schmersal TESF series User manual

TESF
Operating instructions
Hinge 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 selec-
tion, mounting and integration of the components.
1.3 Explanation of the symbols used
Information, hint, note:
This symbol is used for identifying useful additional informa-
tion.
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 manufac-
turer. Detailed information regarding the range of applications can be
found in the chapter "Product description".
1.5 General safety instructions
The user must observe the safety instructions in this operating instruc-
tions manual, the country-specific installation standards as well as all
prevailing safety regulations and accident prevention rules.
Further technical information can be found in the Schmersal
catalogues or in the online catalogue on the Internet:
www.schmersal.net.
The information contained in this operating instructions manual is pro-
vided 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.
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 when safety switchgear is
used. The relevant requirements of the standard ISO 14119
must be 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 ...................................1
1.7 Exclusion of liability .....................................2
2 Product description
2.1 Ordering code .........................................2
2.2 Special versions........................................2
2.3 Destination and use .....................................2
2.4 Technical data .........................................2
2.5 Safety classication .....................................2
3 Mounting
3.1 General mounting instructions .............................3
3.2 Dimensions ...........................................3
4 Electrical connection
4.1 General information for electrical connection..................3
4.2 Contact variants........................................4
4.3 Switch travel...........................................4
4.4 Door gap calculation ....................................5
5 Set-up and maintenance
5.1 Functional testing.......................................5
5.2 Maintenance ..........................................5
6 Disassembly and disposal
6.1 Disassembly...........................................5
6.2 Disposal ..............................................5
7 EU Declaration of conformity
x.000 / Januar 2017 / v.A. - 101183077-EN / H / 2017-01-02 / AE-Nr. 6938
EN Operating instructions. . . . . . . . . . . . .pages 1 to 6
Original

2
Operating instructions
Hinge safety switch TESF
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 result-
ing from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary re-
pairs, conversions and modifications to the device are strictly forbidden;
the manufacturer shall accept no liability for damages resulting from
such invasive work, arbitrary repairs, conversions and/or modifications
to the device.
2. Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
TESF ➀ /
➁
/
➂
/
➃
/
➄
No. Option Description
➀
without end stop
A with end stop
➁
with additional hinge
S without additional hinge
➂
Screw connection
CC Cage clamps
ST24 24V connector
➃
.1 Bottom-side connector
.2 Top-side connector
➄
0 preset for front assembly
180 preset for inside assembly
U adjustable on site
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 TESF hinge safety switch has been designed to prevent, in con-
junction with the control part of a machine, movable safety guards from
being opened before hazardous conditions have been eliminated. They
are also suitable for fitting on profile sections and existing equipment.
Hinge safety switches can only be used for applications, in
which the hazardous condition is terminated without delay
(e.g. run-on movements) when the safety guard is opened.
The user must evaluate and design the safety chain in
accordance with the relevant standards and on the requi-
red safety level.
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
Standards: IEC 60947-5-1; BG-GS-ET-15
Enclosure: Zinc diecast, enclosure cover
self-extinguishing thermoplastic
Hinge bolt: Stainless steel 1.4305
Contact material: Silver, gold-plated
Protection class: IP65
Contact type: Change-over contact with double break Zb
Switching system: A IEC 60947-5-1; slow action,
NC contact with positive break
Connection: Screw terminals,
cage clamps, connector
Cable type: solid wire
Cable section:
- Screw terminals: min. 0.14 mm², max. 1.5 mm²
- Cage clamps: min. 0.25 mm², max. 1 mm²
Cable type: stranded wire
Cable section:
- Screw terminals: min. 0.25 mm², max. 1 mm²,
with conductor ferrules,
- Cage clamps: min. 0.25 mm², max. 0.75 mm²
with conductor ferrules
Cable entry: 2 x M16
Positive break angle: 10°
Actuating speed: max. 180°/0.3 s
Actuating frequency: max. 1200 operations/h
Mechanical life: > 1 million operations
Ambient temperature: −25 °C … +65 °C
Utilisation category: AC-15, DC-13
Rated operating current/voltage Ie/Ue:2 A / 230 VAC;
1 A / 24 VDC
Rated insulation voltage Ui:250 V,
- Connector ST24: 36 V
Rated impulse withstand voltage Uimp:2.5 kV,
- Connector ST24: 0.8 kV
Thermal test current Ithe:2.5 A
Max. rated operating voltage Ue max:24 VDC
230 VAC
- Connector ST24: 24 VAC
Max. fuse rating: 2 A gG D-fuse
Required short-circuit current: 1000 A
Switching of low voltages: 1 mA / 5 VDC
Mechanical data (see Fig.):
- F1: 5,000 N
- F2: 5,000 N
- F3: 1,900 N
- F4: 800 N
F1
F2
F4
F3
F1
F2
F3
F4
2.5 Safety classification
Standards: ISO 13849-1
Envisaged structure:
- Basically: applicable up to Cat. 1 / PL c
- With 2-channel usage and
fault exclusion mechanism*: applicable up to Cat. 3 / PL d
with suitable logic unit
B10d NC contact: 2,000,000
B10d NO contact at 10% ohmic contact load: 1,000,000
Service life: 20 years
* If a fault exclusion to the 1-channel mechanics is authorised.
MT
TF
Bdxx
hs/h3600
D
10Dopop
op
n
0,1 x nop tcycle
(Determined values can vary depending on the application-specific
parameters hop, dop and tcycle as well as the load.)
If multiple safety components are wired in series, the Performance Lev-
el to ISO 13849-1 will be reduced due to the restricted error detection
under certain circumstances.

3
TESF
Operating instructions
Hinge safety switch
EN
3. Mounting
3.1 General mounting instructions
During fitting of the actuator and the sensor, the requirements
of ISO 14119, especially paragraph 7 must be observed!
Four mounting holes are provided for fixing the switch. When used in
applications with function for the protection of man, the components
must be fitted so that disassembly is prevented (e.g. drill out the hexag-
onal recess of the fixing screws, blocking the hexagonal recess using a
plastic cone diamater 5.1 mm). The hinge switch furthermore must be
pinned after assembly and adjustment (Fig. 1). The hinge safety switch
must not be used as an end stop. Any mounting position. The mounting
position however is chosen so that the components are preferably fitted
in the upper part of the safety guard to avoid the ingress of dirt and soil-
ing as well as damage to the components. In case of painting activities,
the components must be covered. The supplied fixing material must
be used. We recommend that the fixing screws are painted after the
component is fitted.
II
II
A)
Fig. 1
Legend:
A = Drill and pin in this area
Please observe the remarks of the standards ISO 12100,
EN 953 and ISO 14119. Also observe the safety distances
to the standards ISO 13857 and EN 349.
3.2 Dimensions
All measurements in mm.
TESFA TESFA/S
6.1
100
25.525.5
41.541.5
75.5
115
90
M16x1,5
51
4
11
21.5
40
6.1
55
5151
25.5
41.5
25.5
41.5
22
11
4
TESF TESF/S
6.1
100
25.525.5
41.541.5
75.5
115
4
11
21.5
90
M16x1,5
51
40
6.1
55
5151
25.5
41.5
25.5
41.5
22
11
4
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. For the
cable entry, only suitable cable glands and for the connector
suitable plugs with an appropriate degree of protection must
be used.
1. Open the enclosure cover of the hinge switch.
2. Connect the wires and cables. For flexible leads, conductor ferrules
must be used. In the area of the metal thread at the cable input in the
wiring compartment, the supplied protective tube (shrink tube) must
be used.
3. After the switch has been fitted, the switching function and the open-
ing angle of the safety guard must be checked. The switching angle
of the NC contacts set in factory is approximately 3°. Caution: for the
TESF.../U version, the following paragraph "Special instructions for
the on-site setting" imperatively must be observed!
4. Follow the steps below to put back the enclosure cover:
– Firmly push the enclosure cover under an angle of approx. 30°
onto the retaining collar (Fig. 2) and simultaneously exercise a
downwards pressure (Fig. 3).
– Uniformly tighten the 3 cover screws (Fig. 4) with 0.6 Nm tighten-
ing torque.
– The contact labelling can be found in the wiring compartment of
the switch.
30°
F
Fig. 2 Fig. 3
F
Fig. 4
After the switch has been fitted, the switching function and the opening
angle of the safety guard must be checked. The opening angle of the
NC contacts set in factory is approximately 3°.

4
Operating instructions
Hinge safety switch TESF
EN
Special instructions for the on-site setting (version TESF.../U)
We recommend a setting including the following steps:
1. Open the safety guard up to the maximum authorised opening angle.
2. Open the enclosure cover of the hinge switch.
3. Wire both NC contacts parallel, connect terminal 11 with 31 and
terminal 12 with 32 (Fig. 5).
4. Connect the continuity tester to the terminals 11/12 of the NC con-
tacts or use the test handles at the terminals (Fig. 5).
5. Use the adjustment tool to set the NC contacts so that their opening
is ensured at the maximum authorised safety guard opening angle.
Turn clockwise to decrease the switching angle, turn counterclock-
wise to increase the switching angle (Fig. 6); when mounted inside
accordingly reversed. The positive break angle is 7° larger than the
set switching angle.
6. After the switch is set, the compliance of the switch with the safe-
ty-technical requirements of the application must be checked.
7. After the switching angle has been set and checked, the blanking
plug for the adjustment opening located at the rear of the adjustment
tool must be inserted in the adjustment opening (1) and torn down by
making lateral movements (2) with the tool (Fig. 7).
After the desired switching point is set, the opening of the set-
ting option imperatively must be sealed with a blanking plug.
This measure prevents tampering at the set switching point
within the meaning of ISO 14119 paragraph 7 and therefore
avoids any loss of the safety function of the device.
The blanking plug is injected to the special adjustment tool
with a predetermined breaking point.
We recommend an additional painting or glueing of the
blanking plug.
Securing the setting screw by means of the blanking plug is a
mandatory instruction for the user, which must be oberved in
order to maintain the CE-Conformity of the component.
bridge
11/31
12/32
Test output
11/12
Fig. 5
+
-
Fig. 6 Fig. 7
The versions TESF.../ST24 must only be used in PELV cir-
cuits according to EN 60204.
4.2 Contact variants
Contacts are shown with safety guard closed.
TESF... / TESF.../CC
11 12 23 24 31 32 43 44
11 12 31 32
23 24 43 44
AA
TESF... / TESF.../CC
1234
11 12
5678
31 32
23 24 43 44
AA
5
8
4
3
2
1
7
6
Accessories
Connecting cable with
M12 coupling, 8-pole, straight
Type designation Cable length Ordering code
A-K8P-M12-S-G-2.5M-BK-2-X-A-4
A-K8P-M12-S-G-5M-BK-2-X-A-4
A-K8P-M12-S-G-10M-BK-2-X-A-4
A-K8P-M12-S-G-15M-BK-2-X-A-4
2.5 m
5.0 m
10 m
15 m
103011415
103007358
103007359
103011414
Pin configuration
5
8
4
3
21
7
6
1 WH
2 BN
3 GN
4 YE
5 GY
6 PK
7 BU
8 RD
4.3 Switch travel
(10°) 180°
3°
11-12
31-32
43-44
23-24
A
A
Key
A Positive break NC contact
T Positive break travel / -angle,
taking tolerances and wear into account

5
TESF
Operating instructions
Hinge safety switch
EN
4.4 Door gap calculation
Calculation of the door gap depending on the opening angle,
door width and overlapping
β3° 4° 5° 6° 7° 8° 9° 10°
C D
100 5.2 7.0 8.7 10.4 12.2 13.9 15.6 17.4
150 7.8 10.5 13.1 15.7 18.3 20.9 23.5 26.0
200 10.5 13.9 17.4 20.9 24.4 27.8 31.3 34.7
250 13.1 17.4 21.8 26.1 30.5 34.8 39.1 43.3
300 15.7 20.9 26.1 31.3 36.5 41.7 46.9 52.1
350 18.3 24.4 30.5 36.6 42.6 48.7 54.7 60.7
400 20.9 27.9 34.8 41.8 48.7 55.6 62.5 69.4
450 23.5 31.4 39.2 47.0 54.8 62.6 70.4 78.1
500 26.2 34.9 43.6 52.2 60.9 69.6 78.2 86.8
550 28.8 38.3 47.9 57.5 67.0 76.5 86.0 95.5
600 31.4 41.8 52.3 62.7 73.1 83.5 93.8 104.1
650 34.0 45.3 56.6 67.9 79.2 90.4 101.6 112.8
700 36.6 48.8 61.0 73.1 85.3 97.4 109.4 121.5
750 39.2 52.3 65.3 78.4 91.4 104.3 117.3 130.2
800 41.8 55.8 69.7 83.6 97.4 111.3 125.1 138.8
850 44.5 59.3 74.0 88.8 103.5 118.2 132.9 147.5
900 47.1 62.7 78.4 94.0 109.6 125.2 140.7 156.2
950 49.7 66.2 82.8 99.3 115.7 132.1 148.5 164.9
1,000 52.3 69.7 87.1 104.5 121.8 139.1 156.4 173.6
1,050 54.9 73.2 91.5 109.7 127.9 146.1 164.2 182.2
1,100 57.5 76.7 95.8 114.9 134.0 153.0 172.0 190.9
1,150 60.2 80.2 100.2 120.1 140.1 160.0 179.8 199.6
1,200 62.8 83.7 104.5 125.4 146.2 166.9 187.6 208.3
1,250 65.4 87.2 108.9 130.6 152.3 173.9 195.4 217.0
1,300 68.0 90.6 113.2 135.8 158.4 180.8 203.3 225.6
1,350 70.6 94.1 117.6 141.0 164.4 187.8 211.1 234.3
1,400 73.2 97.6 122.0 146.3 170.5 194.7 218.9 243.0
1,450 75.8 101.1 126.3 151.5 176.6 201.7 226.7 251.7
1,500 78.5 104.6 130.7 156.7 182.7 208.7 234.5 260.3
β = Door opening angle
C = Door width in mm
D = Door gap in mm for overlapping B = 0 mm
B = Door thickness
Calculation example
The actual door gap "D1" is calculated using door gap "D" calculated by
means of the table above minus the overlapping "B" of door and frame:
D1 = D – B
Example:
A door made of 40 mm aluminium profile with a length of 950 mm
should be secured with a TESF. The safety contact of the TESF opens
to 3° when new according to the technical safety sheet (10° at the end
of its service life). The table above shows the door gap when new at ap-
prox. 49.7 mm. The real door gap can be calculated with the following
equation D1 = D – B; (49.7 – 40 = 9.7); D1 = 9.7 mm. At the end of the
service life the door gap is approx. 164.9 mm and the real door gap is
(164.9 – 40 = 124.9); D1 = 124.9 mm.
C
β
D1
D
B
5. Set-up and maintenance
5.1 Functional testing
The safety function of the safety components must be tested. The
following conditions must be previously checked and met:
1. Correct fixing of the component
2. Check the integrity of the cable entry and connections
3. Check the switch enclosure for damage
5.2 Maintenance
A regular visual inspection and functional test, including the following
steps, is recommended:
1. Check fitting of the hinge safety switch
2. Remove particles of dust and soiling
3. Check cable entry and connections
4. Examination of the switching angle
Damaged or defective components must be replaced.
6. Disassembly and disposal
6.1 Disassembly
The safety switchgear must be disassembled in a de-energised condi-
tion only.
6.2 Disposal
The safety switchgear must be disposed of in an appropriate manner in
accordance with the national prescriptions and legislations.

6EN
TESF-F-EN
Operating instructions
Hinge safety switch TESF
7. EU Declaration of conformity
Name of the component: TESF
Type: See ordering code
Description of the component: Hinge safety switch
Relevant Directives: Machinery Directive
RoHS-Directive
2006/42/EC
2011/65/EU
Applied standards: DIN EN ISO 60947-5-1:2010,
DIN EN ISO 14119:2014,
Person authorised for the compilation
of the technical documentation:
Oliver Wacker
Möddinghofe 30
42279 Wuppertal
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
Place and date of issue: Wuppertal, January 2, 2017
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.