schmersal AES 2285 User manual

AES 2285
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 to ensure the safe
operation 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 machine 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
instructions 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.
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 .....................................3
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
5.2 LED functions..........................................3
6 Set-up and maintenance
6.1 Functional testing.......................................4
6.2 Maintenance ..........................................4
7 Disassembly and disposal
7.1 Disassembly...........................................4
7.2 Disposal ..............................................4
8 Appendix
8.1 Wiring examples .......................................4
8.2 Start conguration ......................................5
8.3 Sensor conguration ....................................5
8.4 Actuator conguration ...................................6
8.5 Pin conguration (depending on the number of doors) ..........6
9 EU Declaration of conformity
x.000 / 05.2016 / v.A. - 101171507-EN / E / 2016-04-08 / AE-Nr. 5950
EN Operating instructions. . . . . . . . . . . . .pages 1 to 8
Original

2
Operating instructions
Safety-monitoring module AES 2285
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 standards ISO 14119
and ISO 13850 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.
The safety-monitoring module must only be used when the enclosure is
closed, i.e. with the front cover fitted.
2. Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
AES 2285
Only if the information described in this operating instructions
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 module for integration in safety circuits is
designed for fitting in control cabinets. It is 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. Up to 6 safety
guards can be monitored by means of the AES 2285 safety-monitoring
module.
Design
The safety-monitoring module has a multichannel structure. It includes
safety relays with monitored positive action contacts. The NO contacts
of the relays, which are wired in series, build the enabling contacts.
6 signalling outputs signal the position of the corresponding safety guard.
The entire concept of the control system, in which the
safety component is integrated, must be validated to the
relevant standards.
2.4 Technical data
General data:
Standards: IEC 60204-1, IEC 60947-5-1, IEC 60947-5-3,
ISO 13849-1, IEC 61508,
BG-GS-ET-14, BG-GS-ET-20
Climate resistance: EN 60068-2-78
Mounting: snaps onto standard DIN rail to EN 60715
Terminal designations: IEC 60947-1
Material of the housings: Plastic, glass-fibre reinforced
thermoplastic, ventilated
Material of the contacts: AgCdO, self-cleaning, positive drive
Weight: 300 g
Start conditions: Automatic or start button
Feedback circuit (Y/N): yes
Pull-in delay for automatic start: typ. 120 ms
Pull-in delay with reset button: typ. 30 ms
Drop-out delay in case of emergency stop: typ. 20 ms / max. 35 ms
Drop-out delay on "supply failure": On request
Mechanical data:
Connection type: Screw connection
Cable section: min. 0.25 mm² / max. 2.5 mm²
Connecting cable: rigid or flexible
Tightening torque for the terminals: 0.6 Nm
With removable terminals (Y/N): yes
Mechanical life: 10 million operations
Electrical life: Derating curve available on request
Resistance to shock: 10 g / 11 ms
Resistance to vibrations
to EN 60068-2-6: 10 ... 55 Hz,
amplitude 0.35 mm
Ambient conditions:
Ambient temperature: – 25 °C … +45 °C
Storage and transport temperature: –40 °C … +85 °C
Protection class: Enclosure: IP40
Terminals: IP20
Clearance: IP54
Degree of pollution: 2
EMC rating: to EMC Directive
Electrical data:
Contact resistance in new state: max. 100 mΩ
Power consumption: max. 3.6 W / 6.6 VA
Rated operating voltage Ue:24 VDC –15%/+20%,
residual ripple max. 10%
Rated operating current Ie:0.125 A
Rated insulation voltage Ui:250 V
Rated impulse withstand voltage Uimp:4 kV
Thermal test current Ithe:6 A
Fuse rating for the operating voltage: F1: internal electronic trip,
tripping current > 1 A; reset after
disconnection of the supply voltage
Monitored inputs:
Cross-wire detection (Y/N): Yes
Wire breakage detection (Y/N): Yes
Earth leakage detection (Y/N): Yes
Number of NO contacts: 1 … 6
Number of NC contacts: 1 … 6
Cable length: 1,500 m with 1.5 mm²,
2,500 m with 2.5 mm²
Conduction resistance: max. 40 Ω
Outputs:
Number of safety contacts: 2
Number of auxiliary contacts: 1
Number of signalling outputs: 6

3
AES 2285
Operating instructions
Safety-monitoring module
EN
Switching capacity of the safety contacts: 13-14 / 23-24:
max. 250 V, 6 A ohmic
(inductive in case of
appropriate protective wiring)
Fuse rating of the safety contacts: 6.3 A slow blow
Utilisation category to IEC 60947-5-1: AC-15 / DC-13
Dimensions H × W × D: 100 × 45 × 121 mm
The data specified in this manual are applicable when the
component is operated with rated operating voltage Ue±0%.
2.5 Safety classification
Standards: ISO 13849-1, IEC 61508
PL: up to d
Control category: up to 3
DC: 60 % … 90 % (low)
CCF: > 65 points
PFH: ≤ 2.00 × 10-8/h
SIL: up to 2
Service life: 20 years
The PFH value of 2.00 × 10-8/h applies to the combinations of contact
load (current through enabling contacts) and number of switching
cycles (nop/y) mentioned in the table below. At 365 operating days per
year and a 24-hours operation, this results in the below-mentioned
switching cycle times (tcycle) for the relay contacts.
Diverging applications upon request.
Contact load nop/y tcycle
20 % 525,600 1.0 min
40 % 210,240 2.5 min
60 % 75,087 7.0 min
80 % 30,918 17.0 min
100 % 12,223 43.0 min
3. Mounting
3.1 General mounting instructions
Mounting: snaps onto standard DIN rails to EN 60715.
Snap the bottom of the enclosure slightly tilted forwards in the DIN rail
and push up until it latches in position.
To avoid EMC disturbances, the physical ambient and opera-
tional conditions at the place where the product is installed,
must meet the provisions laid down in the paragraph
"Electromagnetic Compatibility (EMC)" of IEC 60204-1.
3.2 Dimensions
Device dimensions (H/W/D): 100 x 45 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.
As far as the electrical safety is concerned, the protection
against unintentional contact of the connected and therefore
electrically interconnected apparatus and the insulation of the
feed cables must be designed for the highest voltage, which
can occur in the device.
Wiring examples: see appendix
5. Operating principle and settings
5.1 Operating principle after the operating voltage is switched on
With the guard door closed or the emergency stop command devices
unlocked, the enabling paths are closed as soon as the start button is
pushed. During the start command, the falling edge is detected, when
the contacts of the downstream relays acting on the feedback circuit
are closed.
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 K1 and K2 will go out. The
corresponding signal output signals which guard was opened.
Inputs S11/S12-S22/S73/S74;
S31/S32-S42/S83/S84;
S51/S52-S62/S93/S94
Safety switches or emergency stop command devices with one NC
and one NO contact must be connected to the inputs. If not all inputs
are wired, a bridge must be established between Sx1 and Sx2 of the
non-used input.
Start button/feedback circuit X1/X2
Connect start button/feedback circuit to the inputs X1 and X2 according
to the wiring diagram
Automatic start X1-X3
The automatic start is programmed by connecting the feedback circuit to
the terminals X1-X3. If no start button and no feedback circuit is used, a
bridge must be established between X1 and X3.
Outputs
Enabling paths 13-14, 23-24: NO contacts for safety function
Signalling output Y1-Y6
0 V safety guard open / no enabling signal
24 V safety guard closed / enabling signal
Signalling outputs must not be used in safety circuits.
Auxiliary contact 31-32
Conditions of the enabling paths
The signalling outputs and the auxiliary contact must not be integrated
in the safety circuit.
5.2 LED functions
• K1: Status channel 1
• K2: Status channel 2
• Ui: Status internal operating voltage (LED is on, when the operating
voltage on the terminals A1-A2 is ON and the fuse has not been
triggered)
K1
Ui
K2
13
A1
A1
23 31 S11
X1 X2 X3
S74S73 S83 S93 Y1 Y3 Y5
14 24 32 S84 Y4
S12 S31 S32 S42
S22 S51 S52 S62
S94 Y2 Y6
AES 2285
Fig. 1

4
Operating instructions
Safety-monitoring module AES 2285
EN
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 fixing
2. Check the integrity of the cable entry and connections
3. Check the safety-monitoring module's enclosure for damage.
4. Check the electrical function of the connected sensors and
their influence on the safety-monitoring module and the
downstream actuators
6.2 Maintenance
A regular visual inspection and functional test, including the following
steps, is recommended:
1. Check the correct fixing of the safety-monitoring module
2. Check the cable for damages
3. Check electrical function
The device has to be integrated into the periodic check-ups
according to the Ordinance on Industrial Safety and Health,
however at least 1x/year.
Damaged or defective components must be replaced.
7. Disassembly and disposal
7.1 Disassembly
The safety-monitoring module must be disassembled in a de-energised
condition only.
Push up the bottom of the enclosure and hang out slightly tilted
forwards.
7.2 Disposal
The safety-monitoring module must be disposed of in an appropriate
manner in accordance with the national prescriptions and legislations.
8. Appendix
8.1 Wiring examples
Dual-channel control, shown for a guard door monitor;
with two contacts, where at least one is a positive break contact;
with external reset button
J
• Relay outputs: Suitable for 2-channel control, for increase in
capacity or number of contacts by means of contactors or relays with
positive-guided contacts.
• The control system recognises wire-breakage, earth faults and
cross-wire shorts in the monitoring circuit.
S73
S51 S94
S12
S83
S11
S42
S74
S52
S22
S84
S31 S62
S32 S93
B
D
F
A
C
E
S
S
S
S
S
S
K1 K2
Ui
K3
K4
3
N
M
L1
A1
A2
13 23 31
14 24 32
K2
K1
X1 X2 X3
Y1 Y2 Y3 Y4 Y5 Y6
24 VDC
0V
S12
Y1
S74
S11 S73
S
S22
Y2
S74
S11 S73
S
S32
Y3
S84
S31 S83
S
S42
Y4
S84
S31 S83
S
S52
Y5
S94
S51 S93
S
S62
Y6
S94
S51 S93
S
AES 2285
Fig. 2

5
AES 2285
Operating instructions
Safety-monitoring module
EN
8.2 Start configuration
External reset button (non-monitored start) (see Fig. 3)
• The external reset button is integrated in the feedback circuit in series.
• The safety-monitoring module is activated upon actuation of the reset
button.
Automatic start (Fig. 4)
• The automatic start is programmed by connecting the feedback circuit
to the terminals X1-X3. If the feedback circuit is not required, establish
a bridge.
• Caution: Not admitted without additional measure due to the risk of
gaining access by stepping behind!
• When the AES 2285 safety-monitoring module is used with the
operating mode "Automatic start", an automatic restart after a
shutdown in case of emergency must be prevented by the upstream
control to IEC 60204-1 paragraph 9.2.5.4.2.
Due to the operating principle of the electronic fuse,
the customer must check that no hazard is caused by
an unexpected restart in circuits without reset button
(automatic reset).
X2
X1
K
A
J
K
B
K
BS
K
A
X3
X1
Fig. 3 Fig. 4
8.3 Sensor configuration
Dual-channel emergency stop circuit with command devices to
ISO 13850 and IEC 60947-5-5 (Fig. 5)
Dual-channel guard door monitoring circuit with interlocking
device to ISO 14119 (see Fig. 5)
Dual-channel control of magnetic safety switches according
to IEC 60947-5-3 (see Fig. 5)
• The control system recognises wire breakage and earth faults in the
control circuit.
• Cross-wire shorts between the control circuits are detected.
• Category 3 – PL d to ISO 13849-1 possible.
EMERGENCY
STOP
Door switches Magnetic reed
switches
S11
S22
S11
S74S12 S74
S73 S73
S31
S42
S31
S84S32 S84
S83 S83
S51
S62
S51
S94S52 S94
S93 S93
AA
AA
AA
S11
S22
S11
S74S12 S74
S73 S73
S31
S42
S31
S84S32 S84
S83 S83
S51
S62
S51
S94S52 S94
S93 S93
S11
S22
S11
S74S12 S74
S73 S73
S31
S42
S31
S84S32 S84
S83 S83
S51
S62
S51
S94S52 S94
S93 S93
SS
SS
SS
Fig. 5
The connection of magnetic safety switches to the AES 2285
safety-monitoring module is only admitted when the
requirements of the standard IEC 60947-5-3 are observed.
As the technical data are regarded, the following minimum
requirements must be met:
– switching capacity: min. 240 mW
– switching voltage: min. 24 VDC
– switching current: min. 10 mA
For example, the following safety sensors meet the
requirements:
– BNS33-02z-2187, BNS33-02zG-2187
– BNS260-02z, BNS260-02zG
– BNS260-02-01z, BNS260-02-01zG
When sensors with LED are wired in the control circuit
(protective circuit), the following rated operating voltage
must be observed and respected:
– 24 VDC with a max. tolerance of –5 %/+20 %
Otherwise availability problems could occur, especially in
series-wired sensors, where a voltage drop in the control
circuit is triggered by LED's for instance.

6
Operating instructions
Safety-monitoring module AES 2285
EN
8.4 Actuator configuration
Single-channel control (see Fig. 6)
• Suitable for increase in capacity or number of contacts by means of
contactors or relays with positive-guided contacts.
• If the feedback circuit
is not required, establish a bridge.
•
S
= Feedback circuit
Dual-channel control with feedback circuit (Fig. 7)
• Suitable for increase in capacity or number of contacts by means of
contactors or relays with positive-guided contacts.
• If the feedback circuit
is not required, establish a bridge.
•
S
= Feedback circuit
X1 X2 13
14
K
A
K
A
K
A
S
L1
N
X1 X2 13
14
K
B
K
A
K
B
K
A
K
B
L1
N
K
A
S
Fig. 6 Fig. 7
8.5 Pin configuration (depending on the number of doors)
(Unused sensor inputs must be accordingly bridged)
Number of sensors to be monitored: 1
Pin configuration: NC contacts S11/S12
NO contacts S73/S74
Bridges S11/S22
S31/S32/S42
S51/S52/S62
Number of sensors to be monitored: 2
Pin configuration: NC contacts 1 S11/S12
NC contacts 2 S11/S22
NO contacts 1 S73/S74
NO contacts 2 S73/S74
Bridges S31/S32/S42
S51/S52/S62
Number of sensors to be monitored: 3
Pin configuration: NC contacts 1 S11/S12
NC contacts 2 S11/S22
NC contacts 3 S31/S32
NO contacts 1 S73/S74
NO contacts 2 S73/S74
NO contacts 3 S83/S84
Bridges S31/S42
S51/S52/S62
Number of sensors to be monitored: 4
Pin configuration: NC contacts 1 S11/S12
NC contacts 2 S11/S22
NC contacts 3 S31/S32
NC contacts 4 S31/S42
NO contacts 1 S73/S74
NO contacts 2 S73/S74
NO contacts 3 S83/S84
NO contacts 4 S83/S84
Bridges S51/S52/S62
Number of sensors to be monitored: 5
Pin configuration: NC contacts 1 S11/S12
NC contacts 2 S11/S22
NC contacts 3 S31/S32
NC contacts 4 S31/S42
NC contacts 5 S51/S52
NO contacts 1 S73/S74
NO contacts 2 S73/S74
NO contacts 3 S83/S84
NO contacts 4 S83/S84
NO contacts 5 S93/S94
Bridges S51/S62
Number of sensors to be monitored: 6
Pin configuration:NC contacts 1 S11/S12
NC contacts 2 S11/S22
NC contacts 3 S31/S32
NC contacts 4 S31/S42
NC contacts 5 S51/S52
NC contacts 6 S51/S62
NO contacts 1 S73/S74
NO contacts 2 S73/S74
NO contacts 3 S83/S84
NO contacts 4 S83/S84
NO contacts 5 S93/S94
NO contacts 6 S93/S94
Bridges none

7
EN
AES2285-D-EN
AES 2285
Operating instructions
Safety-monitoring module
9. EU Declaration of conformity
Place and date of issue: Wuppertal, April 20, 2016
Authorised signature
Philip Schmersal
Managing Director
EU Declaration of conformity
Original K.A. Schmersal GmbH & Co. KG
Möddinghofe 30
42279 Wuppertal
Germany
Internet: www.schmersal.com
We hereby certify that the hereafter described components both in their basic design and construction conform
to the applicable European Directives.
Name of the component: AES 2285
Description of the component: Safety-monitoring module for emergency stop circuits,
guard door monitoring and magnetic safety switches
Relevant Directives: Machinery Directive
EMC-Directive
RoHS-Directive
2006/42/EC
2014/30/EU
2011/65/EU
Applied standards: DIN EN 60947-5-3:2014,
EN ISO 13849-1:2008,
DIN EN ISO 13849-2:2013
Notied body for the prototype test: DGUV Test
Prüf- und Zertizierungsstelle
Elektrotechnik
Gustav-Heinemann-Ufer 130
50968 Köln
ID n°: 0340
EC-prototype test certicate: ET 16052
Person authorized for the compilation
of the technical documentation:
Oliver Wacker
Möddinghofe 30
42279 Wuppertal
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.

K. A. Schmersal GmbH & Co. KG
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