schmersal AES 1135 User manual

AES 1135 / 1136
AES 1145 / 1146
Operating instructions
Safety-monitoring module
EN 1
1. About this document
1.1 Function
This operating instructions manual provides all the information you
need for the mounting, set-up and commissioning for the safe opera-
tion and disassembly of the safety-monitoring module. The operating
instructions must be available in a legible condition and a complete
version in the vicinity of the device.
1.2 Target group: authorised qualified personnel
All operations described in this operating instructions manual must
be carried out by trained specialist personnel, authorised by the plant
operator only.
Please make sure that you have read and understood these operating
instructions and that you know all applicable legislations regarding
occupational safety and accident prevention prior to installation and
putting the component into operation.
The machine builder must carefully select the harmonised standards
to be complied with as well as other technical specifications for the
selection, mounting and integration of the components.
1.3 Explanation of the symbols used
Information, hint, note:
This symbol is used for identifying useful additional information.
Caution:Failure to comply with this warning notice could lead
to failures or malfunctions.
Warning:Failure to comply with this warning notice could
lead to physical injury and/or damage to the machine.
1.4 Appropriate use
The products described in these operating instructions are developed to
execute safety-related functions as part of an entire plant or machine. It
is the responsibility of the manufacturer of a machine or plant to ensure
the correct functionality of the entire machinery or plant.
The safety-monitoring module must be exclusively used in accordance
with the versions listed below or for the applications authorised by the
manufacturer. Detailed information regarding the range of applications
can be found in the chapter "Product description".
1.5 General safety instructions
The user must observe the safety instructions in this operating instruc-
tions manual, the country-specific installation standards as well as all
prevailing safety regulations and accident prevention rules.
Further technical information can be found in the Schmersal
catalogues or in the online catalogue on the Internet:
www.schmersal.net.
The information contained in this operating instructions manual is
provided without liability and is subject to technical modifications.
The entire concept of the control system, in which the
safety component is integrated, must be validated to
EN ISO 13849-2.
There are no residual risks, provided that the safety instructions as well
as the instructions regarding mounting, commissioning, operation and
maintenance are observed.
Content
1 About this document
1.1 Function..............................................1
1.2 Target group: authorised qualied personnel. . . . . . . . . . . . . . . . . .1
1.3 Explanation of the symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Appropriate use ........................................1
1.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.6 Warning about misuse...................................2
1.7 Exclusion of liability .....................................2
2 Product description
2.1 Ordering code .........................................2
2.2 Special versions........................................2
2.3 Destination and use.....................................2
2.4 Technical data .........................................2
2.5 Safety classication.....................................2
3 Mounting
3.1 General mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 Dimensions ...........................................3
4 Electrical connection
4.1 General information for electrical connection. . . . . . . . . . . . . . . . . .3
5 Operating principle and settings
5.1 Operating principle after the operating voltage is switched on . . . .3
6 Set-up and maintenance
6.1 Functional testing.......................................3
6.2 Maintenance ..........................................3
7 Disassembly and disposal
7.1 Disassembly...........................................3
7.2 Disposal..............................................3
8 Appendix
8.1 Wiring examples .......................................4
8.2 Integral System Diagnostics (ISD). . . . . . . . . . . . . . . . . . . . . . . . . .4
9 Declaration of conformity
9.1 EC Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
x.000 / v.A. / 12.2011 / BZ-Nr. 50137-17V900 / Teile-Nr. 1172884-EN / Ausgabe E
EN Operating instructions. . . . . . . . . . . . .pages 1 to 6
Translation of the original operating instructions

2
Operating instructions
Safety-monitoring module
AES 1135 / 1136
AES 1145 / 1146
EN
1.6 Warning about misuse
In case of inadequate or improper use or manipulations of
the safety-monitoring module, personal hazards or damages
to machinery or plant components cannot be excluded. The
relevant requirements of the standard EN 1088 must be
observed.
1.7 Exclusion of liability
We shall accept no liability for damages and malfunctions resulting from
defective mounting or failure to comply with this operating instructions
manual. The manufacturer shall accept no liability for damages result-
ing from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary re-
pairs, conversions and modifications to the device are strictly forbidden;
the manufacturer shall accept no liability for damages resulting from
such invasive work, arbitrary repairs, conversions and/or modifications
to the device.
2. Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
AES 113
➀
No. Option Description
➀
5 without start-up test
6 with start-up test
AES 114
➀
No. Option Description
➀
5 without start-up test
6 with start-up test
Only if the information described in this operating instruc-
tions manual are realised correctly, the safety function and
therefore the compliance with the Machinery Directive is
maintained.
2.2 Special versions
For special versions, which are not listed in the order code below 2.1,
these specifications apply accordingly, provided that they correspond to
the standard version.
2.3 Destination and use
The safety-monitoring modules for integration in safety circuits are
designed for fitting in control cabinets. They are used for the safe
evaluation of the signals of positive break position switches for safety
functions or magnetic safety sensors on sliding, hinged and removable
safety guards as well as emergency stop control devices.
Design
The safety-monitoring modules have a dual-channel structure. They
include two safety relays with monitored positive action contacts. The
NO contacts of the relays, which are wired in series, build the enabling
contacts.
2.4 Technical data
Standards: EN 60204-1; EN 60947-5-3;
EN ISO 13849-1; IEC 61508;
BG-GS-ET-14; BG-GS-ET-20
Start conditions: Automatic
Feedback circuit available: no
Start-up test: AES ...5: no; AES ...6: yes
Pull-in delay for automatic start: adjustable 0.1 / 1.0 second
Drop-out delay in case of emergency stop: < 50 ms
Rated operating voltage Ue: 24 VDC
Rated operating current Ie: 0.2 A
Rated insulation voltage Ui: 250 V
Rated impulse withstand voltage Uimp: 4 kV
Thermal test current Ithe: 6 A
Internal electronic fuse: no
Power consumption: < 5 W
Inputs monitoring:
Cross-wire short detection: yes
Wire breakage detection: yes
Earth connection detection: yes
Number of NC contacts: convertible 1NC → 2NC
Number of NO contacts: convertible 1NO → 0NO
Outputs:
Stop category 0: 1
Stop category 1: 0
Number of safety contacts: 1
Number of auxiliary contacts: 0
Number of signalling outputs: 2
Switching capacity of the safety contacts: max. 6 A
Switching capacity of the signalling outputs: Y1, Y2 = 100 mA
Utilisation category to EN 60947-5-1: AC-15: 230 V / 3 A
DC-13: 24 V / 2 A
Max. fuse rating of the safety contacts: 6 A gG D-fuse
Fuse rating of the signalling outputs:
- AES 1135/1136: short-circuit proof;
- AES 1145/1146: short-circuit proof, p-type
Mechanical life: 20 million operations
LED display: ISD
Ambient conditions:
Operating temperature: 0 °C ... +55 °C
Storage and transport temperature: −25 °C ... +70 °C
Protection class: Enclosure: IP40
Terminals: IP20
Clearance: IP54
Degree of pollution: 2
Mounting: Snaps onto standard DIN rail to EN 60715
Connection type: Screw connection
Min. cable section: 0.25 mm²
Max. Cable section: 2.5 mm², solid strand or multi-strand
lead (including conductor ferrules)
Tightening torque: 0,6 Nm
Max. cable length: 1000 m of 0.75 mm² conductor
Weight: 190 g
Dimensions (H x W x D): 100 x 22.5 x 121 mm
2.5 Safety classification
Standards: EN ISO 13849-1; IEC 61508
PL: up to d
Control category: up to 3
PFH-value: 1.0 x 10-7 / h; Applicable for applications with up
to max. 50,000 switching cycles / year and
max. 80 % contact load. Diverging
applications upon request.
SIL: up to 2
Service life: 20 years

3
AES 1135 / 1136
AES 1145 / 1146
Operating instructions
Safety-monitoring module
EN
3. Mounting
3.1 General mounting instructions
Mounting: snaps onto standard DIN rails to EN 60715.
3.2 Dimensions
Device dimensions (H/W/D): 100 x 22.5 x 121 mm
4. Electrical connection
4.1 General information for electrical connection
The electrical connection may only be carried out by
authorised personnel in a de-energised condition.
Wiring examples: see appendix
To avoid EMC disturbances, the physical ambient and
operational conditions at the place where the product
is installed, must meet the provisions laid down in the
paragraph "Electromagnetic Compatibility (EMC)" of
DIN EN 60204-1.
5. Operating principle and settings
5.1 Operating principle after the operating voltage is switched on
Without start-up test AES 1135 / AES 1145:
1. The functionality of the safety-monitoring module is tested.
2. If the safety guard is closed or the emergency stop button released,
the enabling paths of the safety-monitoring module will close. The
LED is green.
3. The cable and the connected safety switch are only tested when the
safety guard is opened or the emergency stop button when actuated
With start-up test AES 1136 / AES 1146:
1. The functionality of the safety-monitoring module is tested.
2. The safety guard or the emergency stop button must be actuated, in
order to check the cables and the connected safety switch (start-up
test).
3. If the safety guard is closed or the emergency stop button released,
the enabling paths of the safety-monitoring module will close. The
LED is green.
If the safety guard is opened or the emergency-stop button is actuated,
the enabling paths of the safety-monitoring module will open. The
machine is stopped and the LED flashes yellow.
Inputs: S14/S22
Connect a safety switch with one NC and one NO contact or two safety
switches with one contact each or an emergency-stop button at input
S14/S22.
Safety switch with two NC contacts: X1
For an operation with two NC contacts, input X1 must be supplied
with 24 VDC.
Outputs
Enabling paths 13-14: NO contacts for safety functions
Additional outputs Y1/Y2:
AES 1135/1136 Y1: Authorized operation (release output closed)
Y2: No authorized operation (release output opened)
AES 1145/1146 Y1: Safety guard opened (release output opened)
Y2: Failure (release output opened)
The additional outputs Y1 and Y2 must not be integrated in the safety
circuit; they may only be used for signalling purposes.
Enable delay time
The enable delay time can be increased from 0.1 s to 1 s by changing
the position of a jumper link connection. Remove the enclosure cover
carefully by means of a screwdriver. Change the position of the jumper
link connection B1.
Jumper link connection closed = 1 s
6. Set-up and maintenance
6.1 Functional testing
The safety function of the safety-monitoring module must be tested.
The following conditions must be previously checked and met:
1. Correct fitting of the safety-monitoring module
2. Fitting and integrity of the power cable
6.2 Maintenance
In the case of correct installation and adequate use, the safety-
monitoring module features maintenance-free functionality.
We recommend a regular visual inspection and functional test,
including the following steps:
• Check the correct fixing of the safety monitoring module
• Check the cable for damage.
Damaged or defective components must be replaced.
7. Disassembly and disposal
7.1 Disassembly
The safety monitoring module must be disassembled in the de-
energised condition only.
7.2 Disposal
The safety monitoring module must be disposed of in an appropriate
manner in accordance with the national prescriptions and legislations.

4
Operating instructions
Safety-monitoring module
AES 1135 / 1136
AES 1145 / 1146
EN
8. Appendix
8.1 Wiring examples
The application examples shown are suggestions. They however do not
release the user from carefully checking whether the switchgear and its
set-up are suitable for the individual application.
The wiring example refers to a closed safety guard and a voltage-free
state. Inductive loads (e.g. contactors, relays, etc.) are to be provided
with suitable interference suppression circuitry. Do not connect ad-
ditional loads to terminal S..
AES 1135/1136
L1
A1
100mA
S13
K1
K3
14
A2
max.
Y1 Y2 X1
K4
3
K2
S14 S21 S22 13
+24 VDC
0 V
N
M
A1
A2
A
A
AES 1145/1146
A
AES 1145/1146
AES 1135/1136
L1
A1
100mA
S13
K1
K3
14
A2
max.
Y1 Y2 X1
K4
3
K2
S14 S21 S22 13
+24 VDC
0 V
N
M
A1
A2
Legend
A Positive break
A S Non-contact safety sensor
A Safety switch
8.2 Integral System Diagnostics (ISD)
The safety monitoring modules LED display to show the different
switching conditions and faults. The following tables show the different
switching conditions.
Tables switching condition indication
Diagnostic LED System condition
The LED is green. Enabling paths closed
LED flashes yellow
(0.5 Hz)
Enabling paths open
LED flashes yellow
(2 Hz)
Safety guard closed, however no release;
possible causes: incorrect operation (only
one contact actuated upon opening) or
voltage drop → perform start-up test
In case of error messages, the LED lights orange intermittently. During
these intermissions, the LED flashes one up to seven times with short
pulses.
Table error indications
Indication (orange)
LED
Error Cause
1 impulse Inputs S1 Defective supply
voltage lead, defective
switch, erroneous
fitting of the switch;
switch only partially ac-
tuated* for at least 5 s
4 impulses Interference signals
at the inputs (no
safe evaluation as-
sured)
Too high capacitive or
inductive interference
at the switch's cables
or the supply voltage
lead
5 impulses One or both relays
did not close within
the monitoring time
Too low operating
voltage Ue;
defective relay
6 impulses Relay not disabled
upon the actuation
of the switch
May be due to contact
welding
7 impulses Dynamic monitoring
of both channels
(cross-monitoring)
failure
Fault in one channel;
internal data transmis-
sion interrupted
* Partial actuation: position of the switch, in which only one contact was actuated.
Deleting the error message
The fault message is deleted once the fault has been rectified and after
the connected switch has been actuated to check the various functions.

5
AES 1135 / 1136
AES 1145 / 1146
Operating instructions
Safety-monitoring module
EN
AES 1135-C-EN
9. Declaration of conformity
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.
9.1 EC Declaration of conformity
Name of the safety component: AES 1135 / AES 1136 /
AES 1145 / AES 1146
Description of the safety component: Safety-monitoring module for non-contact
safety switches and safety relay combination
in connection with the BNS series magnetic
safety switches
Harmonised EC-Directives: 2006/42/EC-EC-Machinery Directive
2004/108/EC EMC-Directive
Person authorized for the compilation
of the technical documentation:
Ulrich Loss
Möddinghofe 30
42279 Wuppertal
Notied body, which approved the
full quality assurance system, referred
to in Appendix X, 2006/42/EC:
TÜV Rheinland Industrie Service GmbH
Alboinstraße 56
12103 Berlin
ID n°: 0035
Place and date of issue: Wuppertal, October 7, 2009
Authorised signature
Heinz Schmersal
Managing Director
EC Declaration of conformity
Translation of the original
declaration of conformity
valid as of December 29, 2009
K.A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Möddinghofe 30, 42279 Wuppertal
Germany
Internet: www.schmersal.com
We hereby certify that the hereafter described safety components both in its basic design and
construction conform to the applicable European Directives.

K. A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Möddinghofe 30, D - 42279 Wuppertal
Postfach 24 02 63, D - 42232 Wuppertal
Phone: +49 - (0)2 02 - 64 74 - 0
Telefax +49 - (0)2 02 - 64 74 - 1 00
E-Mail: [email protected]
Internet: http://www.schmersal.com