schmersal AZ 200 T User manual

AZ 200 T
Operating instructions
Safety switch
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 switchgear. 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 switchgear 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 Purpose ..............................................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 Rear side Electrical connection
4.1 General information for electrical connection..................3
5 Operating principle and diagnostic functions
5.1 Safety switch with conventional diagnostic output..............4
5.2 Safety switch with serial diagnostic function ..................5
6 Set-up and maintenance
6.1 Functional testing.......................................5
6.2 Maintenance ..........................................5
7 Disassembly and disposal
7.1 Disassembly...........................................5
7.2 Disposal ..............................................5
8 Appendix
8.1 Wiring examples .......................................6
8.2 Connection example ....................................7
9 EU Declaration of conformity
x.000 / 11.2017 / v.A. - 101186190-EN / H / 2017-11-24 / AE-Nr. 8380
EN Operating instructions. . . . . . . . . . . . .pages 1 to 8
Original

2
Operating instructions
Safety switch AZ 200 T
EN
1.6 Warning about misuse
In case of improper use or manipulation of the safety switch-
gear, 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
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 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:
AZ 200➀-T-➁
No. Option Description
➀
SK Screw connection
CC Cage clamps
ST1 M23 x 1 connector (8+1) pole
ST2 M12 x 1 connector, 8 pole
➁
Outputs
1P2P 1 p-type diagnostic output and
2 p-type safety outputs
3P2P 3 p-type diagnostic output and
2 p-type safety outputs
SD2P serial diagnostic output and
2 p-type safety outputs
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 Purpose
The AZ 200 with non-contact electronic safety sensors is designed for
application in safety circuits and is used for monitoring the position of
movable safety guards. The integrated door detection sensor monitors
the closed condition of the safety guard, the sensor of the actuator
monitors the actuator position. The safety function consists of safely
switching off the safety outputs when the safety guard is opened and
maintaining the safe switched off condition of the safety outputs for as
long as the safety guard is open. The opening of the safety guard is
detected by the safety sensors.
LED functions
The safety switchgear signals the operational state as well as errors
through three coloured LED’s installed on the front side of the device.
green supply voltage on
red: Error (see flash codes)
Yellow operating condition
2.4 Technical data
Standards: IEC 60947-5-3, EN ISO 13849-1,
IEC 61508
Material of the enclosure: glass-fibre reinforced thermoplastic,
self-extinguishing
Mechanical life: ≥ 1 million operations
Latching force: 30 N
Protection class: IP67 to IEC/EN 60529
Insulation protection class: II, X
Overvoltage category: III
Degree of pollution: 3
Realisation of the electrical connection: Screw terminals or cage
clamps, M12 or M23 connector
Cable section: min. 0.25 mm², max. 1.5 mm²
(including conductor ferrules)
Tightening torque for the cover screws: 0.7 ... 1 Nm (TorxT10)
Cable entry: M20 x 1.5
Series-wiring: max. 31 devices (not applicable
for ordering suffix -3P2P)
Cable length: max. 200 m (Cable length and
cable section alter the voltage drop
depending on the output current)
Switching distances to IEC 60947-5-3:
Rated operating distance Sn:6.5 mm
Assured switching distance sao:4.0 mm
Assured switch-off distance sar:30 mm
Hysteresis: max: 1.5 mm
Repeat accuracy: < 0.5 mm
Ambient conditions:
Ambient temperature: −25 °C ... +70 °C
Storage and transport temperature: −25 °C ... +85 °C
Resistance to vibration: 10 ... 55 Hz, amplitude 1 mm
Resistance to shock: 30 g / 11 ms
Switching frequency: 1 Hz
Response time: < 60 ms
Duration of risk: < 120 ms
Time to readiness: < 4000 ms
Max. actuating speed: ≤ 0.2 ms
Electrical data:
Rated operating voltage Ue:24 VDC -15% / +10%
(stabilised PELV)
Rated operating current Ie:0.7 A
No-load current Io:max. 0.1 A
Rated impulse withstand voltage Uimp:0.8 kV
Rated insulation voltage Ui:32 VDC
Device insulation: internal short-circuit proof
Screw terminals or cage clamps: ≤ 4 A when used to UL 508
- Connector M12: ≤ 2 A
- Connector M23: ≤ 4 A
EMC rating: to EN 61000-6-2
Safety inputs: X1 and X2 (-1P2P and -SD2P)
Rated operating voltage Ue3:- 3 V ... 5 V (Low)
15 V ... 30 V ( High)
Rated operating current Ie3:typically 2 mA at 24 V
Safety outputs Y1 and Y2: p-type, short-circuit proof
Rated operating voltage Ue1:0 V ... 4 V under Ue
Rated operating current Ie1:max. 0.25 A each
Utilisation category: DC-13
Leakage current Ir: ≤ 0.5 mA
Diagnostic output OUT / OUT2 / OUT3: short-circuit proof, p-type
Rated operating voltage Ue2:0 V ... 4 V under Ue
Rated operating current Ie2:(lout + lout2 + lout3 ≤ le2)
-1P2P: max. 0.05 A
-3P2P: max. 0.1 A
Utilisation category: DC-13
Wiring capacitance for serial diagnostics: max. 50 nF
cULus: Use isolated power supply only
For use in NFPA 79 Applications only Adapters
providing field wiring means are available from
the manufacturer. Refer to manufacturers information.

3
AZ 200 T
Operating instructions
Safety switch
EN
2.5 Safety classification
Standards: EN ISO 13849-1, IEC 61508, IEC 60947-5-3
PL: up to e
Control category: up to 4
PFH: 4 x 10-9 / h
SIL: up to 3
Service life: 20 years
Classification: PDF-M
3. Mounting
3.1 General mounting instructions
For fitting the AZ 200 T safety switch and the actuator, two mounting
holes for M6 screws with washers (washers included in delivery)
are provided. The safety switch must not be used as end stop. Any
mounting position. The mounting position however must be chosen so
that the ingress of dirt and soiling in the used opening is avoided. The
unused actuator opening must be sealed by means of the dust-proof
flap (included in delivery).
Please observe the remarks of the standards EN ISO 12100,
EN 953 and EN 1088.
Admissible mounting set-up
Inadmissible mounting set-up
Mounting of the actuators and the safety switches
Refer to the mounting instructions manual for the corresponding
actuator.
3.2 Dimensions
All measurements in mm.
40
220
155,5
5
6,5
32,5
38
7,5
M20x1,5
3,3
GN
RD
YE
20 1
±
4. Rear side 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.
The power supply for the safety switch must provide protection against
permanent overvoltage. To that effect, stabilised PELV supply units
must be used. The safety outputs can be directly integrated in the
safety circuit of the control system. For applications up to PL e / control
category 4 to EN ISO 13849-1, the safety outputs of the safety switch
(max. 31 components in a series-wiring) must be connected to a
safety-monitoring module of the same control category (refer to wiring
examples). Inductive loads (e.g. contactors, relays, etc.) are to be
provided with suitable interference suppression circuitry.
Requirements for the connected safety-monitoring module:
Dual-channel safety input
suitable for 2 p-type semi-conductor outputs
Test function
The safety-monitoring module must tolerate internal functional tests of
the sensors with cyclic switch-off of the sensor outputs for max. 2 ms
(typically < 1 ms). The switch-off stage of the test cycle is temporarily
reduced by an active ohmic discharge of the cable. The safety-
monitoring module does not need to have a cross-wire short monitoring
function, if necessary, the cross-wire short monitoring function must be
disabled.
Cable
The cable entry is realised by a metric M20 x 1.5 gland. This gland
must be dimensioned by the user so that it is suitable for the cable
used. A cable gland with strain relief and suitable IP protection class
must be used.
40 5
The maximum cable length is 200 m (for ST2 M12 connectors approx.
20 m depending on the cable section used for an operating current
of 0.5 A). The maximum cable section is 1.5 mm2, incl. conductuor
ferrules. Prior to the connection, the cable must be stripped by 40+5
mm and insulated by 5 mm. The fitted 24V, X1, X2 bridge is included in
the delivery of …-1P2P and …-SD2P.

4
Operating instructions
Safety switch AZ 200 T
EN
5. Operating principle and diagnostic functions
5.1 Safety switch with conventional diagnostic output
Mode of operation of the safety outputs
The opening of the safety guard causes the safety outputs to be
disabled within the risk time.
Recommended suitable safety-monitoring modules
Control category 4, PL e: SRB 031MC, SRB 301LC / B, SRB 301ST,
SRB 304ST, SRB 324ST, PROTECT PSC
Control category 3, PL d: AES 1135, AES 1235
Operating principle of the electronic diagnostic output
The short-circuit proof diagnostic output can be used for central
visualisation or control functions, e.g. in a PLC. The closed condition of
the safety guard and the inserted condition of the actuator is indicated
by means of a 24V signal.
The diagnostic output is not a safety-related output!
Diagnostic outputs
The AZ 200 .-.1P2P safety switch has a diagnostic output: OUT
OUT: Door closed, actuator inserted and no fault detected
The AZ 200 .-.3P2P safety switch has three diagnostic outputs:
OUT, OUT2, OUT3
OUT: Door closed, actuator inserted
OUT2 Error warning
OUT3 Guard door detected
The diagnostic outputs are protected against short-circuits by means of
a common current limitation circuit.
Therefore: IOUT + IOUT2 + IOUT3 ≤ Ie2
Error
Errors, which no longer guarantee the function of the AZ 200 T (internal
errors) cause the safety outputs to be disabled. Any error that does not
immediately affect the safe functionality of the safety switch (e.g. cross-
wire short, temperature error, safety output, short circuit to 24 VDC) will
lead to a delayed shut-down (refer to table 2).
After fault rectification, the error message is reset by opening and re-
closing the corresponding safety guard. The safety outputs enable and
allow a restart.
If more than one fault is detected at the safety outputs, the
AZ 200 will be electronically locked and a normal fault reset
will no longer be possible. The AZ 200 locks itself when the
following faults occur; in that case, the component can only
be reset by switching off the operating voltage.
Cross-wire short at the enabled safety outputs
both safety outputs (Y1 and Y2) bridged at +Ub
Error warning
A fault has occurred, which causes the safety outputs to be disabled
after 30 minutes. The safety outputs initially remain enabled. This
enables the shutdown of the process in a controlled manner. An error
warning is deleted in the slave when the error cause is eliminated.
Table 1: the diagnostic function of the AZ 200 safety switch
The safety switchgear signals the operational state as well as errors through three coloured LED’s installed on the front side of the device.
System condition LED Safety outputs Diagnostic outputs
Y1, Y2 -1P2P -3P2P
green red yellow OUT OUT OUT2 OUT3
Safety guard open On Off Off 0 V 0 V 0 V 0 V 0 V
Door closed,
actuator not inserted
On Off Off 0 V 0 V 0 V 0 V 24 V
Door closed,
actuator inserted
On Off On 24 V
(if X1 = X2 = 24 V)
24 V 24 V 0 V 24 V
Error warning1), actuator inserted,
shutdown approaching
On Flashes 2) On 24 V
(if X1 = X2 = 24 V)
0 V 24 V 24 V 24 V
Error On Flashes Off 0 V 0 V 24 V / 0 V 24 V 24 V / 0 V
1) after 30 min -> 0 V
2) refer to flash code

5
AZ 200 T
Operating instructions
Safety switch
EN
Table 2: flash codes red LED
Flash codes
(red)
Designation Autonomous
switch-off after
Error cause
1 flash pulse Error (warning) at output Y1 30 min Fault in output test or voltage at output Y1,
although the output is disabled.
2 flash pulses Error (warning) at output Y2 30 min Fault in output test or voltage at output Y2,
although the output is disabled.
3 flash pulses Error (warning) cross-wire short 30 min Cross-wire short between the output cables or fault at both outputs
4 flash pulses Error (warning) temperature
too high
30 min The temperature measurement reveals an internal temperature
that is too high
5 flash pulses Actuator fault 0 min incorrect or defective actuator
6 flash pulses Error actuator combination 0 min An invalid combination of targets was detected at the 4 coils of the
AZ 200.-T. (Currently set: blocking bolt detected & door target not
detected => blocking bolt breakage detection or tamper attempt)
Continuous red
signal
Internal error 0 min
Diagnostic error (warning)
If an error (warning) is signalled in the response byte, detailed fault
information can be read out.
Flash codes red LED refer to table 2
Accessories for the series-wiring
To provide for a comfortable wiring and series-wiring of SD
components, the SD junction boxes SD-2V-F-SK (variant for the field in
closed enclosure) and SD-2V-S-SK (variant for DIN rail mounting in the
control cabinet) are available.
6. Set-up and maintenance
6.1 Functional testing
The safety function of the safety components must be tested. The
following conditions must be previously checked and met:
1. Check max. axial misalignment of actuator and safety switchgear
2. Check fixation of the safety switch and the actuator
3. Check the integrity of the cable entry and connections
4. Check the switch enclosure for damage
6.2 Maintenance
A regular visual inspection and functional test, including the following
steps, is recommended:
1. Check max. axial misalignment of actuator and safety switchgear
2. Check fixation of the safety switch and the actuator
3. Remove particles of dust and soiling
4. Check cable entry and connections
Damaged or defective components must be replaced.
7. Disassembly and disposal
7.1 Disassembly
The safety switchgear must be disassembled in a de-energised
condition only.
7.2 Disposal
The safety switchgear must be disposed of in an appropriate manner in
accordance with the national prescriptions and legislations.
Table 3: I/O data and diagnostic data
5.2 Safety switch with serial diagnostic function
Safety switches with serial diagnostic cable have a serial input and
output cable instead of the conventional diagnostic output. If safety
switches are wired in series, the diagnostic data is transmitted through
the series-wiring of the inputs and outputs.
Max. 31 safety switches can be wired in series. For the evaluation of the
serial diagnostic cable, either the PROFIBUS-Gateway SD-I-DP-V0-2 or
the Universal Gateway SD-I-U-... are used. This serial diagnostic interface
is integrated as slave in an existing field bus system. In this way, the
diagnostic signals can be evaluated by means of a PLC.
The response data and the diagnostic data are automatically and
permanently written in an input byte of the PLC for each safety switch
in the series-wired chain. In case of a communication error between the
field bus gateway and the safety switch, the switching condition of the
interlocking device is maintained.
Error
A fault has occurred, which causes the safety outputs to be disabled.
The fault is reset, when the cause is eliminated and bit 7 of the request
byte changes from 1 to 0 or the safety guard is opened.
Faults at the safety outputs are only deleted upon the next release, as
the fault rectification cannot be detected sooner.
If more than one fault is detected at the safety outputs, the
AZ 200 will be electronically locked and a normal fault reset
will no longer be possible. The AZ 200 locks itself when the
following faults occur; in that case, the component can only
be reset by switching off the operating voltage.
Cross-wire short at the enabled safety outputs
both safety outputs (Y1 and Y2) bridged at +Ub
Error warning
A fault has occured, which causes the safety outputs to be disabled
after 30 minutes. The safety outputs initially remain enabled. This
enables the shutdown of the process in a controlled manner. An error
warning is deleted when the cause of error is eliminated.

6
Operating instructions
Safety switch AZ 200 T
EN
Table 3: I/O data and diagnostic data
Bit n° Request byte Response byte Diagnostic error warning Diagnostic error
Bit 0: --- Safety output activated Error output Y1 Error output Y1
Bit 1: --- Actuator detected Error output Y2 Error output Y2
Bit 2: --- --- Cross-wire short Cross-wire short
Bit 3: --- --- Temperature too high Temperature too high
Bit 4: --- Input condition X1 and X2 --- incorrect or defective actuator
Bit 5: --- Guard door detected Internal device error Internal device error
Bit 6: --- Error warning Communication error between the
field bus Gateway and the safety
switch
---
Bit 7: Error reset Error (enabling path switched off) --- ---
The described condition is reached, when Bit = 1
Wiring example 3: series-wiring of the AZ 200.-T-1P2P.
The series-wiring of multiple AZM 200 solenoid interlocks is realised by
wiring in the control cabinet or in on-site junction boxes.
In the example, 3 AZ 200.-T-1P2P safety switches (max. 31
components) are wired in series. The diagnostic output ("OUT") are
separately wired to a conventional PLC for evaluation or control. The
maximum cable length of the safety circuits must not exceed 200 m.
In the series-wiring, the 24V-X1-X2 bridge must be removed from all
components up to the last component (refer to wiring example).
AZ 200.-T-1P2P
Y1 Y2 OUTGND
24V 24V X1 X2
AZ 200.-T-1P2P
Y1 Y2 OUTGND
24V 24V X1 X2
AZ 200.-T-1P2P
Y1 Y2 OUTGND
24V 24V X1 X2
+24VDC
0V
IN
IN
IN
n participants
max. 31 components in
series
Diagnostic output
Safety outputs
Safety-monitoring
module
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.
Wiring example 1: AZ 200.-T-1P2P.
Y1 Y2 OUTGND
24V 24V X1 X2 IN
GND
24V
AZ 200.-T-1P2P
S12
A1 S22
A2
+24VDC
0V
SPS/PLC
OUT3
OUT1 OUT2
IN3
IN1 IN2
SRB
Wiring example 2: AZ 200.-T-3P2P.
S12
A1 S22
A2
+24VDC
0V
SPS/PLC
OUT3
OUT1 OUT2
GND
24V
OUT4
AZ 200.-T-3P2P
Y1 Y2 OUTGND
24V 24V OUT2 OUT3 IN
IN3
IN1 IN2 IN4
SRB

7
AZ 200 T
Operating instructions
Safety switch
EN
8.2 Connection example
Table 4: wiring of the solenoid interlock with cable or with integrated connector
Pin configuration
of the version
with connector
Wiring, safety switch with 1
diagnostic output ...-1P2P
Wiring, safety switch with
serial diagnostic ...-SD2P
Wiring, safety switch with 3
diagnostic outputs ...-3P2P
integrated connector
Pin 1 24 V Operating voltage 24 V Operating voltage 24 V Operating voltage M23 connector (8+1) pole
(suffix -ST1)
1
2
9
3
45
6
7
8
M12, 8-pole (suffix -ST2)
5
8
4
3
2
1
7
6
Pin 2 X1 Safety input 1 X1 Safety input 1 OUT 2 diagnostic output 2
Pin 3 GND Ground GND Ground GND Ground
Pin 4 Y1 Safety output 1 Y1 Safety output 1 Y1 Safety output 1
Pin 5 OUT diagnostic output OUT SD output OUT diagnostic output 1
Pin 6 X2 Safety input 2 X2 Safety input 2 OUT 3 diagnostic output 3
Pin 7 Y2 Safety output 2 Y2 Safety output 2 Y2 Safety output 2
Pin 8 IN (do not use) IN SD input IN (do not use)
Pin 9 spare spare spare
Suffix
-SK
-CC
AZ 200.-.-1P2P
Y1 Y2 OUTGND
24V 24V X1 X2 IN
AZ 200.-.-SD2P
Y1 Y2 OUTGND
24V 24V X1 X2 IN
AZ 200.-.-3P2P
Y1 Y2 OUTGND
24V 24V OUT2 OUT3 IN

8EN
AZ 200 T-C-EN
Operating instructions
Safety switch AZ 200 T
9. EU Declaration of conformity
Name of the component: AZ 200
Type: See ordering code
Description of the component: Safety Switch for safety functions
Relevant Directives: Machinery Directive
EMC-Directive
RoHS-Directive
2006/42/EC
2014/30/EU
2011/65/EU
Applied standards: EN 60947-5-1:2004 + AC:2005 + A1:2009,
EN 60947-5-3:2013,
ISO 14119:2013,
EN ISO 13849-1:2008 + AC:2009,
EN 61508 parts 1-7:2010,
EN 62061:2005 + AC:2010 + A1:2013
Notied body for the prototype test: TÜV Rheinland Industrie Service GmbH
Alboinstr. 56, 12103 Berlin
ID n°: 0035
EC-prototype test certicate: 01/205/5122.01/15
Person authorised for the compilation
of the technical documentation:
Oliver Wacker
Möddinghofe 30
42279 Wuppertal
Place and date of issue: Wuppertal, December 19, 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.
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