SAFEGUARDING
Requirements & Techniques
For more than 50 years, Schmersal has dedicated itself to understanding manmachine safety hazards. Based on that experience, this handbook has been prepared. It represents a compilation of our responses to the most frequently-asked
questions from people who are actively engaged in designing machine-guard systems. A complementary tutorial video is also available upon request.
The handbook concludes with a convenient condensed catalog of selected
Schmersal interlock safety switches and controllers that satisfy a vast array of safety
applications and challenges. Should you desire more detailed technical data, please
write or call for these product catalogs.
INTRODUCTION
CHANGING MAN-MACHINE
SAFEGUARDING RULES
Today worker safety is an issue of major concern to manufacturers worldwide. OSHA guidelines, more stringent
ANSI standards, and the recently adopted European
Machinery Directive (EMD) are evidence of the
increased emphasis being given to employee safety in
the workplace.
The goal of these new and emerging guidelines is to provide heightened levels of protection to machine operators, helpers, and maintenance personnel. Toward this
goal they have embraced several new safety system
concepts including:
. positive-break contacts
. greater tamper-resistance
. positive-guided relays
. fault detection
. single component failure control reliability
SAFETY-SPECIFIC COMPONENTS
New switches, sensors and controls have been designed
specifically for safety applications. They include:
. positive-break hinge
switches
. positive-break limit
switches
. positive-break
safety edges
. safety controllers
TOWARD A BETTER
UNDERSTANDING
The emergence of new safety
requirements, and the related
devices which satisfy these
criteria, have precipitated
many questions. Typical of
these are:
3
International symbol for Positive-Break contacts
TABLE OF CONTENTS
Topic
Page
Safety
Guard
Closed
Safety
Guard
Open
Contacts forced
open by nonresilient
mechanical member
Contacts
Closed
POSITIVE-BREAK NORMALLY-CLOSED CONTACTS
FORCED TO OPEN BY A NON-RESILIENT MECHANICAL MECHANISM.
Positive-Break Contacts
Positive-Mode Mounting
Actuator
Safety Category
Gap Tolerance
NormallyClosed Contacts
(for monitoring)
B 1 2 3 4
NormallyOpen Contacts
(for machine control)
S1
P1
F1
Starting Point
P2
S2
Actuator
F2
P1
P2
NormallyClosed Contacts
Open
NormallyOpen Contacts
Closed
Positive-Guided Contacts
Risk Assessment
I. Man-Machine Safeguarding
Principles & Practices
Difficult to defeat is a subjective term related to workers propensity to override or bypass safety devices
intended to protect them from injury. Colloquially it
means that the relevant devices or systems cannot be
defeated or bypassed using readily available means
Actuator key
typically mounted to
movable guard
Four optional
actuator key
entry locations
(one on back
of unit)
Positive-break switch
mechanism, typically
mounted to guard
frame
FIGURE 1
MOVABLE
MACHINE GUARD
ACTUATING A
SAFETY INTERLOCK
SWITCH WITH
POSITIVE-BREAK
CONTACTS
FIGURE 2
Conventional versus Positive-Break Contacts
. Spring failure
. Inability of the spring force to overcome stuck or
welded contacts.
FIGURE 3
A positive linkage switch actuator is designed to eliminate possible slippage between the actuator and its
Pinned
Square
Actuator
Serrated
Positive Linkage
FIGURE 4
Safety
Guard
Closed
Safety
Guard
Open
Contacts
Closed
Contacts forced
open by nonresilient
mechanical member
FIGURE 5
POSITIVE-MODE INSTALLATION
Safety
Guard
Closed
Contacts
Closed
Safety
Guard
Open
Contacts open
by internal
spring force
FIGURE 6
NEGATIVE-MODE INSTALLATION
10
10
Self-Checking: The performing of periodic self-diagnostics on a safety control circuit to ensure critical individual
components are functioning properly. Faults or failures in
selected components will result in system shut-down.
Redundancy: In safety applications, redundancy is the
duplication of control circuits/components such that if one
component/circuit should fail, the other (redundant) component/circuit will still be able to generate a stop signal.
When coupled with a self-checking feature, a safety circuit component failure, or component failure within the
safety circuit monitoring module or safety relay module,
11
12
11
the event of a component or interconnection wiring failure in the safety circuit, or in the safety circuit controller,
the unit will shut down the system in a safe state.
FIGURE 8
13
14
12
15
. Use of interlock switches or machine guarding position sensors, which are tamper-resistant/difficult to
defeat.
16
13
17
18
(5) SCHMERSALs safety interlocks and related controllers have been proven in thousands of installations worldwide.
(1) All SCHMERSAL safety interlocks have been thirdparty tested and certified to meet relevant directives
all are CE-compliant.
14
(7) SCHMERSALs safety controllers are easily integrated with their more than 200 positive-break interlock
switches and coded-magnet sensors to achieve any
desired safety level. And, they are also compatible
with other manufacturers safety-approved components.
19
Control reliability implies that the safety device or system is designed, constructed and installed such that the
failure of a single component within the device or system
20
Safety systems which are single component failure control reliable meet the requirements of a Category 3
safety-related control system as defined by the harmonized European machinery safety standard EN954-1.
15
21
POSITIVE-GUIDED CONTACTS
CONVENTIONAL CONTACTS
UN-ENERGIZED STATE
Actuator
Gap Tolerance
Actuator
NormallyClosed
Contacts
(for monitoring)
NormallyOpen
Contacts
(for machine control)
Gap Tolerance
NormallyClosed
Contacts
(for monitoring)
NormallyOpen
Contacts
(for machine control)
ENERGIZED STATE
Actuator
Actuator
NormallyClosed
Contacts
Open
NormallyOpen
Contacts
Closed
NormallyClosed
Contacts
Open
NormallyOpen
Contacts
Closed
UN-ENERGIZED STATE
WELD
WELD
Normally-Closed
Normally-Open
Contacts will
Contact
remain open,
welded
maintaining a minimum
closed
gap of 0.5mm
Normally-closed
Contacts will
return to
N.C. state
NormallyOpen Contact
Welded
Closed
FIGURE 9
POSITIVE-GUIDED VS. CONVENTIONAL CONTACTS
16
22
Control reliability implies that the safety device or system is designed, constructed and installed such that the
failure of a single component within the device or system
shall not prevent normal machine stopping action from
taking place but shall prevent a successive machine
cycle from being initiated. To achieve this, safety controllers are typically designed with dual logic circuits,
each of which can provide safety circuit checking/monitoring. These functionally-equivalent logic circuits crossmonitor each other, as well as checking the safety circuit
for component failures, short circuits, open circuits, etc.
Since these controllers detect faults in the safety circuit
components and interconnection wiring to effect
machine shutdown, such redundant self-monitoring circuits enhance safety system reliability. In so doing they
23
Fail-to-safe safety devices are designed such that a component failure will cause the device to attain rest in a safe
condition. This term is generally applied to electronic safety interlock systems using non-mechanical presence or
position sensors (such as reed switches, proximity switch-
17
24
25
(3) use of positive-break safety interlock switches together with a safety controller, such that the possibility of a
contact weld resulting in the loss of the safety function
is eliminated.
(1) the use of an overrated contactor to preclude the possibility of contact welding.
18
26
27
Safety Category
B 1 2 3 4
S1
P1
F1
Starting Point
P2
S2
F2
P1
P2
FIGURE 10
Another methodology is outlined in ANSIs Technical
Report B11.TR3. This guideline suggests a task-based
review of potential hazards by both the equipment designer and the ultimate end-user.
19
28
Safety
General Safety
System Requirements
General Safety
System Behavior
Safety
Cat.
General Safety
System Requirements
General Safety
System Behavior
A single fault or
failure in the safety system can
lead to the loss of
the safety function.
Here a single
fault or failure in
the safety system
will not lead to the
loss of the safety
function and,
where possible,
will be detected.
A single fault or
failure in the safety system can
lead to the loss of
the safety function. However, the
use of well tried
safety principles
and safety components results in a
higher level of
safety system reliability.
4*
Here a single
fault or failure in
the safety system
will not lead to the
loss of the safety
function, and it will
be detected in
time to prevent the
loss of the safety
function.
Cat.
.
.
.
.
.
20
.
.
.
FIGURE 11
29
Within the above defined levels of risk, a Category 3 safety system would satisfy OSHA and ANSIs requirement for
a control reliable safety circuit. Here use of an appropriate fail-to-safe, safety controller in combination with one or
more safety interlock switches and/or coded-magnet sen-
30
31
ed to the Machinery Directive. Use of a safety circuit controller ensures meeting Category 1 and 2 requirements
without a time-consuming study of the machine control
system.
21
32
Category 4 safety system requirements are typically associated with extremely high-risk applications in which:
(a) The severity of a potential injury is extremely high (e.g.
amputation or death).
(b) The employee/operator is exposed to the hazard highly frequently or continuously.
(c) There is little possibility of the employee/operator
avoiding the hazard.
Classic safety hierarchy states that dangers should be:
(1) designed out;
(2) guarded against, if they cannot be designed out; and
then
(3) (as a last resort) warned against.
Since this classic safety hierarchy reflects general
machine design practice, few machines present Category
4 risk conditions.
22
33
What is the
34
35
23
36
37
24
38
The European Machinery Directive applies to all machinery that is powered and has moving parts. Excluded are
manually-powered equipment, motor vehicles, medical
39
40
25
V. Safety Controllers
41
26
Safety controllers detect and locate system faults. Units are available for use with guard interlock switches,
coded-magnet sensors, safety edges, light curtains, E-stops and emergency cable-pull switches to satisfy
a broad range of application requirements.
42
43
What is the difference between a single and dualchannel safety controller, and when should
each be used?
44
cuit faults, and shut down the machine until the fault is
corrected, greatly heighten the safety level.
change state. As such they provide a higher level of safety than single-channel units.
Single-channel safety controllers are suitable for relatively low levels of risk assessment (e.g. EN 954-1 Safety
Categories B, 1 and 2). Dual-channel units are appropriate when designing control reliable safety systems
that is, systems in which a single component failure will
not prevent normal machine stopping action from taking
place, but will prevent a successive machine cycle from
being initiated.
(4) the need/desire to monitor the integrity of the positive-guided contacts in the controlled output device
(e.g. motor contactor, control relay, et al).
(5) the level of safety desired (this is usually determined
by a structured risk assessment).
27
45
28
46
47
29
AZ16
Optional
quick-connect
termination
Up to 3 contacts,
for dual-channel
reliability with
signalling
3 threaded
knock-out
conduit entry
points for easy
installation
Electricallyinsulated contacts
for added safety (no
potential for crossover)
Difficult-to-defeat
multiple-cam
actuating mechanism
(mechanical life: 10 million)
normally-closed
contacts (ensure circuit interruption)
High-strength, corrosion-resistant
polymeric housing (no ground
connector required)
4 actuator-key
entry points,
for ease of
mounting
Optional maintained or
ejecting actuator key
(for application
versatility)
VII.
Short-Form POSITIVE-BREAK
Catalog
KEYED INTERLOCK SWITCHES
Housing
Material
Envelope
Dimensions
Contact
Configurations
1 NO & 1 NC
2 NC
1 NO & 1 NC
2 NC
Glass-fiber,
reinforced thermoplastic
1 NC
1 NO & 1 NC
2 NC
1 NO & 2 NC
3 NC
AZ335
Die-cast aluminum
1 NO & 1 NC
2 NC
1 NO & 2 NC
3 NC
AZ415
Die-cast aluminum
2 NO & 2 NC
SDG
Die-cast aluminum
1 NO & 2 NC
2 NO & 1 NC
3 NC
SHGV
(Key transfer
system)
Die-cast aluminum
1 NO & 2 NC
2 NO & 1 NC
3 NC
TZG
Glass-fiber,
reinforced thermoplastic
1 NO & 1 NC
2 NC
Switch Series
ST14
Glass-fiber,
reinforced thermoplastic
AZ17
AZ17zi
Glass-fiber,
reinforced thermoplastic
AZ15/16
AZ16zi
31
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
Envelope
Dimensions
Contact
Configurations
AZM170
AZM170zi
Glass-fiber,
reinforced thermoplastic
1 NO & 1 NC
2 NC
AZM160
AZM160zi
Glass-fiber,
reinforced thermoplastic
2 NO & 2 NC
1 NO & 3 NC
AZM161
Glass-fiber,
reinforced thermoplastic
2 NO & 4 NC
3 NO & 3 NC
AZM415
Die-cast aluminum
2 NO & 2 NC
3 NO & 3 NC
TZF/TZM
Glass-fiber,
reinforced thermoplastic
2 NO & 1 NC
TKF/TKM
Die-cast aluminum
2 NO & 2 NC
TZK
Glass-fiber,
reinforced thermoplastic
1 NO & 2 NC
Switch Series
TG-1
32
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
POSITIVE-BREAK
EMERGENCY CABLE-PULL SWITCHES
Contact
Actuating
Configurations
Force
Conforms
to
Housing
Material
Maximum
Span
UL
CSA
CE (EN418)
Die-cast
aluminum
65 feet
1 NO & 1 NC
2 NO & 2 NC
13.5 lbs.
Yes
(Optional)
ZS73
CE
BG
Die-cast
EN418
aluminum
IEC 947-5-1
EN 60947-5-1
165 feet
1 NO & 1 NC
2 NC
6-90 lbs.
Yes
(Optional)
ZS75
CE
BG
Die-cast
EN418
aluminum
IEC 947-5-1
EN 60947-5-1
165 feet
1 NO & 1 NC
2 NC
2 NO & 2 NC
4 NC
6-90 lbs.
Yes
(Optional)
Die-cast
aluminum
80 feet
1 NO & 1 NC
2 NC
4-45 lbs.
No
UL
CSA
IEC 947-5-1 Die-cast
ZS75
EN
60947-5-1 aluminum
Bidirectional
EN418
DIN VDE
0660-200
165 feet
2 NO & 2 NC
4 NC
4-45 lbs.
Yes
(Optional)
Switch Series
ZS71
ZS441
IEC 947-5-1
EN 60947-5-1
EN418
DIN VDE
0660-200
Rated*
POSITIVE-BREAK
E-STOP PUSHBUTTON STATIONS
UL
CSA
EN418
EN 60947-5-1
AD
Series
2 NO & 2 NC
1 NO & 3 NC
4 NC
Die-cast
aluminum
ED
Series
N/A
Plastic
N/A
1 NO & 2 NC
2 NO & 1 NC
3 NC
33
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
CODED-MAGNET SENSORS/SWITCHES
These rugged presence-sensing devices feature a sealed (IP67) housing, making them ideal interlocks in hostile environments. Their tamper-resistant design and small size make them attractive alternatives to conventional proximity sensors, magnetic switches, and limit switches. Used with SCHMERSALs matched safety system fault detection and control modules (safety controllers), they allow achieving the highest levels of machine safety.
Sensor Series
BNS 250
Note:
Approximate
Envelope
Dimensions
Operating
Voltage
Contact
Configuration(s)
1.0"1.4"0.5"
24 VDC
1 NO & 1 NC
1 NO & 2 NC
BNS 33
3.5"1.0"0.5"
24 VAC/DC
120 VAC/DC
1 NO & 1 NC
1 NO & 2 NC
1 NO
1 NC
2 NC
BNS 303
1.25" 0
100 VAC/DC
1 NO & 1 NC
1 NO & 2 NC
BNS 300
1.25" 0
24 VDC
1 NC
BNS 333
4.5"1.7"1.7"
24 VDC
1 NC
When used in safety applications, coded-magnet sensors must be used with a suitable safety controller
to satisfy the desired safety control category/level of assessed risk. Schmersal offers a wide selection of
safety controllers to meet most application requirements. (Ask for Catalog GK-2).
34
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
POSITIVE-BREAK HINGED
SAFETY INTERLOCK SWITCHES
Housing
Material
Angular Displacement
for Contact Opening
Contact
Configurations
ES 95 SB
Glass-fiber,
reinforced thermoplastic
1 NO & 1 NC
2 NC
TVS 335
TVS 355
Die-cast aluminum,
enamel finish
1 NO & 1 NC
2 NC
TV8S-521
Die-cast zinc,
chrome-plated
1 NO & 1 NC
2 NC
TC 235
Glass-fiber,
reinforced thermoplastic
4.5
1 NO & 1 NC
2 NC
1 NC
TC 236
Die-cast zinc,
enamel finish
4.5
1 NO & 1 NC
2 NC
1 NC
TESZ*
Glass-fiber,
reinforced thermoplastic
4.5
1 NO & 2 NC
3 NC
Switch Series
Die-cast zinc,
enamel finish
35
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
Switch Series
Z/T235
Note:
Housing
Dimensions
Degree of
Protection
Contact
Configurations
114"114"212"
IP67
1 NO & 1 NC
2 N0
2NC
114"214"2"
IP67
1 NO & 1 NC
2 N0
2NC
112"114"3"
IP67
1 NO & 1 NC
2 N0
2NC
1 NO & 2 NC
3 NC
112"112"3"
IP67
1 NO & 1 NC
2 N0
2NC
Die-cast zinc
TZ/T236
Glass-fiber reinforced
thermoplastic
Z/T256
Glass-fibre reinforced
thermoplastic
Z/T335
Die-cast aluminum
Z/T336
Glass-fibre reinforced
thermoplastic
Z/T336
Die-cast aluminum
Z332
Die-cast aluminum
112"112"3"
IP65
1 NO & 1 NC
C50
Glass-fiber reinforced
thermoplastic
1"118"34"
IP30
1 NO & 1 NC
While ideal as a safety interlock switch for safety systems, these rugged limit switches offer the reliability
and benefits of positive-break contacts for any position-sensing application.
36
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
SELECTION GUIDE
SCHMERSALs Series SE Safety Edges/Bumpers are available as subassembly components or as custom assemblies produced to user
specifications. The following pages provide details regarding operation,
construction and ordering details. Among the user options are safety
edge profile, mounting frame profile and length. Please contact us if you
have any questions, special needs or require assistance with properly
specifying the safety edge which meets your requirements.
37
For complete specifications, please request SCHMERSAL Catalog GK-1, or visit our website at www.schmersalusa.com.
OVERVIEW OF
SCHMERSALS SAFETY CONTROLLERS
(For complete specifications and selection guide, please ask for Catalog GK-2)
BASIC FUNCTION
The SCHMERSAL family of safety circuit monitoring,
fault detection and control modules includes two basic
designs. One utilizes relay logic. The other uses solidstate (microprocessor) logic. Pioneered by SCHMERSAL, these safety controllers provide added features
and capabilities unachievable with conventional safety
relay modules.
Both designs feature redundant, dual-channel crossmonitoring logic circuits. These continuously check for,
and detect, faults in the systems safety circuit components and interconnection wiring. Modules also detect
when a machine guard interlock/E-stop switch is actuated and, depending upon the model, are capable of
detecting the following types of potential safety circuit
faults:
Relay-Based
AZR & SRB Series Safety Controllers
38
Microprocessor-Based
AES Series Safety Controllers
SAFETY CONTROLLERS
(For detailed specifications ask for Catalog GK-2)
or visit our website at www.schmersalusa.com
Part
No.
Application
Guards or
Devices
Monitored
Inputs/
Guard
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
Feedback
Available
Voltages
Housing Max.
Size
Safety
(mm)
Cat.
AES
6112
Monitoring
coded
magnet
switches of
type
BNS12Z
1 NO/
2 NC
No
24VDC
48
AES
7112
Monitoring
coded
magnet
switches of
type
BNS12Z
1 NO/
2 NC
No
24VAC
120VAC
230VAC
48
AES
1102
Monitoring
coded
magnet
switches of
type
BNS12Z
1 NO/
2 NC
No
24VDC
24VAC
120VAC
230VAC
22.5
AES
1112
Monitoring
coded
magnet
switches of
type
BNS12Z
1 NO/
2 NC
No
24VDC
24VAC
120VAC
230VAC
22.5
This series of safety controllers was specifically designed as a low-cost way of monitoring coded-magnet switches. They feature
triple redundancy; however, there is no internal cross-monitoring nor fault detection. Loss of a channel will not be detected. For this
reason they are suitable for a maximum of Safety Category 1.
Selected Features:
. Compliant
. Positive-guided control relays
. Visual fault indication
. Designed expressly for use with
coded-magnet sensors
39
Guards or
Devices
Monitored
Inputs/
Guard
Monitoring
E-Stops
AZR
11RT2
Monitoring
Guard
Switches
or
E-Stops
AZR
31T2
Monitoring
Guard
Switches or
E-Stops
2 NC
AZR
31R2
Monitoring
Guard
Switches
or E-Stops
Part
No.
Application
AZR
31TO
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
3 1
Feedback
Available
Voltages
Housing Max.
Size
Safety
(mm)
Cat.
Yes
24VDC
24 VAC
22.5
Yes
24VDC
24 VAC
22.5
3 1
Yes
24VDC
24VAC
120VAC
230VAC
45
2 NC
3 1
Yes
24VDC
24VAC
120VAC
230VAC
45
1 NC
3 2
Yes
24VDC
24VAC
120VAC
230VAC
45
1NO/1NC 1
or 2 NC
2-Hand
Control
AZR
32T1
40
Monitoring
E-Stops
Selected Features:
Compliant
Positive-guided control relays
Controlled-contactor or relay feedback monitoring
Wide range of compatible input devices
Multiple safety contacts
Auxiliary signaling contacts
.
.
.
.
.
.
Guards or
Devices
Monitored
Inputs/
Guard
Monitoring
E-Stops
1 NC
AZR
31S1
Zero
Speed
Monitor
3
Voltage
AZR
20P2
Press
Monitor
AZR
62A2
Output
Expander
AZR
63V2
Timed
Output
Expander
Part
No.
Application
AZR
32V1
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
3 1
Feedback
Available
Voltages
Housing Max.
Size
Safety
(mm)
Cat.
Yes
24VDC
24VAC
120VAC
230VAC
45
3 1
No
24VDC
24VAC
120VAC
230VAC
45
2 NC
1 1
No
24VDC
24VAC
120VAC
230VAC
45
6 2
No
24VDC
24VAC
120VAC
230VAC
100
No
24VDC
24VAC
120VAC
230VAC
100
6 2
For complete specifications and wiring information for SCHMERSALs wide range of safety controllers,
please request Catalog GK-2, or visit our website at www.schmersalusa.com.
41
Part
No.
AES
1135
Application
Monitoring
Guard
Switches
or
E-Stops
Guards or
Devices
Monitored
1
Inputs/
Guard
1 NO/
1 NC
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
Feedback
Available
Voltages
Housing Max.
Size
Safety
(mm)
Cat.
No
24VDC
22.5
No
24VDC
22.5
or
2 NC
AES
1145
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
or
2 NC
AES
1165
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
No
24VDC
22.5
AES
2135
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
No
24VAC
120VAC
230VAC
55
No
24VAC
120VAC
230VAC
55
or
2 NC
AES
2165
Monitoring
Guard
Switches
or
E-Stops
Selected Features:
42
1 NO/
1 NC
. Compliant
. Positive-guided control relays
. Fault identification diagnostics
. Wide range of compatible input devices
Part
No.
Application
Guards or
Devices
Monitored
Inputs/
Guard
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
Feedback
Available
Voltages
Housing Max.
Size
Safety
(mm)
Cat.
AES
1235
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
Yes
24VDC
22.5
AES
2335
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
Yes
24VDC
55
AES
3335
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
Yes
24VDC
100
Yes
120VAC
230VAC
or
2 NC
3 2
AES
3365
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
Yes
24VDC
100
AES
3535
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
4 1 2
Yes
24VDC
100
4 1 2
Yes
24VDC
100
or
2 NC
AES
3565
Monitoring
Guard
Switches
or
E-Stops
1 NO/
1 NC
43
Part
No.
44
Application
Guards or
Devices
Monitored
Inputs/
Guard
Monitoring
Guard
Switches
or
E-Stops
AES
A1067
Input
Expander
for
AES3267
2 NC
or
3 NC
AES
3337
Monitoring
Guard
Switches
or
E-Stops
2 NC
ASL
2103
Monitoring
of
SL
Bumpers
1 NC
Housing Max.
Size
Safety
(mm)
Cat.
Feedback
Available
Voltages
Yes
24VDC
100
No
24VDC
22.5
3 2 4
Yes
24VDC
100
Yes
24VDC
24VAC
120VAC
230VAC
50
1 NO/1NC 2 2 2
or
1 NO/2 NC
or
2 NC
or
3 NC
AES
3267
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
Part
No.
AES
E3035
Application
Guards or
Devices
Monitored
Input
Expander
for
AES
Series
Inputs/
Guard
1 NO/
1 NC
or
2 NC
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
Feedback
Available
Voltages
No
24VDC
Housing Max.
Size
Safety
(mm)
Cat.
100
Time-Saving, Highly-Visible
Fault Diagnostic Chart
FAULT LOCATION
No faults detected and relay contacts closed
Guard open
Guard misaligned (or) Welded/stuck switch
contact (or) No start signal
Guard 1 open
Guard 2 open
Guard 1 switch circuit (S1)
Guard 2 switch circuit (S2)
Guard 1 & 2 switch circuits
Capacitive/inductive interference on inputs
Drop in supply voltage (or)
Internal relay malfunction
Welded/stuck internal relay contact
AES monitoring circuit
EXCLUSIVELY FOR: AES 3355, 3365, 3555, 3565
Each Schmersal Series AES safety controller comes with its own easy-to-use fault
locator chart. This self-adhesive label may be affixed to the side of the module, or
prominently displayed on the control cabinet. It enables service personnel to quickly and easily translate the monitors colored, flashing LED pattern to identify, locate
and correct the safety circuit fault thus minimizing equipment downtime.
45
Part
No.
Application
Guards or
Devices
Monitored
Inputs/
Guard
NO-Safety
Auxiliary
Semiconductor
Timed-NO
Timed-Auxiliary
Outputs
Feedback
Available
Voltages
Housing Max.
Size
Safety
(mm)
Cat.
FWS
1105
Zero
Speed
Monitor
2
1
Proximity
Switches
No
24VDC
22.5
FWS
1106
Zero
Speed
Monitor
1 or 2 1
Proximity
Switches
&
1 Stop
Signal
No
24VDC
22.5
FWS
2316
Zero
Speed
Monitor
1 or 2 3
Proximity
Switches
&
1 Stop
Signal
No
24VDC
120VAC
230VAC
50
FWS
3506
Zero
Speed
Monitor
1 or 2 4 1 2
Proximity
Switches
&
1 Stop
Signal
No
24VDC
100
AZS
2305
On
Delay
Timer
Yes
24VDC
120VAC
230VAC
50
1 NO/
1 NC
FWS Zero Speed Monitors and the AZS 2305 Timer Module are designed to apply power to a locking solenoid switch to unlock after
motion has stopped.
46
The contents of this booklet represent a brief overview of selected current international and U.S. machine guarding safety standards and guidelines affecting machinery builders and users. The material presented is intended
to inform the reader of some of the current and emerging safety issues which may need to be considered.
Due to the booklets brevity, and to the diversity of applications which may be affected, we strongly encourage
consulting with official regulatory bodies and relevant safety standards/guidelines.
Toward this goal a partial listing of selected references has been provided. We trust this brief tutorial was of value
and that it encourages further investigation.
REFERENCES
The following are some of the current and emerging
safety standards and guidelines which may affect
your equipment design and its use.
Occupational Health & Safety Administration, Code
of Federal Regulations, Part 1910 (OSHA 29 CFR
1910).
ANSI Technical Report B11.TR3:2000, Risk
Assessment and Risk Reduction A guide to
estimate, evaluate and reduce risks associated
with machine tools.
ANSI Standard B11.19-1990, Safeguarding
Reference for B11 Machine Tool Safety Standards
ANSI Standard B11.20-1991, Safety Requirements
for Construction, Care, and Use of Machine
Tools Manufacturing Systems/Cells.
47