schmersal EBW-AZ User manual

EBW-AZ
Operating instructions
Safety-monitoring module
1
EN
EN Operating instructions...................... pages 1 to 6
Translation of the original operating instructions
FR
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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 qualied 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 specications 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 proper 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-specic installation standards as well as all
prevailing safety regulations and accident prevention rules.
Further technical information can be found in the
Elan 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 modications.
There are no residual risks, provided that the safety instructions as well
as the instructions regarding mounting, commissioning, operation and
maintenance are observed.
1.6 Warning about misuse
In case of inadequate or improper use or manipulations of the
safety-monitoring module, personal hazards or damage to ma-
chinery or plant components cannot be excluded. The relevant
requirements of the standard EN 1088 must be observed.
19.01.2010 / Index: 87/10 / Teile-Nr. 1211805-EN
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 Appropriateuse........................................1
1.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.6 Warningaboutmisuse...................................1
1.7 Exclusionofliability.....................................2
2 Product description
2.1 Orderingcode .........................................2
2.2 Specialversions........................................2
2.3 Destinationanduse.....................................2
2.4 Technicaldata.........................................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 LEDfunctions..........................................3
5.2 Descriptionoftheterminals...............................3
5.3 Notes................................................3
5.4 Setting report for EBW devices . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
6 Set-up and maintenance
6.1 Functionaltesting.......................................5
6.2 Maintenance ..........................................5
7 Disassembly and disposal
7.1 Disassembly...........................................5
7.2 Disposal..............................................5
7.3 ECDeclarationofconformity..............................6

2
Operating instructions
Safety-monitoring module EBW-AZ
EN
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 resulting
from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary repairs,
conversions and modications to the device are strictly forbidden; the
manufacturer shall accept no liability for damages resulting from such inva-
sive work, arbitrary repairs, conversions and/or modications to the device.
2 Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
EBW-AZ
This device is designed as single-channel standstill and
movement monitor (set-up rotation velocity / speed).
The device detects a movement signal through an external
sensor and converts this signal in accordance with a preset
limit value into a control command.
The limit value to be monitored can be set from 0.08 Hz to 1 kHz.
The output relay is invertible through a change-over switch,
in which it is energised or de-energised when the upper or
lower limit of the limit value is exceeded.
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 specications 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 tting in control cabinets. They are used for the safe
evaluation of the signal of an externally installed frequency generator
(possible signals: PNP, NPN, Namur or tacho).
The safety function is dened as the status change of the relay
contacts 13-14 and 21-22 (Caution: the function of the relay can be
inverted through a change-over switch) when a predened limit value
is reached. The contacts 13-14 and 21-22 meet the following require-
ments under observation of a B10d value assessment
(also refer to "Requirements of DIN EN ISO 13849-1"):
– Control category B - PL b to DIN EN ISO 13849-1
– SIL 1 to DIN EN 61508-2
– SILCL 1 to DIN EN 62061
(meets the requirements of control category B to DIN EN 954-1)
When the device is used as "stand alone" equipment or in conjunction with
a second independent channel, a higher control category can be obtained.
To determine the Performance Level (PL) of the entire safety function
(e.g. sensor, logic, actuator) to DIN EN ISO 13849-1, an analysis of all
relevant components is required.
2.4 Technical data
General data:
Standards: IEC/EN 60204-1, EN 60947-5-1;
EN ISO 13849-1, IEC/EN 61508
Climate resistance: EN 60068-2-78
Fixing: Snaps onto standard DIN
rails to DIN EN 60715
Terminal designations: EN 60947-1
Material of the enclosure: glass-bre, thermoplastic
Material of the contacts: AgSnO2
Weight: aprox. 180 g
Start conditions: Automatic
Feedback circuit (Y/N): No
Response time: Relay switching time typically 50 ms
plus system response time, which
depends on the generator frequency
(i.e. approx. 50 ms + 1/f)
Mechanical data:
Connection type: Screw connection
Cable section: min. 0.25 mm2/ max. 2.5 mm2
Connecting cable: rigid or exible
Tightening torque
for the terminals:
0.6 Nm
With removable terminals (Y/N): No
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: 0°C … +50°C
Storage and transport
temperature:
–40°C … +85°C
Protection class: Enclosure: IP 40
Terminals: IP 20
Wiring compartment: IP 54
Air clearances and creepage
distances to IEC/EN 60664-1:
4 kV/2 (basic insulation)
EMC rating: to EMC Directive
Electrical data:
Contact resistance
in new state:
max. 100 mΩ
Power consumption: max. 2.1 VA
Rated operating voltage Ue: 24 VDC +10% / –10%,
residual ripple max. 10%
Rated current: 120 mA
Max. fuse rating of the
operating voltage (F1):
Intern 500 mA / 250 V
Monitored inputs (sensor inputs)
Cross-wire detection (Y/N): No
Wire breakage detection (Y/N): No
Earth leakage detection (Y/N): No
Conduction resistance: max. 40 Ω
Outputs:
Number of safety contacts: 1 NC contact / 1 NO contact
Number of auxiliary contacts: 0
Number of signalling outputs: 0
Switching capacity of
the safety contacts:
13-14; 21-22:
max. 230 V / 3 A ohmic
(inductive in case of appropriate
protective wiring, max. 2 A)
Fuse rating of
the safety contacts:
4 A slow blow
Utilisation category
to EN 60947-5-1:
AC-15 / DC-13: EN 60947-5-1
Dimensions (H/W/D): 83 mm × 45 mm × 126.5 mm
The data specied in this manual is applicable when the component
is operated with rated operating voltage Ue± 0%.

3
EBW-AZ
Operating instructions
Safety-monitoring module
EN
2.5 Safety classication
Standards: EN ISO 13849-1, IEC 61508,
EN 60947-5-1
PL: up to b
Control category: up to B
DC: < 60%
CCF: > 65 points
SIL: up to 1
Service life: 20 years
B10d value (for one channel): Low voltages range 20%: 20,000,000
40%: 7,500,000
60%: 2,500,000
80%: 1,000,000
Maximum load 100%: 400,000
MTTF
B d x x
h
s/h3600
d
10d op op
op
n
0,1 x nop tcycle
For an average annual demand rate of nop = 126,720 cycles per
year, Performance Level PL e can be obtained at maximum load.
nop = average number of activations per year
dop = average number of operating days per year
hop = average number of operating hours per day
tcycle = average demand rate of the safety function in s
(e.g. 4 × per hour = 1 × per 15 min. = 900 s)
(Specications can vary depending on the application-specic
parameters hop, dop and tcycle as well as the load.)
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 down until it latches in position.
3.2 Dimensions
All measurements in mm.
Device dimensions (H/W/D): 83 mm × 45 mm × 126.5 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.
5 Operating principle and settings
5.1 LED functions
• UB: Status supply voltage
• Rel.: Status switching relay K1
5.2 Description of the terminals
Voltages: A1
A2
+24 VDC
0 VDC
Outputs: 13-14
21-22
NO-contact
NC-contact
Input sensor: 24 V
IN
0 V
TG
+24 VDC (to be used for the voltage
supply of the external sensor)
Input sensor
Sensor
Input tachogenerator
Potentiometer: Fine adjustment of the frequency
DIP switch: DZW-SSW (possible functions rotational
speed monitor - standstill monitor)
A1 24V IN 0V
A2 13 14 21
TC
22
22
21
14
13
100%
10%
UB
Rel.
DZW
EBW-AZ-24V
Typ:
SSW
Fig. 1
5.3 Notes
Operating principle
EBW devices detect and process signals with different quality and operating
frequency, which are prepared in the "input level" and "monitoring/
standstill detection" parts of the control. The period length of the limit
value for the control command is also set in this part of the control.
The period length of the generator signals is continuously compared
to the preset period length of the reference oscillator and transmitted
as dynamic signal to the output level of the EBW devices.
The operating principle of the EBW devices is based upon a real-time
measurement, i.e. the actual period length of the input signals is continu-
ously measured/counted and compared to the preset value. A control
command is given at the end of the period, during which the actual
value of a movement diverges from the upper or lower limit of the
preset limit value.
For the standstill signal setting, a suitable limit value must be determined
in terms of a relative standstill, i.e. the residual movement, which remains
below the limit value, still must have come to an absolute standstill or a
hazard-free situation under observance of an access speed of 1.6 m/sec.
1)
a)
b)
2)
c)
d)
3)
e)
f)
4)
g)
h)
Fig. 2: single-channel mouvement monitor EBW
1) Input level a) Signal preparation
b) Generator adjustment
2) Monitoring c) Period length setting
d) Fine adjustment
3) R-C oscillator e) Signal conversion
f) static/dynamic
4) Output level
g) Converter/Relay
h) Output

4
Operating instructions
Safety-monitoring module EBW-AZ
EN
Wiring possibilities (Fig. 3 and 4)
• All commercially available generators with NPN, PNP, NAMUR
and SINUS signals can be connected.
• An adjustment to the generator type regarded is provided internally
in the device, optionally this can be done in factory or according to
setting instructions.
• The control command of the relay contacts is not saved, i.e. the
upper or lower limit of the limit value being exceeded causes a
status change of the positive-guided output contacts.
A1 24V IN 0V TG
A2 13 14 21 22
14 22
13 21
EBW-AZ-24V
Typ:
DZW
SSW
100%
10%
Rel.
UB
A1 24V IN 0V TG
A2 13 14 21 22
14 22
13 21
EBW-AZ-24V
Typ:
PNP NPN
b)
NAMUR
a)
DZW
SSW
100%
10%
Rel.
UB
A1 24V IN 0V TG
A2 13 14 21 22
14 22
13 21
EBW-AZ-24V
Typ:
DZW
SSW
100%
10%
Rel.
UB
A1 24V IN 0V TG
A2 13 14 21 22
14 22
13 21
EBW-AZ-24V
Typ:
DZW
SSW
100%
10%
Rel.
UB
Fig. 3
a) Tacho
b) Potential-free output contacts
Proximity switch PNP
Voltage range: Umax. 30 VDC (< 4.0 V … > 4.5 V)
Signal load: approx. 18 mA (at UB 24 VDC)
Frequency range: < 100 kHz
Proximity switch NPN
Voltage range: Umax. 30 VDC (< 4.0 V … > 4.5 V)
Signal load: approx. 18 mA (at UB 24 VDC)
Frequency range: < 100 kHz
NAMUR
Voltage range: Umax. 30 VDC (< 4.0 V … > 4.5 V)
Signal load: approx. 9 mA (at UB 24 VDC)
Frequency range: < 100 kHz
Tachogenerator
Voltage range: Umax. 44 VAC (effective)
Signal load: approx. 9.0 mA (at UB44 VACeff.)
Frequency range: < 100 kHz
"signal recognition" (min.): approx. 1.44 VAC 4.66 Hz
Fig. 4
Due to the specic design of the EBW devices as standstill
monitor, it must be observed that a control command does
not trigger a restart interlock, i.e. if necessary, a special ON
or RESET signal must be otherwise realised in the electrical
safety circuit, if this is required prior to a restart.
For the denition of the mouvement limit value to be monitored,
the device setting versions furthermore must be observed.
In addition to that, it must be ensured that any incidental or
manipulative alteration of the frontal set-up potentiometer or the
change-over switch of the EBW-AZ devices to EN 292 is preven-
ted or does not lead to a hazardous situation. If the customer is
unable to full this condition, the use of the EBW-WB devices,
which have no external setting devices, is recommended.
Adjustment
In factory or by the customer
Frequency range PNP/
Namur
NPN Tacho Jumper
0.08 … 1 Hz 1 5 9 B4
0.8 … 10 Hz 2 6 10 B3
8 … 100 Hz 3 7 11 B2
80 Hz … 1 kHz 4 8 12 B1
Jumper 1 + 3 2 + 3 4 –
Fig. 5: Type classication
(example: frequency range 8...100Hz, signal generator PNP sensor = type 3)
Opening the enclosure
Necessary to adjust the solder straps located on the circuit board
of the device (Fig. 6).
To this effect, carefully separate the bottom part of the enclosure
from the upper part by means of a suitable tool.
Do not open the device when live!
J1
J2 J3
J4
B1
B2 B3
B4
Fig. 6: lateral view of the left circuit board of the device, programming
by solder straps
When the enclosure is open, the electrostatic discharge
requirements must be respected and observed. After the
setting is completed, the enclosure must be closed again.
Only touch the components after electrical discharge!
Adjust the solder straps J1...J4 to the sensor (Fig. 7)
PNP/Namur NPN Tacho
J1 ×
J2 ×
J3 × ×
J4 ×
Fig. 7
Adjust the solder straps B1...B4 to the required frequency
range (Fig. 8)
Hz Right hinged (approx. 10%) Left hinged (approx. 100%)
B4 0.08 Hz 1 Hz
B3 0.8 Hz 10 Hz
B2 8 Hz 100 Hz
B1 80 Hz 1,000 Hz
Fig. 8

5
EBW-AZ
Operating instructions
Safety-monitoring module
EN
Fine adjustment of the programmed frequency
The ne adjustment is realised by means of the potentiometer in the
enclosure cover, right hinged approx. 10%, left hinged approx. 100%
(also see Fig. 8).
Relay K1 is energised in the standstill monitoring operating
mode (change-over switch in enclosure cover), when the
lower limit of the set frequency is exceeded or, in the rotational
speed monitoring operating mode, the frequency is exceeded.
The chosen setting must be registered in the eld provided
to that effect on the device using an unerasable marker. The
following setting report must be completed and added to the
manual of the plant.
5.4 Setting report for EBW devices
This report regarding the setting of the device must be completed
accordingly by the customer and enclosed in the technical manual
of the machine.
The setting report must be available whenever a safety check is performed.
Company:
Device n° EBW device:
Sensor
type
Limit rotational speed
[rpm]
Resolution
[Imp/U]
Cut-off frequency
[Hz]
Frequency range
(B1 … B4)
Sensor programming
(J1...J4)
Set on (date) Signature of the responsible person
For the EBW-AZ version, the chosen type (1...12) must be
registered in the eld provided to that effect on the cover
sticker using an permanent marker!
The safety-monitoring module is used in the following machine:
Machine n°
Machine type
Parameter settings
checked on:
Parameter settings
checked by:
Signature
Note for EBW-AZ devices, which have not been set up:
The proper parameter setting according to the enclosed
setting instructions is realised by the user under his/her
own responsibility.
The setting report must be added to the machine documentation
in accordance with the EC Machinery Directive!
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 xing
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 inuence
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 xing of the safety-monitoring module
2. Check the cable for damages
3. Check electrical function
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.
Unlock the bottom of the enclosure by means of a slot screwdriver,
push up 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.

6
Operating instructions
Safety-monitoring module EBW-AZ
EN
EBW-AZ-B-EN
Appendix
Note
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.
EC Declaration of conformity
Translation of the original declaration of conformity
valid as of December 29, 2009
Elan Schaltelemente GmbH & Co. KG
Im Ostpark 2 · 35435 Wettenberg
Germany
Internet: www.elan.de
We hereby certify that the hereafter described safety components both in its basic design and
construction conform to the applicable European Directives.
Place and date of issue: Wuppertal, October 6, 2009
Authorised signature
Heinz Schmersal
Managing Director
Name of the safety component: EBW-AZ
Description of the safety component: Safety-monitoring module for motor
standstill monitoring or set-up rotational
velocity / speed monitoring
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
7.3 EC Declaration of conformity
Elan Schaltelemente GmbH & Co. KG
Im Ostpark 2, D - 35435 Wettenberg
Postfach 1109, D - 35429 Wettenberg
Telefon: +49 - (0)641 9848 - 0
Telefax +49 - (0)641 - 9848 - 420
E-Mail: [email protected]
Internet: www.elan.de