLES OF ULISSE/ILION PHOTOCELLS (WITHOUT K1K2
EXTERNAL CONTACTORS) ......................................................................................................... 7
CONNECTION OF AUS X WITH 1 COUPLE OF ULISSE/ILION PHOTOCELLS (WITH K1K2
EXTERNAL CONTACTORS) ......................................................................................................... 8
SERIES CONNECTION OF AUS X WITH 2 COUPLES OF ULISSE/ILION PHOTOCELLS (WITH
K1K2 EXTERNAL CONTACTORS) ............................................................................................... 8
CONNECTION OF AUS X WITH 4 COUPLES OF ULISSE/ILION PHOTOCELLS (WITHOUT K1K2
EXTERNAL CONTACTORS) ......................................................................................................... 9
SIGNAL DESCRIPTION..................................................................................................... 10
The RESTART command..........................................................................................................10
The SYSTEM_TEST command .................................................................................................. 11
K1K2 FEEDBACK input............................................................................................................. 11
SYSTEM STATUS output...........................................................................................................11
INSTALLATION AND ELECTRICAL CONNECTIONS........................................................ 11
Characteristics of the output circuit. .....................................................................................12
Use of K1 and K2 auxiliary contact elements. .......................................................................12
Warnings regarding the connection cables............................................................................ 12
STATUS INDICATORS ..................................................................................................... 13
DIMENSIONS ................................................................................................................... 14
TECHNICAL DATA AUS X ............................................................................................... 15
Status indicators with 1 photocell ..........................................................................................16
Status indicators with 2 photocells ........................................................................................17
FAULT DIAGNOSIS ...................................................................................................................17
MODULO AUS XM .......................................................................................... 18
OPERATING MODES DESCRIPTION ................................................................................ 18
AUTOMATIC............................................................................................................................. 18
MANUAL...................................................................................................................................19
CONNECTION OF EXTERNAL CONTACTORS K1 and K2.........................................................20
CONNECTON EXAMPLES ................................................................................................ 21
CONNECTION OF AUS XM WITH 2 COUPLES OF ULISSE/ILION PHOTOCELLS (MANUAL MODE,
WITH K1K2 EXTERNAL CONTACTORS, TIMEOUT MUTING = 30s) .............................................21
CONNECTION OF AUS XM WITH 1 COUPLE OF ULISSE/ILION PHOTOCELLS (MANUAL MODE,
WITH K1K2 EXTERNAL CONTACTORS, TIMEOUT MUTING = 30s) .............................................22
CONNECTION OF AUS XM WITH 2 COUPLES OF ULISSE/ILION PHOTOCELLS IN SERIES (MANUAL
MODE, WITH K1K2 EXTERNAL CONTACTORS, TIMEOUT MUTING = 30s).................................. 23

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CONNECTION OF AUS XM WITH 4 COUPLES OF ULISSE/ILION PHOTOCELLS IN SERIES
(AUTOMATIC MODE, TIMEOUT MUTING = )........................................................................... 24
MUTING FUNCTION........................................................................................................ 24
Muting sequence..................................................................................................................... 25
MUTING OVERRIDE FUNCTION...................................................................................... 26
Override with maintained action control ............................................................................... 27
Override with pulse control .................................................................................................... 27
SIGNALS DESCRIPTION .................................................................................................. 28
The RESTART command.......................................................................................................... 29
The SYSTEM_TEST command.................................................................................................. 29
K1K2 FEEDBACK input ............................................................................................................ 30
SYSTEM STATUS output .......................................................................................................... 30
INSTALLATION AND ELECTRICAL CONNECTIONS........................................................ 30
Characteristics of the output circuit. ..................................................................................... 30
Use of K1 and K2 auxiliary contact elements........................................................................ 31
Warnings regarding the connection cables. .......................................................................... 31
STATUS INDICATORS ..................................................................................................... 32
DIMENSIONS ................................................................................................................... 32
TECHNICAL DATA .......................................................................................................... 33
Status indicators with 1 photocell connected........................................................................ 34
Status indicators with 2 photocells connected...................................................................... 34
Status indicators (MUTING module) ....................................................................................... 34
Fault diagnosis........................................................................................................................ 35
Fault diagnosis (modulo MUTING).......................................................................................... 35
GUARANTEE................................................................................................... 36

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This symbol indicates an important personal safety warning. Failure to
comply with the warning may result in very high risk for exposed personnel.
INTRODUCTION
The ReeR control unit is a safety device complying with
IEC 61496-1, IEC 61496-2 specifications. When connected to a Ilion or
a ULISSE/ILION UPC safety photocell, it forms a type 2 ESPE (Electro-
sensitive Protective Equipment).
Possible connections: from 1 to 4 photocells
Restart manual or automatic selectable
2 N.O. outputs with guided contact safety relays
1 system monitor PNP output
1 external contactors feedback input
Connected safety photocells periodic autotest (every 5s) .
Possible connections: from 1 to 4 photocells
Manual or automatic selectable Restart
2 N.O. outputs with guided contact safety relays
1 system monitor PNP output
1 external contactors feedback input
Muting function with two sensors logic
1 Muting function enable input
1 muting lamp output
Muting Override function integrated
Selectable muting timeout
Connected safety photocells periodic autotest (every 5s).
The control unit also guarantees that:
the output lines are open if the photocell is intercepted;
the output lines are enabled only with correct response
times;
in manual mode, maintenance of the RESTART contact
closed is not interpreted as AUTO mode.
For safe use of the device, it is essential to read and understand the contents
of this handbook.
Failure to comply with the prescriptions indicated in this handbook may result
in very high risks for the operating personnel of the machine protected.
Carefully consider the risks analysis of the application and the
legislation of the barrier application Country to establish if the
application is compatible with the safety category 2.

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NEW SAFETY PARAMETERS FOR TYPE 2 BARRIERS AND
MANDATORY LABELLING

With the publication of Edition 3 of the harmonized EN 61496-1
standard it is no longer possible to use a Type 2 safety light barrier
for safety functions assessed as SIL 2 / PL d.
If a safety level of SIL 2 / PL d (or higher) is required and it is
nevertheless intended to use a safety light barrier, then it will be
necessary to use a Type 4 safety light barrier.
This regulatory requirement derives from the fact that the reduction of
risk that can be obtained via a photoelectric safety barrier is not only
a function of the safety level of its electronic parts, but is also
determined by its systematic capabilities (for example:
environmental influences, EMC, optical performance and detection
principle).
The systematic capability of a Type 2 photoelectric barrier may in fact
not be sufficient to ensure adequate risk reduction for SIL 2 / PL d
applications.
The standard also establishes that the labelling of Type 2 safety
barriers must indicate such limitation to SIL 1 / PL c.
The PFHd values declared for the electronic control part of the
device, on the other hand, are not limited and therefore it is possible
to use the PFHd value provided by the manufacturer of the device in
the global assessment of the safety function, even if it exceeds the
SIL 1 / PLc range.

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AUS X CONTROL UNIT
OPERATING MODES DESCRIPTION
0 Vdc
+24 Vdc
Automatic
+24 Vdc
+24 Vdc through a N.O. contact
Manual
0 Vdc
0 Vdc
Non-permissible
conditions
+24 Vdc
+24 Vdc
Table 1
AUTOMATIC
In this operating mode, the outputs of the control unit follow the
status of the photocell:
•with the protected area free (outputs of the photocells active), the
relay outputs of the control unit are active.
•with the protected area occupied (outputs of the photocells de-
activated), the relay outputs of the control unit are de-activated.
Figure 1
Use in manual mode (start/restart interlock activated) is mandatory in the
case in which the safety device controls an access protecting a danger zone
and once a person has passed through the opening, he/she may remain in
the danger zone without being detected (use as trip device according to
IEC 61496). Failure to comply with this rule may result in very serious risks
for the persons exposed.
Check correct functioning of the entire safety system (control unit+photocell)
following each re-installation. In particular, if the original operating mode was
Manual, check that the unit has been reconfigured in this mode.

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MANUAL
In this operating mode, the outputs of the control unit are activated
only if the protected area is free and after sending the RESTART signal
to the control unit using the push-button or by means of a specific
command on the RESTART input (terminal 4).
Once the protected area has been occupied, the relay outputs are de-
activated. The sequence described above must be repeated in order to
re-activate them.
The RESTART command is active with a 0VDC ---> +24VDC transition.
The minimum duration of the command is 100 ms.
Figure 2
CONNECTION OF EXTERNAL CONTACTORS K1 and K2
Control of external contactors K1K2 can be activated in both operating
modes. If this control must be used, the series of normally closed
contacts of the external contactors must be connected to terminal 11
of the control unit (figures 3 and 4).
Figure 3
Automatic functioning with K1K2 relays

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Figure 4
Manual functioning with K1K2 relays
CONNECTON EXAMPLES
CONNECTION OF AUS X WITH 2 COUPLES OF ULISSE/ILION PHOTOCELLS
(WITHOUT K1K2 EXTERNAL CONTACTORS)
Figure 5

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CONNECTION OF AUS X WITH 1 COUPLE OF ULISSE/ILION PHOTOCELLS
(WITH K1K2 EXTERNAL CONTACTORS)
Figure 6
SERIES CONNECTION OF AUS X WITH 2 COUPLES OF ULISSE/ILION
PHOTOCELLS (WITH K1K2 EXTERNAL CONTACTORS)
Figure 7
In this case, the 2 photocells are connected in series and the INPUT
BARR2 (terminal 8) is not utilized; this signal must be connected to
the TEST BARR2 (terminal 10).

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CONNECTION OF AUS X WITH 4 COUPLES OF ULISSE/ILION PHOTOCELLS
(WITHOUT K1K2 EXTERNAL CONTACTORS)
Figure 8

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SIGNAL DESCRIPTION
1
24VDC
Power supply 24Vdc
2
0VDC
Power supply 0Vdc
3
PE
Ground connection
4
RESTART
Input
Restart command
5
MAN/AUTO
Input
Manual/Automatic Configuration
6
SYSTEM_TEST
Input
Test of the system external request
7
INPUT BARR1
Input
Safety photocell number 1
status input
8
INPUT BARR2
Input
Safety photocell number 2
status input
9
TEST_BARR1
Output
Safety photocell number 1 TEST
10
TEST_BARR2
Output
Safety photocell number 2 TEST
11
K1K2 (Feedback)
Input
Feedback external contactors K1K2
12
SYSTEM STATUS
Output
Output status
13
Relay B NO1
Output
Safety relay B, contact 1 (N.O.)
14
Relay B NO2
Output
Safety relay B, contact 2 (N.O.)
15
Relay A NO1
Output
Safety relay A, contact 1 (N.O.)
16
Relay A NO2
Output
Safety relay A, contact 2 (N.O.)
Table 2
The RESTART command
The RESTART command must be sent to the control unit
connecting terminal 4 to the +24Vdc.
The contact used for the RESTART command must be able
to switch a voltage of 24Vdc and a current of 20mA
(guaranteeing a closing time > 100ms). This data is
particularly important in the case of automatic
management of the RESTART command sending, for
example using a PLC.
The SYSTEM RESET TIME is obtained adding the reset time
of any external contactors K1K2 to the reset time of the
AUS X control unit (100ms).
In the case of manual activation, a normally open external
button can be used, temporary closing of which generates
the RESTART command.
The Restart control must be installed outside the danger area in a position
where the danger area and the entire work area concerned are clearly visible.
It must not be possible to reach the control from inside the danger area.

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The SYSTEM_TEST command
The SYSTEM_TEST command must be forwarded to the control unit
connecting the terminal 6 to the +24Vdc.
The contact used for the SYSTEM_TEST command must be able to
switch a current of 20mA and a voltage of 24Vdc (with a switching time
of >40ms). The AUS X control unit, after receiving this signal, provides
to switch off the emitters of the connected safety photocells,
The operator must verify the effective stopping of the hazardous
machine (due to the de-activation of the control unit outputs) for all the
time the SYSTEM_TEST command stays active.
The effective stopping of the system must be verified by an operator and
cannot be an operation of the control unit.
K1K2 FEEDBACK input
Using the K1 and K2 auxiliary safety contactors with guided contact
safety type, it is necessary to connect the +24Vdc to the
through the series of the K1-1 e K2-1 N.C. control
contacts. The control of the correct switching of K1 and K2 is
performed with a delay of 300ms after the real command.
When the K1-1 e K2-1 N.C. control contacts are not used (or no control
is provided) it is mandatory to connect the terminal 11 (
) to the terminal 12 ( ).
SYSTEM STATUS output
The SYSTEM STATUS output reports exactly the output safety relays status :
When the output relays are opened, the SYSTEM STATUS reports 0VDC.
When the output relays are closed, the SYSTEM STATUS reports
+24VDC.
INSTALLATION AND ELECTRICAL CONNECTIONS
Install the AUS X control unit in an environment with a protection rating of at
least IP54.
If more modules AUS X must be installed in the same board panel, in order to
avoid overheatings, maintain between them one minimal distance of 2cm.
The AUS X control unit must be supplied with a 24Vdc 20.
The external power supply must comply with the standard EN 60204-1.
During the installation of the AUS X control unit be sure to avoid short circuits
between the contacts 7 and 8.

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Characteristics of the output circuit.
For the output circuit, the control unit uses two guided contact safety
relays.
These relays are rated by the manufacturer for voltage and current
values above those indicated in the technical data; however, to assure
correct insulation and to avoid damage or premature aging, protect
each output line with a 4A slow-blow fuse and check that load
characteristics comply with the indications given in the table below.
Minimum switching voltage
18 Vdc
Minimum switching current
20 mA
Maximum switching voltage
250Vac
Maximum switching current
2A
Use of K1 and K2 auxiliary contact elements.
For loads with higher voltage and current characteristics than those
indicated in the table above, use of auxiliary external relays or
contactors suitable for the load to be controlled is recommended.
The K1 and K2 auxiliary contactors or relays must be of the guided
contact safety type.
Referring to the table below, pay particular attention to the
configuration of the control contacts on terminal 11 and that of the
contacts of use.
Control contacts
K1-1 normally closed
K2-1 normally closed
Use contacts
K1-2 normally open
K2-2 normally open
Control contacts K1-1 and K2-1 (terminal 11) must be able to switch
a current of 20mA and a voltage of 24Vdc.
To increase the electrical life of internal relays A and B, it is
advisable to use anti-disturbance devices which must be connected
across the coils of K1 and K2.
Warnings regarding the connection cables.
For light curtain/control unit connections of more than 50m, cables
with a cross-section of at least 1mm2 must be used.
It is good practice to separate the power supply of the control unit
from that of other electrical appliances (electrical motors, inverters,
frequency variators) or other sources of disturbance.
The path of the connection cables between the control unit ands
the sensors, the connection referring to the test command and
feedback contacts connected to terminal 11 must be different from
that of other power cables.

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STATUS INDICATORS
Green
Photocell 1 free
Photocell 1 intercepted
Green/
Red
Fault detected *
Photocell 2 free
Photocell 2 intercepted or absent
Green/
Red/
YELLOW
Output relays opened
The number of blinkings shows the
kind of FAIL (only with IN2/FAIL RED) *
Output relays closed
Photocells free - Output relays opened
(only in manual mode)
Table 3
* REFER TO THE "FAULT DIAGNOSIS" SECTION TO HAVE A DETAILED
EXPLANATION OF THE POSSIBLE FAULT
5 6 7 8
1 2 4
13 14 15 16
9 10 11 12
IN1
IN2
FAIL
GUARD
BREAK
AUS X

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DIMENSIONS

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TECHNICAL DATA AUS X
Safety category
2
Power supply
Vdc
24 20%
Power requirement
W
5 max
Output
Relay
2 N.O. contacts (2A; 250V)
System Status Output
100mA; 24Vdc
Response time
ms
30 max
Operating modes
Manual or Automatic, selectable
from terminal block
External relay control
2 N.C. contacts (20mA; 24Vdc)
Number of
connectable photocells
1 ÷ 4
Connections
Terminal block with protection
against reversal of polarity
Status indicators
Led
Power On –Photocell Status –Fail
Max. length of connections
m
100
Operating temperature
°C
0 ÷ 55
Enclosure protection rating
IP 20
Terminal block protection
rating
IP 2X
Fastening
Fast attachment to rail according
to EN 50022-35
Dimensions (h x w x d)
mm
99 x 22,5 x 114,5
Weight
g
150
B10d
800.000
Device lifetime
20 years
Safety level
Type 2
EN 61496-1:2013
SILCL 1
IEC 62061(ed.1)
Cat.2
EN ISO 13849-1:2008
Load
Number of Commutations
PFHd *
DCavg #
MTTFd #
PL #
CCF #
2A@230Vac
1 every 30s
2,64E-08
98,92%
26,04
c
80%
1 every min
1,55E-08
98,85%
50,18
c
80%
1 every hour
4,98E-09
97,28%
100,00
c
80%
1 every day
4,82E-09
96,95%
100,00
c
80%
0,5A@24Vdc
1 every 30s
4,87E-08
98,96%
13,27
c
80%
1 every min
2,64E-08
98,92%
26,04
c
80%
1 every hour
5,16E-09
97,54%
100,00
c
80%
1 every day
4,83E-09
96,97%
100,00
c
80%
Table 4
* IEC 62061
# ISO 13849-1

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STATUS INDICATORS / FAULT DIAGNOSIS
Status indicators with 1 photocell
ON
RED
RED
Power on TEST
OFF
OFF
RED
Photocell INTERCEPTED,
outputs in OFF
ON
OFF
YELLOW
Photocell FREE,
outputs in OFF
ON
OFF
GREEN
Photocell FREE,
outputs in ON
Shows the
photocell_1 status
OFF
YELLOW: blinks 2
times per second
System TEST
Table 5

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Status indicators with 2 photocells
ON
RED
RED
Power on TEST
OFF
OFF
RED
Photocell INTERCEPTED,
outputs in OFF
OFF
ON
RED
ON
OFF
RED
ON
ON
YELLOW
Photocell FREE,
outputs in OFF
ON
ON
GREEN
Photocell FREE,
outputs in ON
Shows the
photocell_1 status
Shows the
photocell_2 status
YELLOW: blinking 2
times per second
System TEST
Table 6
FAULT DIAGNOSIS
OFF
ON
(2 pulses)
Possible fault to the
Microcontroller board
OFF
ON
(3 pulses)
Internal relays fault
OFF
ON
(4 pulses)
K1K2 external relays
fault
OFF
ON
(5 pulses)
User configuration
failure
OFF
ON
(6 pulses)
User configuration
changed without
system restart
OFF
ON
(7 pulses)
Possible overload or
SYSTEM STATUS
connection error
Table 7
If it is not possible to clearly identify the malfunction and to remedy it, stop
the machine and contact Reer's Assistance Service.

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MODULO AUS XM
OPERATING MODES DESCRIPTION
0 Vdc
+24 Vdc
Automatic
+24 Vdc
+24 Vdc through a N.O. contact
Manual
0 Vdc
0 Vdc
Non-permissible
conditions
+24 Vdc
+24 Vdc
Table 8
AUTOMATIC
In this operating mode, the outputs of the control unit follow the
status of the photocell:
•with the protected area free (outputs of the photocells active), the
relay outputs of the control unit are active.
•with the protected area occupied (outputs of the photocells de-
activated), the relay outputs of the control unit are de-activated.
Figure 9
Use in manual mode (start/restart interlock activated) is mandatory in the
case in which the safety device controls an access protecting a danger zone
and once a person has passed through the opening, he/she may remain in
the danger zone without being detected (use as trip device according to
IEC 61496). Failure to comply with this rule may result in very serious risks
for the persons exposed.
Check correct functioning of the entire safety system (control unit+photocell)
following each re-installation. In particular, if the original operating mode was
Manual, check that the unit has been reconfigured in this mode.

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MANUAL
In this operating mode, the outputs of the control unit are activated
only if the protected area is free and after sending the RESTART signal
to the control unit using the push-button or by means of a specific
command on the RESTART input (terminal 15).
Once the protected area has been occupied, the relay outputs are de-
activated. The sequence described above must be repeated in order to
re-activate these.
The RESTART command is active with a 0VDC ---> +24VDC transition.
The minimum duration of the command is 100 ms.
Figure 10