schmersal ZSD1 User manual

EN Operating instructions. . . . . . . . . . . . .pages 1 to 6
Translation of the original operating instructions
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actuelle du mode d’emploi dans
votre langue nationale officielle
sur l’Internet,
www.schmersal.net.
ES Encontrará el manual de
instrucciones actual en su
idioma oficial de la UE en
nuestra página de Internet
www.schmersal.net.
NL U vindt de huidige versie van de
gebruikshandleiding in uw
officiële landstaal op het Inter-
net, www.schmersal.net.
IT Il manuale d‘istruzioni aggior-
nato nella vostra lingua (lingua
ufficiale UE) è scaricabile in
Internet all‘indirizzo
www.schmersal.net.
JP EU公用語で書かれた最新の取扱
説明書は,インターネッ
(www.schmersal.net) からダウ
ンロードできます。
17.10.2010 / Index: 940/10 / Teile-Nr. 1211452-EN
ZSD1/ZSD2/ZSD4
Operating instructions
Enabling 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 operat-
ing 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 damages 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 machinery or plant.
The safety switchgear must exclusively be 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 Elan
catalogues or in the online catalogue on the Internet:
www.schmersal.net.
The information contained in this operating instructions manual is
provided without liability and is subject to technical 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 inadequate or improper use or manipulations of the
safety switchgear, personal hazards or damage to machinery
or plant components cannot be excluded. The relevant re-
quirements of the standard EN 13850 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 Appropriateuse........................................1
1.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.6 Warningaboutmisuse...................................1
1.7 Exclusionofliability.....................................2
2 Product description
2.1 Orderingcode .........................................2
2.2 Specialversions........................................2
2.3 Destinationanduse.....................................2
2.4 Actuatingfeatures......................................2
2.5 TechnicaldataHE3B-M2PY...............................2
2.6 Safety classication .....................................3
3 Mounting of ZSD1LC.., ZSD1.1LC, ZSD2LC.. and ZSD2.1LC
3.1 Dimensions ...........................................4
4 Electrical connection
4.1 Importantnotes........................................4
4.2 Wiring................................................4
5 Set-up and maintenance
5.1 Functionaltesting.......................................4
5.2 Maintenance ..........................................4
6 Disassembly and disposal
6.1 Disassembly...........................................4
6.2 Disposal..............................................4
7 Appendix
7.1 ECDeclarationofconformity..............................5

2
Operating instructions
Enabling switches ZSD1/ZSD2/ZSD4
EN
1.7 Exclusion of liability
We shall accept no liability for damages and malfunctions resulting from
defective mounting or failure to comply with this operating instructions
manual. The manufacturer shall accept no liability for damages resulting
from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary 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:
ZSD
➀➁➂➃➄➅
No. Option Description
➀
1.1LC Pilot 10 enclosure with HE3B-M2P 3-stage
enabling switch (1NC/1NO) with 5 m cable
➁
1LC/TZG Pilot 10 enclosure with HE3B-M2PY 3-stage
enabling switch (1 NC/1 NO contact) with TZG
(1 NC/1 NO contact or 2 NC contacts)
+ TZ/CO actuator, with 5 m cable
➂
2.1LC Pilot 20 enclosure with HE3B-M2PY 3-stage
enabling switch and 2 additional pushbuttons
(1 NO contact each) without cable
➃
2.1LC/
TZG..
Pilot 20 enclosure with HE3B-M2PY 3-stage
enabling switch and 2 additional pushbuttons
(1 NO contact each), additionally with TZG
(1 NC/1 NO contact or 2 NC contacts)
and TZ/CO actuator, without cable
➄
4/TZG.. Pilot 20 enclosure with 2-stage enabling switch,
1 emergency stop and 1 pushbutton (1 NO contact)
with TZG (1 NC/1 NO contact or 2 NC contacts)
and TZ/CO actuator, without cable
➅
4.1 Pilot 20 enclosure with 2-stage enabling switch,
1 emergency stop and 1 pushbutton (1 NO contact)
with TZG (1 NC/1 NO contact or 2 NC contacts)
and TZ/CO actuator, without TZG / TZ/CO,
without cable
Not all component variants, which are possible according to this order
code, are available.
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 Destination and use
The electromechanical enabling switches of the ZSD series are for
instance used on industrial robots and automated production systems
to activate the control functions for hazardous situations through other
control devices.
An enabling device is an additional manually-operated control device,
which is used in conjunction with the start equipment and enables a
machine function, when it is continuously actuated.
The redundant contact configuration enable signal evaluation with
common safety relay modules. The contact configuration enables the
signal processing according to EN 954-1 PL e (level 2 ↔ 3) or
PL c (level 2 ↔ 1).
2.4 Actuating features
for ZSD1LC.., ZSD1.1LC, ZSD2LC.., ZSD2.1LC
Level 1 2 3
Actuating travel: 0.0 0.8 1.8 1.7 1.9
Actuating force (N) 0.0 3.0 20
NO contact (NO1-C1) open closed open
NO contact (NO2-C2) open closed open
Wiring example
NO1-C1, NO2-C2: connections of the NO contacts
NC1 NC2
NO1 NO2
C1 C2
Connection Conductor number
NO1 1
C1 2
NO2 3
C2 4
2.5 Technical data HE3B-M2PY
Standards: ISO 12100, ISO 11161, ISO 10218,
IEC 60204-1, IEC EN 60947-5-1, EN 292,
EN 775, prEN 11161, UL 508,
CSA C22.2 Nr. 14, JIS C8201-5-1,
ANSI/RIA R 15.06
Ambient temperature: Silicone: −25 °C … +60 °C (no icing)
PVC: −10 °C … +60 °C (no icing)
Storage temperature: −40 °C … +80 °C (no icing)
Rel. air humidity: 45 … 85% (no condensation)
Degree of pollution: 3
Contact resistance: 50 mΩ (initial value)
Insulation resistance: 100 mΩ min. (Megger DC 500 V)
Withstand voltage: 1.5 kV
Switching frequency: 1,200 s/h
Mechanical lifetime: Level 1-2-1: 106operations min.
Level 1-2-3-1: 105operations min.
Electrical lifetime: 105operations (at full load)
Resistance to shocks: Operation: 100 m/s2
destructive: 500 m/s2
Resistance to vibrations: Operation: 5 … 55 Hz,
amplitude 0.5 mm min.;
destructive: 16.7 Hz,
amplitude 1.5 mm min.
Connection: soldering
Cable section: 0.5 mm2max./conductor
Max. soldering temperature: 260 °C / 3 seconds max.
Tensile strength of the connection: 20 N min.
Recommended torque: 0.68 … 0.88 Nm
Protection class: with rubber cap: IP65
without rubber cap: IP40
(IEC 60529)
Max. fuse rating: 50 A (250 V)
Recommended fuse: 250 V / 10 A quick-blow (IEC 60127-1)
Weight: approx. 18 g
Maximum admissible actuating force: 500 N min.
Electrical specifications:
Rated operating voltage: 125 VAC / VDC
Rated operating current: 3.0 A

3
ZSD1/ZSD2/ZSD4
Operating instructions
Enabling switches
EN
Rated data: 30 V 125 V
Ohmic load (AC-12): – 1.0 A
Inductive load (AC-15): – 0.7 A
Ohmic load (DC-12): 1.0 A 0.2 A
Inductive load (DC-13): 0.7 A 0.1 A
Contact configuration: 2 change-over contact
Min. load: 3 VAC /VDC and 5 mA (approximate value)
Embeddable command devices for ZSD2... and ZSD4...
Standards: IEC EN 60947-5-1 / -5
Frontal execution: plastic encapsulated, protection class IP65
Contacts: Cross-point contacts, depending on the execution
available as NC or NO contact, NC contacts
with positive break to IEC EN 60947-5-1 / -5
Temperature range: 0 °C … +65 °C
Termination and min/max cable section: 0.14 … 1.5 mm2
Rated operating voltage Ue:250 V
Rated insulation voltage Ui:250 V
Operating current le
depending on the utilisation
category and the test voltage: AC-15: 2 A / 250 VAC
DC-13: 1 A / 24 VDC
Max. fuse rating: gG 3 A
Switching of low voltages: 5 V / 1 mA
Other information: refer to technical data / electrical specification
of the basic components
Safety switch TZG..
Standards: IEC EN 60947-5-1
Protection class: switching compartiment: IP67
deflecting head: IP00
Actuating forces: inserting the actuator: 10 N
extracting the actuator: 20 N
Ambient temperature: 0 °C … +65 °C
Materials used: glass-fibre reinforced thermoplastic with
self-extinguishing properties to UL 94-V-0,
metal components with corrosion protection,
with protective cover (metallic)
Cable entries: M20 × 1.5
Termination: self-releasing screw terminals
with double-slot screws
Cable connection: 0.5 … 2 × 2.5 mm2rigid
or 2 × 1.5 mm flexible
with conductor ferrules
Terminal designations: DIN EN 50005 / 50013
Mechanical life: at least 1 × 106operations
Resistance to shock: 30 g / 18 ms
Resistance to vibrations: >15 g / 10 … 200 Hz
Climatic resistance to DIN EN 60068: Part 2-30
Rated operating voltage Uemax.: 400 V (slow action switch version)
Rated insultion voltage Ui:400 V (slow action switch version)
Thermal nominal current Ithe2:10 A (slow action switch version)
Rated operating current Uedepending on
the utilisation category and the test voltage: 250 V ~ / 8 A
Control circuits of the electronics: 24 V / 10 mA
Insulation group: C to VDE 0110
Air clearances and creepage distances to DIN VDE 0110-1: 4 kV/3
Max. fuse rating: 10 A gG slow-blow
(slow action switch version)
2.6 Safety classification
Standards: EN ISO 13849-1, IEC 61508, EN 60947-5-1
SIL: Level 2 ↔ 1: Stop 0: up to 2
Level 2 ↔ 3: Stop 1: up to 3
PL: Level 2 ↔ 1: up to c
Level 2 ↔ 3: up to e
Category: Level 2 ↔ 1: Stop 1: up to 2'
Level 2 ↔ 3: Stop 0: up to 4
CCF: > 65 points
Service life: 20 years
B10d value (for one channel): 100,000
MTTF
B d x x
h
s/h3600
d
10d op op
op
n
0,1 x nop tcycle
For an average annual demand rate of nop = 126,720 cycles per year,
Performance Level PL e can be obtained at maximum load.
nop = average number of activations per year
dop = average number of operating days per year
hop = average number of operating hours per day
tcycle = average demand rate of the safety function in s
(e.g. 4 × per hour = 1 × per 15 min. = 900 s)
(Specifications can vary depending on the application-specific
parameters hop, dop and tcycle as well as the load.)
Actuating features
The redundant contact configuration enable signal evaluation with
common safety relay modules. The contact configuration enables the
signal processing according to EN ISO 13849-1 PL c (level 2 ↔ 3)
or PL c (level 2 ↔ 1).
The contact configuration enables the signal processing according
to PL c (levels 2 ↔ 1) or PL e (levels 2 ↔ 3) to EN ISO 13849-1.
3. Mounting of ZSD1LC.., ZSD1.1LC, ZSD2LC.. and ZSD2.1LC
Recommended torque for the securing nut: 0.68 … 0.88 Nm.
Please remove the lug of the rubber cap when no positioning hole is
available (avoid damaging of the rubber cap in order to maintain
protection class IP 65!).
30
Ø 16,2
Ø 3,2*
0,5 … 4 mm**
a)
b)
* Positioning hole; ** Material strength;
a) Anti-twist safeguard; b) Securing nut

4
Operating instructions
Enabling switches ZSD1/ZSD2/ZSD4
EN
3.1 Dimensions
All measurements in mm.
HE3B-M2PY enabling switch
(54)
39,5
14,5
14,5
R1
NC
NO
C
R2
30
(39)
27,5
(34,5)
11,5
25,59
158
a) c)
d)
b)
5
5
9,5
13
15,52
25
Ø 3
a) Soldering terminals 2.8 × 0.5 t; b) Securing nut;
c) Anti-twist safeguard; d) Rubber cap
ZSD1LC.. enabling switch with TZG
70 85 75
24
15
15
69,5
573
30
190
95
52
48
50
62
6
20
107
5,3
TZ/CO
TZG...TZG...
ZSD2LC.. enabling switch with TZG
115 85 75
24
15
15
79,5
57
3
30
190
95
52
48
50
62
20
107
5,3
TZ/CO
TZG...
6
4. Electrical connection
4.1 Important notes
The electrical connection may only be carried out by
authorised personnel in a de-energised condition.
At least one contact with positive break must be integrated
in the safety circuit.
After wiring, the contact elements must be cleaned (i.e. remove excess
cables etc.).
4.2 Wiring
ZSD1LC.., ZSD1.1LC, ZSD2LC.., ZSD2.1LC
enabling switches with safety-monitoring module
13A1 X1 X2 S12 S22 23
14A2 24
A1 S21 S11 S12 S22
A2 X1 X2
1
2
3
4
23
14 24
SRB 301 ST V.2
MC
SRB 301 ST V.2
MC
nQS
QS
nQS
QS
h)
Reset a)
KA
KA
1)
3M
b) c)
d)
e) f)
g)
13
a) Emergency stop; b) Automatic mode; c) Set-up mode;
d) Jog key; e) Channel 1; f) Channel 2;
g) with cross-wire short detection; h) Control system
ZSD4.. enabling switch (2-stage, 1-channel,
additionally 1 emergency stop command device)
Reset
13A1 X1 X2 S12 S22 23
14 24A2
A1 S11 S12 S22
A2
a)
b) c) d)
e)
13 23
14 24
KA
KA
1)
SRB 301 ST V.2
MC
SRB 301 ST V.2
MC
nQS
QS
nQS
QS
f)
3M
a) Emergency stop; b) Automatic mode; c) Set-up mode;
d) Enabling switch; e) Jog key; f) Control system
5. Set-up and maintenance
5.1 Functional testing
The safety function of the enabling switch must be tested. The following
conditions must be checked and met:
• Check the integrity of the cable entry and connections.
• Check the enabling switch for damages.
5.2 Maintenance
A regular visual inspection and functional test, including the following
steps, is recommended:
• Check the correct fixing of the enabling switch and the contact
elements.
• Remove particles of dust and soiling.
• Check cable entry and connections.
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.

5
ZSD1/ZSD2/ZSD4
Operating instructions
Enabling switches
EN
The currently prevailing Declaration of Conformity
can be downloaded from the Internet: www.elan.net
Name of the safety component: ZSD1 / ZSD2 / ZSD4
Description of the safety component: Enabling switches
Harmonised EC-Directives: 2006/42/EC - EC-Machinery Directive
Person authorized for the compilation
of the technical dokumentation:
Ulrich Loss
Möddinghofe 30
42279 Wuppertal
7. Appendix
7.1 EC Declaration of conformity
Place and date of issue: Wuppertal, October 6, 2009
Authorised signature
Heinz Schmersal
Managing Director
EC Declaration of conformity
Translation of the original declaration
of conformity
Elan Schaltelemente GmbH & Co. KG
Im Ostpark 2, 35435 Wettenberg
Germany
Internet: www.elan.de
We hereby certify that the hereafter described safety components both in its basic design and
construction conform to the applicable European Directives.

Elan Schaltelemente GmbH und Co. KG
Im Ostpark 2, D - 35435 Wettenberg
Postfach 11 09, D - 35429 Wettenberg
Telefon +49 - (0)6 41 - 98 48 - 0
Telefax +49 - (0)6 41 - 98 48 - 4 20
E-Mail: [email protected]
Internet: http://www.elan.de