schmersal AZ 200 User manual

AZ 200
Operating instructions
Safety switches
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 Comprehensive quality insurance to 2006/42/EC ..............2
2.4 Purpose ..............................................2
2.5 Technical data .........................................2
2.6 Safety classication .....................................3
3 Mounting
3.1 General mounting instructions .............................3
4 Electrical connection
4.1 General information for electrical connection..................3
5 Operating principle and diagnostic functions
5.1 Mode of operation of the safety outputs......................4
5.2 Diagnostic-LEDs .......................................4
5.3 Operating principle of the electronic diagnostic output ..........4
5.4 Safety switch with serial diagnostic function SD ...............5
6 Set-up and maintenance
6.1 Functional testing.......................................6
6.2 Maintenance ..........................................6
7 Disassembly and disposal
7.1 Disassembly...........................................6
7.2 Disposal ..............................................6
8 Appendix
8.1 Wiring examples .......................................6
8.2 Wiring conguration and connector accessories ...............7
9 EU Declaration of conformity
x.000 / 01.2020 / v.A. - 101186190-EN / I / 2020-01-06/ AE-Nr. 11745
EN Operating instructions. . . . . . . . . . . . .pages 1 to 8
Original

2
Operating instructions
Safety switches AZ 200
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 ISO 14119 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 terminals
CC Cage clamps
ST1 M23 x 1 connector (8+1) pole
ST2 M12 x 1 connector, 8 pole
➁
1P2P 1 p-type diagnostic output and 2 p-type
safety outputs
SD2P serial diagnostic output and
2 p-type safety outputs
Actuator suitable for
AZ/AZM 200-B1-… Sliding safety guards
AZ/AZM 200-B30-… Hinged safety guards
Only if the information described in this operating instructions
manual are realised correctly, the safety function and therefo-
re 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 Comprehensive quality insurance to 2006/42/EC
Schmersal is a certified company to appendix X of the Machinery
Directive. As a result, Schmersal is entitled to autonomously conduct
the conformity assessment procedure for the products listed in
Appendix IV of the MD without involving a notified body. The prototype
test certificates are available upon request or can be downloaded from
the Internet at www.schmersal.com.
2.4 Purpose
The non-contact, electronic safety switchgear 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.
The safety switchgears are classified according to
ISO 14119 as type 4 interlocking devices.
Series-wiring
Series-wiring can be set up for devices AZ 200...-1P2P. Response
and risk times remain unchanged by series-wiring. The number of
components is only limited by the external cable protection according to
the technical data and the line loss. Series-wiring of up to 31
AZ200…-SD components with serial diagnostics is possible. In devices
with the serial diagnostics function (ordering suffix -SD), the serial
diagnostics connections are wired in series and connected to a SD-
Gateway for evaluation purposes. Wiring examples for series-wiring,
refer to appendix
The user must evaluate and design the safety chain in
accordance with the relevant standards and the required
safety level. If multiple safety switchgears are involved in
the same safety function, the PFH values of the individual
components must be added.
The entire concept of the control system, in which the safety
component is integrated, must be validated to the relevant
standards.
2.5 Technical data
Standards: IEC 60947-5-3, ISO 14119, ISO 13849-1, IEC 61508
Enclosure: glass-fibre reinforced thermoplastic, self-extinguishing
Working principle: inductive
Coding level according to ISO 14119: low
Mechanical life: ≥ 1 million operations
Latching force: 30 N
Protection class: IP66, IP67 to IEC 60529
Insulation protection class: II, P
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 (Torx T10)
Cable entry: M20 x 1.5
Series-wiring: Unlimited number of components,
please observe external cable protection,
max. 31 components in case of serial diagnostics
Length of the sensor chain: max. 200 m
Switching distances to IEC 60947-5-3:
Rated operating distance Sn:6.5 mm
Assured switching distance Sao:4 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
Actuating speed: ≤ 0.2 m/s

3
AZ 200
Operating instructions
Safety switches
EN
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 fuse rating: 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
Accepted test pulse duration on input signal: ≤ 1.0 ms
- With test pulse interval of: ≥ 100 ms
Classification: ZVEI CB24I
Sink: C1 Source: C1 C2 C3
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
Test pulse duration: ≤ 1.0 ms
Test pulse interval: 1000 ms
Classification: ZVEI CB24I
Source: C1 Sink: C1
Diagnostic output OUT: short-circuit proof, p-type
Rated operating voltage Ue2:0 V ... 4 V under Ue
Operating current Ie2:max. 0,05 A
Utilisation category: DC-13
Wiring capacitance for serial diagnostics: max. 50 nF
LED switching conditions display:
green LED: Supply voltage
yellow LED: Operating condition
red LED: Fault
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.
2.6 Safety classification
Standards: ISO 13849-1, IEC 61508
PL: e
Control Category: 4
PFH value: 4 x 10-9 / h
SIL: suitable for SIL 3 applications
Mission time: 20 years
3. Mounting
3.1 General mounting instructions
For fitting the 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).
Minimum distance between two safety switches: 100 mm
Please observe the relevant requirements of the standards
ISO 12100, ISO 14119 and ISO 14120.
Mounting of the actuators
Refer to the mounting instructions manual for the corresponding
actuator.
The actuator must be permanently fitted to the safety guards
and protected against displacement by suitable measures
(tamperproof screws, gluing, drilling of the screw heads).
Dimensions
All measurements in mm.
40
220
155,5
5
6,5
32,5
38
7,5
M20x1,5
3,3
20 1
±
50
Power
Fault
Status
ST1
GN
RD
YL
M23
24,4
15,5
M12
40
220
155,5
32,5
5
6,5
7,5
20±150
ST3
3,3
38
7,7
13,3
89
ST2
GN
RD
YL
M23
24,4
15,5
M12
40
220
155,5
32,5
5
6,5
7,5
20±150
ST3
3,3
38
7,7
13,3
89
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.
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 in accordance with ISO 13849-1, the safety
outputs of the safety switch must have an assessment with the same
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
Configuration of the safety controller
If the safety switchgear is connected to electronic safety-
monitoring modules, we recommend that you set a
discrepancy time of 100 ms. The safety inputs of the safety-
monitoring module must be able to blank a test impulse of
approx. 1 ms. 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.
Information for the selection of suitable safety-monitoring
modules can be found in the Schmersal catalogues or in the
online catalogue on the Internet: www.schmersal.net.
If the safety component is wired to relays or to non-safety relevant
control components, a new risk analysis must be carried out.

4
Operating instructions
Safety switches AZ 200
EN
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.
5. Operating principle and diagnostic functions
5.1 Mode of operation of the safety outputs
The opening of the safety guard causes the safety outputs to be
disabled within the risk time.
5.2 Diagnostic-LEDs
The safety switchgear signals the operational state as well as errors
through three coloured LEDs installed on the front side of the device.
green (Power) Supply voltage on
yellow (Status) Switching condition
red (Fault) Fault (refer to table 2)
5.3 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.
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 a safety switch will lead to a
delayed shut-down (refer to table 2).
After fault rectification (fault at output Y1 or Y2, temperature fault), the
fault is acknowledged by opening and relocking the relevant guard door.
The safety outputs enable and allow a restart.
Automatic, electronic locking takes place if more than one
fault is detected at the safety outputs or a cross circuit is
detected between Y1 and Y2. This means that normal fault
acknowledgement is no longer possible. To reset this type
of interlocking, the safety switch must be isolated from the
power supply after elimination of the error causes.
Table 1: The diagnostic function of the safety switchgear
System condition LED Safety outputs Diagnostic output
Y1, Y2 -1P2P
green red yellow OUT
Guard open On Off Off 0 V 0 V
Door closed,
actuator not inserted
On Off Off 0 V 0 V
Door closed,
actuator inserted
On Off On 24 V
(if X1 = X2 = 24 V)
24 V
Error warning1), actuator inserted,
shutdown approaching
On Flashes 2) On 24 V
(if X1 = X2 = 24 V)
0 V
Error On Flashes Off 0 V 0 V
1) after 30 min: shut-down due to error
2) see flash code
Table 2: Error messages / flash codes red diagnostic LED
Flash codes 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 actuators were detected
(blocking bolt detection or tamper attempt).
Continuous red
signal
internal error 0 min Device defective

5
AZ 200
Operating instructions
Safety switches
EN
5.4 Safety switch with serial diagnostic function SD
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. The request data for each safety switch are
transmitted to the component through an output byte of the PLC. 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.
Automatic, electronic locking takes place if more than one
fault is detected at the safety outputs or a cross circuit is
detected between Y1 and Y2. This means that normal fault
acknowledgement is no longer possible. To reset this type
of interlocking, the safety switch must be isolated from the
power supply after elimination of the error causes.
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.
Diagnostic error (warning)
If an error (warning) is signalled in the response byte, detailed fault
information can be read out.
Accessories SD interface
For ease of wiring and series-wiring of SD devices,
considerable accessories are available. Detailed information
is available on the Internet, www.schmersal.net.
On wiring SD devices, please pay attention to the voltage
drop on the cables and the current carrying capacity of the
individual components.
Table 3: I/O data and diagnostic data
The described condition is reached, when Bit = 1
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 1) Communication error between the
field bus Gateway and the safety
switch
---
Bit 7: Error reset Error (enabling path switched off) --- ---
1) after 30 min: disabling due to fault

6
Operating instructions
Safety switches AZ 200
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.
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: 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 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
Diagnostic output
Safety outputs
Safety-
monitoring
module
n-participants
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.
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
Adequate measures must be taken to ensure protection
against tampering either to prevent tampering of the safety
guard, for instance by means of replacement actuators.
Damaged or defective components must be replaced.

7
AZ 200
Operating instructions
Safety switches
EN
8.2 Wiring configuration and connector accessories
Safety switch
function
Pin configuration of the connector Colour code of
the Schmersal
connector
to DIN 47100
Possible colour codes
for more commercially
available connectors
based on
IEC 60947-5-2:2007
1 diagnostic output
1P2P
with serial
diagnostic function
SD2P
Connector plug ST1
M23, (8+1)-pole
Connector plug
ST2 M12, 8-pole
5
8
4
3
2
1
7
6
5
8
4
3
2
1
7
6
24V Ue1 1 WH BN
X1 Safety input 1 2 2 BN WH
GND GND 3 3 GN BU
Y1 Safety output 1 4 4 YE BK
OUT Diagnostic output SD output 5 5 GY GY
X2 Safety output 2 6 6 PK PK
Y2 Safety output 2 7 7 BU VT
IN without function SD input 8 8 RD OR
without function 9 -
AZ 200.-.-1P2P
Y1 Y2 OUTGND
24V 24V X1 X2 IN
AZ 200.-.-1P2P
Y1 Y2 OUTGND
24V 24V X1 X2 IN
Terminal block
-SK or -CC
Terminal block
-SK or -CC
Connector accessories
Connector with female plug
IP67, M23, (8+1)-pole - 8 x 0.75 mm²
Versions Ordering code
with soldering terminals
with crimp terminals
101209970
101209994
Further versions in other lengths and with angled cable exit are available upon request.

8EN
AZ 200 T-C-EN
Operating instructions
Safety switches AZ 200
Name of the component: AZ 200
Type: See ordering code
Description of the component: Safety Switch for safety functions
Relevant Directives: 2006/42/EC
2014/30/EU
2011/65/EU
Machinery Directive
EMC-Directive
RoHS-Directive
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, 19. December 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.
9. EU Declaration of conformity
K.A. Schmersal GmbH & Co. KG
Möddinghofe 30, D - 42279 Wuppertal
Deutschland
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