schmersal TESK Series User manual

TESK
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
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 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 Adjustment and inspection of the switching angle ..............4
3.3 Dimensions ...........................................5
4 Electrical connection
4.1 General information for electrical connection..................6
4.2 Contact variants........................................6
4.3 Switch travel...........................................6
5 Set-up and maintenance
5.1 Functional testing.......................................6
5.2 Maintenance ..........................................6
6 Disassembly and disposal
6.1 Disassembly...........................................6
6.2 Disposal ..............................................6
7 Appendix
7.1 Wiring conguration and connector accessories ...............7
7.2 Door gap calculation ....................................8
7.3 Load specications .....................................9
8 EU Declaration of conformity
x.000 / 06.2016 / v.A. - 103005958-EN / B / 2016-03-16 / AE-Nr. 5816
EN Operating instructions. . . . . . . . . . . .pages 1 to 10
Original

2
Operating instructions
Hinge safety switch TESK
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 when safety switchgear is
used. 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 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:
TESK- ➀ -
➁
-
➂
-
➃
-
➄
No. Option Description
➀
S Standard hinge
L Long hinge half
➁
APreset for front assembly
I Preset for inside assembly
U Freely adjustable switching angle
➂
22 2 NO contacts / 2 NC contacts
12 1 NO contacts / 2 NC contacts
13 1 NO contacts / 3 NC contacts
02 2 NC contacts
11 1 NO contacts / 1 NC contacts
➃
L1 Cable downwards
L2 Cable upwards
ST1 Connector plug bottom
ST2 Connector plug top
➄
3M Cable length 3 m (only L1 / L2)
5M Cable length 5 m (only L1 / L2)
10M Cable length 10 m (only L1 / L2)
20M Cable length 20 m (only L1 / L2)
30M Cable length 30 m (only L1 / L2)
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 TESK 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
required 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 pin: Galvanised steel / Steel C45
Mounting: 4 x M6 screws DIN 7984 or ISO 4762
with TESK-L… 6 screws,
Tightening torque 4.3 Nm
Contact material: Silver, gold-plated
Contact type: Change-over contact
with double break Zb
Switching system: IEC 60947-5-1; Slow action,
A positive break NC contacts
termination: connector plug M12 or cable
Connector plug: M12, 5-pole or 8-pole, A-coded
Connection cable: Y-UL 2464 / 9 x AWG 22 / 9 x 0.34 mm²
Y-UL 2464 / 5 x AWG 22 / 5 x 0.34 mm²
Temperature resistance of the cable:
- at rest: -25°C ... +80°C
- in motion: -5°C ... +80°C
Switching angle: 3° adjusted from zero point
Forced opening angle: 10° adjusted from zero point
Positive break torque: 0.35 Nm
Max. swivel angle: 270°
Actuating speed: max. 90° / 0.5 s
Bounce duration: in accordance with actuating speed
Switchover time: in accordance with actuating speed
Actuating frequency: max. 120 operations/h
Mechanical life: > 1 million switch cycles
- Note: The mechanical life relates to an opening
angle of 90° without passing over the switch
point. With pendulum flap functions that involve
moving over the switch point, the life cycle is reduced.
Resistance to shock: 30 g / 11 ms
Resistance to vibration: 10 ... 150 Hz,
amplitude 0.35 mm
Ambient temperature: −25 °C … +65 °C
Storage and transport temperature: −40 °C … +85 °C
Protection class: IP65 to IEC 60529
Protection class:
- with cable: I
- with connector plug M12, 8-pin: III
- with connector plug M12, 5-pin: I

3
TESK
Operating instructions
Hinge safety switch
EN
Utilisation category: AC-15, DC-13
Rated operating current/voltage Ie/Ue:
-with cable: 2 A / 230 VAC
1 A / 24 VDC
-with connector plug M12: 1 A / 24 VDC
Rated insulation voltage Ui:
- with cable: 300 V
- with connector plug, M12 8-pin: 30 V (PELV to DIN EN 60204-1)
- with connector plug, M12 5-pin: 60 V
Rated impulse withstand voltage Uimp:
- with cable: 2.5 kV
- with connector plug, M12 8-pin: 0.5 kV
- with connector plug, M12 5-pin: 0.8 kV
Thermal test current Ithe:2.5 A
Rated operating voltage Uemax:
- with cable: 230 V
- with connector plug M12, 8-pin: 30 V
- with connector plug M12, 5-pin: 60 V
Max. fuse rating: 2 A gG D-fuse
Switching of low voltages: 1 mA / 3 VDC
Mechanical breaking load (see fig. 1):
- F1: 5,000 N
- F2: 5,000 N
See Section 7.3 Load details
F1
F2
F1
F2
Fig. 1
C
For use in NFPA 79 Applications only.
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
10d op op
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
Level to ISO 13849-1 will be reduced due to the restricted error
detection under certain circumstances.
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 elongated holes are provided for fixing the switch. To facilitate the
alignment of the door to the post, alignment pins are supplied (not for
indoor use) that can be inserted into corresponding holes on the bottom
of the hinge switch (Fig. 2). Once installed, these can be removed again.
Fig. 2
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 hexagonal recess of the fixing screws, blocking the hexagonal
recess using a plastic cone diameter 5.1 mm).
The hinge switch furthermore must be pinned after assembly and
adjustment (Fig. 3).
A) A)
Fig. 3
Key
A = Drill and pin in this area
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 soiling as well as damage to the
components. In case of painting activities, the components must be
covered. Recommended mounting material, see technical data.
We recommend that the fixing screws are painted after the component
is fitted and to apply the accompanying caps (Figure 4.)

4
Operating instructions
Hinge safety switch TESK
EN
The minimum bending radius must be observed for versions
with a cable connection!
Please note the load information "Determining the
permissible forces as a function of door size and number
of hinges" (see Section 7.3 Load details)
The hinge safety switch must not be used as an end stop.
For applications in which heavy doors are used and for use
on hoods, especially if these can close with little or no braking
effect, further measures are to be implemented to prevent the
securing bolts from working loose. A reduction in the service
life is also expected. The use of hydraulic struts on hoods
is not permitted as otherwise the hinge switch would be
damaged beyond repair.
Fig. 4
Please observe the relevant requirements of the standards
ISO 12100, ISO 14119 and ISO 14120. Also observe the
safety distances to the standards ISO 13857 and EN 349.
3.2 Adjustment and inspection of the switching angle
After the switch has been fitted, the switching function and the opening
angle of the safety guard must be checked. The switching angle of the
NC contacts set in factory is approximately 3°.
Caution: for the TESK...-U version, the following paragraph
"Special instructions for the on-site setting" must be observed!
Special instructions for the on-site setting (version TESK...-U)
We recommend a setting including the following steps:
1. Open guard system up to maximum permissible door gap
(see table chapter 7.2 Determining door gap).
2. Use the adjustment tool to set the normally-closed contacts in such
a way that they are securely opened with the maximum permissible
door gap. Turning clockwise results in a smaller switch angle while
turning anticlockwise results in a larger switch angle (fig. 6); this is
the opposite when mounted inside. To decrease the switching angle,
turn counterclockwise to increase the switching angle (Fig. 6); when
mounted inside accordingly reversed.The positive break angle is 7°
larger than the set switching angle.
3. After the switch is set, the compliance of the switch with the
safety-technical requirements of the application must be checked
(see Section 7.2 Door gap calculation).
4. 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).
-
+
1
2
Fig. 6 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 5.7 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.

5
TESK
Operating instructions
Hinge safety switch
EN
3.3 Dimensions
All measurements in mm.
TESK-S...
TESK-ZS
116
101
6.1
66.8
82
20
78
15 15.5 15
40
17.5
TESK-L...
TESK-ZL
60
15 15.5 37.5 15
20
6.1
116
66.8
82
20
98
101
TESK-…ST…
11
TESK-…L…
Ø6.6
70
70
B
Ø5.8
C
D
Key
B = Minimum bending radius of the connection cable
C = Cable 5-core (B = 29 mm)
D = Cable 9-core (B = 33 mm)

6
Operating instructions
Hinge safety switch TESK
EN
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
connection of different connector versions only connectors
with the appropriate protection rating may be used.
The versions TESK-…-22ST… and TESK-…-13ST…
and TESK-...-12ST...should only be used PELV circuits in
accordance to EN 60204.
4.2 Contact variants
Contacts are shown with safety guard closed.
TESK-…22L…TESK-…13L…
WH 11
VT 23
12 BK
24 RD
BN 31 32 BU
GY 43 44 PK
PE GN/YE
WH 11
VT 23
12 BK
24 RD
BN 31 32 BU
GY 41 42 PK
PE GN/YE
TESK-…12L…TESK-…02L…
WH 11
VT 23
12 BK
24 RD
BN 31 32 BU
PE GN/YE
BN 21 22 BU
12 BKWH 11
PE GN/YE
TESK-…11L…
WH 11
BN 23
12 BK
24 BU
PE GN/YE
TESK-…22ST…TESK-…13ST…
11
23
12
24
31 32
12345678
43 44
5
8
4
3
2
1
7
6
11
23
12
24
31 32
41 42
12345678
5
8
4
3
2
1
7
6
TESK-…12ST…TESK-…02ST…
11
23
12
24
31 32
12345678
5
8
4
3
2
1
7
6
11
21
12
22
PE
12345
3
2
5
1
4
TESK-…11ST…
11
23
12
24
PE
12345
3
2
5
1
4
4.3 Switch travel
TESK-...22... TESK-...13...
(10°) 180°
3°
11-12
31-32
43-44
23-24
A
A
(10°) 180°
3°
11-12
31-32
41-42
23-24
A
A
A
TESK-...12... TESK-...02...
(10°) 180°
3°
11-12
31-32
23-24
A
A
(10°) 180°
3°
11-12
21-22
A
A
TESK-...11...
(10°) 180°
3°
11 - 12
23 - 24
A
Key
A Positive break NC contact
T Positive break travel / -angle
(Switching angle tolerance -1° / +3°)
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
condition only.
6.2 Disposal
The safety switchgear must be disposed of in an appropriate manner
in accordance with the national prescriptions and legislations.

7
TESK
Operating instructions
Hinge safety switch
EN
7. Appendix
7.1 Wiring configuration and connector accessories
Connector plug ST M12, 5-pole
3
2
5
1
4
Pin configuration of
the connector
Colour code or
conductor numbering
of the below-mentioned
Schmersal connectors
Possible colour code of other
commercially available connectors
to EN 60947-5-2:
2007 DIN 47100
Connecting cables with female connector
IP67, M12, 5-pole - 5 x 0.25 mm²
1 BN 1 BN WH
2 WH 2 WH BN
Cable length Part number 3 BU 3 BU GN
5.0 m
15.0 m
103010816
103010820
4 BK 4 BK YE
5 GY 5 GY GY
Connector plug ST2 M12, 8-pole
5
8
4
3
2
1
7
6
Pin configuration of
the connector
Colour code or
conductor numbering
of the below-mentioned
Schmersal connectors
Possible colour code of other
commercially available connectors
to EN 60947-5-2:
2007 DIN 47100
Connecting cables with female connector
IP67, M12, 8-pole - 8 x 0.23 mm²
1 BN 1 BN WH
2 WH 2 WH BN
Cable length Part number 3 BU 3 BU GN
2.5 m
5.0 m
10.0 m
103011411
103011412
103011413
4 BK 4 BK YE
5 GY 5 GY GY
6 VT 6 PK PK
Connecting cables with female connector
IP69K, M12, 8-pole - 8 x 0.21 mm²
7 RD 7 VT BU
8 PK 8 OR RD
Cable length Part number
5.0 m
5.0 m
101210560
101210561 (angled)
Colour code key
Code Colour Code Colour Code Colour Code Colour
BK black GN green PK pink WH white
BN brown GY grey RD red YE yellow
BU blue OR orange VT violet

8
Operating instructions
Hinge safety switch TESK
EN
7.2 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 is the door gap in mm with an overlap at B = 0 mm.
B is the thickness of the door
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
C
β
D1
D
B
Example:
A door made of 40 mm aluminium profile with a length of 950 mm
should be secured with a TESK. The safety contact of the TESK 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.

9
TESK
Operating instructions
Hinge safety switch
EN
Doors with two hinges
Force [N] B [mm]
400 500 600 700 800 900 1000 1100 1200
H [mm] up to 1000 400 400 400 400 400 400 400 400 350
up to 1800 400 400 400 400 350 350 300 300 250
up to 2400 400 400 400 300 250 250 200 200 150
up to 2600 400 400 300 200 150 150 100 100 50
not recommended
Doors with three hinges
Force [N] B [mm]
400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
H [mm] up to 1800 750 750 750 700 650 650 600 600 550 500 450 400
up to 2400 750 750 700 600 550 550 500 500 450 400 350 300
up to 2600 750 700 600 500 450 450 400 400 400 400 350 300
BDC
F
0.55 x H
H/8 H/5
H/8 H/5
H/5
0.6 x H
H
C = Use of one hinge switch and an additional hinge
D = Use of one hinge switch and two additional hinges
With larger doors the have three hinges make sure the two of
the hinges are located in the upper third.
We recommend that the safety hinge switch is placed in the
middle when three hinges are used.
The hinge safety switch must not be used as an end stop.
For applications in which heavy doors are used, especially
if these can close with little or no braking effect, further
measures are to be implemented to prevent the securing
bolts from working loose. If necessary, damping/braking
measures may be required.
For applications with a different assembly, e.g. hoods,
a reduced service life is expected.
If necessary, damping or braking measures may need to be
implemented.
7.3 Load specifications
Determining the permissible forces as a function of door size and
number of hinges.
Doors with one hinge
Force [N] B [mm]
100 200 300 400 500
H [mm] up to 200 200 150 100 70 50
up to 300 200 150
not recommen-
ded
B
F
H/2 H/2
H
The hinge should be placed in the middle with doors that only
have one hinge.

10 EN
TESK-B-EN
Operating instructions
Hinge safety switch TESK
8. EU Declaration of conformity
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.
Name of the component: TESK
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 60947-5-1:2010,
DIN EN ISO 14119:2014
Person authorized for the compilation
of the technical documentation:
Oliver Wacker
Möddinghofe 30
42279 Wuppertal
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.
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