Schmersal Safety Controllers

GK-2 CATALOG-HANDBOOK
FOR MONITORING &

CONTROL OF MACHINE
GUARD SYSTEMS USING:
. Safety Interlock Switches
. Coded-Magnet Sensors
. E-Stop Actuators
. Safety Edges
. Safety Mats
. Light Curtains/Beams
. Two-Hand Controls
. Muting Systems
Safety Controllers
Safety Controllers
Microprocessor-based FaultFinder Series AES Safety Electromechanically-based FaultFinder Series

Controllers with Integrated System Diagnostics SRB/AZR Safety Controllers
What are Safety Controllers?

Safety controllers are connected between machine guarding presence-sensing input devices and the machine’s stop control
elements (such as a motor contactor or control relay). These controllers contain redundant, self-checking safety system
monitoring circuits and positive-guided output relays. Each is designed to detect faults in the safety system’s components
and interconnection wiring, and their own internal monitoring circuits and output relays. Detection of a fault,or of an open
machine guard, disables the module’s output signal(s) facilitating machine stoppage, and/or prevents the restarting of the
machine until the fault has been corrected. Units are available for use with guard interlock switches, coded-magnet sensors,
safety edges, two-hand controls, light curtains, E-stops and emergency cable-pull switches to satisfy a broad range of appli-
cation requirements.
What are their functions?

In addition to detecting open guards and/or actuated safety input devices, safety controllers are capable of detecting the fol-
lowing types of safety system faults: guard monitoring switch/sensor failure, “open-circuit” in interconnection wiring, “short-
circuit” in interconnection wiring, “short-to-ground” in interconnection wiring, welded contact in controlled output device (such
as positive-guided motor contactor), failure of safety controller’s positive-guided relay(s), fault in safety system monitoring
circuit, and insufficient operating voltage. Some microprocessor-based safety controllers also feature integrated system diag-
nostics with visual LED outputs which indicate fault type and location — thus minimizing machine downtime. Safety con-
trollers increase the reliability of the machine guarding safety system. Their ability to detect safety circuit/component faults,
and shut down the machine until the fault has been corrected, ensure that the safety system will perform when called upon
to do so.
When should they be used?

There are a variety of applications in which the use of safety controllers is recommended. These include (but are not limited
to):
• Applications in which the assessed risk level is relatively high (e.g. EN954, Category 3 or 4).
• Applications for which the designer wishes to satisfy ANSI’s B11 requirements for “control reliability.”
• Applications having relatively low levels of assessed risk for which the designer wishes to heighten the performance/relia-
bility of the safety system.
COPYRIGHT © 2000 SCHMERSAL LLC

TYPICAL APPLICATIONS
MACHINE GUARDING SOLENOID-LATCHING

SAFETY INTERLOCK*
SAFETY
CONTROLLER
SAFETY INTERLOCK*
Series AES Safety Controller

Easy-to-install DIN-rail mounting
Quick Fault Locator … minimizes

equipment downtime
Rugged, corrosion-
resistant housing
O C ATOR
LT L
Multi-color LED
flashes pulse codes
FAU
QUICK
los ed
ION tacts c
to identify fault type LOCAT and relay con
FAULT tecte d
ODE lts de witch
ULT C No fau tuck s
LED FA N” Guard
open
(o r) W elded/s
“O ned l (or)
GREEN 0.5 Hz misalig t signa
SE @ Guard (or) No star
E L L OW PU L 2 Hz c t ir e d
Y SE @ con ta requ
Positive-guided W PUL p test
YELLO Start-u circuit on inp
uts
relay outputs a rd sw it ch
in te rference
G u e
ductiv
itive/in e (or)
PULSE
) Capac ly voltag on
RED (1 in su p p n c ti
L SES) Dro p ma lf u
contac
t
RED (4
P U l relay l relay
S) Interna rn a
PULSE tu c k in te
3536
*See inside back cover for more RED (5 Welde
d/s cuit S 1236
, 3336,
o n it o ring cir SIVELY FOR: AE
S) AES m U
information about SCHMERSAL PULSE EXCL
RED (6 S)
Safety Interlock Switches. PULSE
RED (7
TABLE OF CONTENTS
Topic Page
Alphanumeric Product Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About Schmersal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Achieving Control Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Basic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Controller Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product Section Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendices
• AES / AZR Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
• AES Series “Integral System Diagnostic” Charts . . . . . . . . . . . . . . . . . . . . . . 186
• AES / AZR Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
• Selected Machine Safeguarding Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 193
• Machine Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Copyright © 2000 by SCHMERSAL All Rights Reserved.

SCHMERSAL is continuously working to improve our products and to add new ones.
We reserve the right, therefore, to change all listed product specifications and ratings without notice.
2
ALPHANUMERIC PRODUCT INDEX
Product Page Product Page
Series Series
AES 1102 . . . . . . . . . . . . . . . . . . . . . . . . . 16 FWS 1106 . . . . . . . . . . . . . . . . . . . . . . . . . 76
AES 1112 . . . . . . . . . . . . . . . . . . . . . . . . . 18 FWS 2316 . . . . . . . . . . . . . . . . . . . . . . . . . 78
AES 1135, 1136, 1145 & 1146 . . . . . . . . . 20 FWS 3505-2204 . . . . . . . . . . . . . . . . . . . . . 80
AES 1165 & 1166 . . . . . . . . . . . . . . . . . . . 22 SRB-LV . . . . . . . . . . . . . . . . . . . . . . . . . . 154
AES 1235 & 1236 . . . . . . . . . . . . . . . . . . . 24 SRB-MSK . . . . . . . . . . . . . . . . . . . . . . . . 158
AES 2135 & 2136 . . . . . . . . . . . . . . . . . . . 26 SRB-NA-R-C.14 . . . . . . . . . . . . . . . . . . . . . 82
AES 2165 & 2166 . . . . . . . . . . . . . . . . . . . 28 SRB-NA-R-C.15 & SRB-NA-R-C.15/1 . . . . . 86
AES 2335 & 2336 . . . . . . . . . . . . . . . . . . . 30 SRB-NA-R-C.16 & SRB-NA-R-C.16/1 . . . . . 90
AES 3335 & 3336 . . . . . . . . . . . . . . . . . . . 32 SRB-NA-R-C.17 . . . . . . . . . . . . . . . . . . . . . 94
AES 3335AC . . . . . . . . . . . . . . . . . . . . . . . 34 SRB-NA-R-C.18 . . . . . . . . . . . . . . . . . . . . . 98
AES 3365 & 3366 . . . . . . . . . . . . . . . . . . . 36 SRB-NA-R-C.19 . . . . . . . . . . . . . . . . . . . . 102
AES 3535 & 3536 . . . . . . . . . . . . . . . . . . . 38 SRB-NA-R-C.20 . . . . . . . . . . . . . . . . . . . . 106
AES 3565 & 3566 . . . . . . . . . . . . . . . . . . . 40 SRB-NA-R-C.21 . . . . . . . . . . . . . . . . . . . . 110
AES 6112 . . . . . . . . . . . . . . . . . . . . . . . . . 42 SRB-NA-R-C.27 . . . . . . . . . . . . . . . . . . . . 114
AES 7112 . . . . . . . . . . . . . . . . . . . . . . . . . 44 SRB-NA-R-C.33 . . . . . . . . . . . . . . . . . . . . 118
ASL 2103 . . . . . . . . . . . . . . . . . . . . . . . . . . 70 SRB-NA-R-C.34 . . . . . . . . . . . . . . . . . . . . 122
AZR 11 RT2 . . . . . . . . . . . . . . . . . . . . . . . . 46 SRB-NA-R-C.35 . . . . . . . . . . . . . . . . . . . . 126
AZR 31 R2 . . . . . . . . . . . . . . . . . . . . . . . . . 52 SRB-NA-R-C.36 . . . . . . . . . . . . . . . . . . . . 130
AZR 31 S1 . . . . . . . . . . . . . . . . . . . . . . . . . 56 SRB-NA-R-C.38 . . . . . . . . . . . . . . . . . . . . 134
AZR 31 T0 . . . . . . . . . . . . . . . . . . . . . . . . . 58 SRB-C.44 . . . . . . . . . . . . . . . . . . . . . . . . . 138
AZR 31 T2 . . . . . . . . . . . . . . . . . . . . . . . . . 60 SRB-C.46 . . . . . . . . . . . . . . . . . . . . . . . . . 142
AZR 62 A2 . . . . . . . . . . . . . . . . . . . . . . . . 66 SRB-C.47 . . . . . . . . . . . . . . . . . . . . . . . . . 146
AZR 63 V2 . . . . . . . . . . . . . . . . . . . . . . . . . 68 SRB-NA-R-C.EW . . . . . . . . . . . . . . . . . . . 150
AZS 2305 . . . . . . . . . . . . . . . . . . . . . . . . . . 72 SRB-ZB-Mo . . . . . . . . . . . . . . . . . . . . . . . 162
FWS 1105 . . . . . . . . . . . . . . . . . . . . . . . . . 74 SRB-ZHK . . . . . . . . . . . . . . . . . . . . . . . . . 166
3
ABOUT SCHMERSAL
K.A. SCHMERSAL GmbH & Co. was founded as a

family business in 1945. The firm initially focused on the
design and manufacture of electromechanical switches
for industrial applications.
Our first products included heavy-duty, cast-encapsu-
lated limit switches for (post-war) civil engineering and
construction applications. This program quickly expand-
ed to include:
• grey cast iron limit switches
• light metal limit switches
• robust precision limit switches
• spindle limit switches
• gear motor switches
• elevator switch gears
• CENELEC position switches
• miniature snap-acting switches, and
• command devices for machine and crane control Armed with diverse electronic and electromechanical
systems. capabilities, the firm has continued to welcome unique
With this early post-war product program, the firm customer-specific problems. Operating from their mod-
quickly established itself as a specialist in monitoring, ern headquarters in Wuppertal, Germany, an industrial
switching, and controlling elevators, material handling suburb of Dusseldorf with a population of 400,000, the
systems, machine tools, and other industrial equipment. firm’s 400 employees maintain close contact with their
Many of these initial products satisfied unique require- worldwide customer base.
ments for safety switches. Such products included: This close contact, coupled with a commitment to
• explosion-proof switches for gasoline pumps respond to the needs of their customers, continues to
• door contacts and locks for personnel/freight eleva- serve as a basis for continued new product development
tors to meet the constantly changing market.
• cable monitoring switches for mountain cablecar By 1953 the company had established a reputation as
systems, and a leading producer of innovative safety switches.
• snap-acting limit switches featuring positive-opening SYSTEM SAFETY: PROTECTION FOR MAN AND
contacts for lignite diggers, construction cranes, and MACHINE
other machinery. Recent trends for a safer workplace in many industries
Today the product range has expanded to include a have led the company to give this field even greater
broad selection of non-contact electronic presence/posi- attention. Newest product developments have focused
tion sensing sensors and switches. These are designed on advanced safety switches which satisfy the stringent
using state-of-the-art inductive, capacitive, magnetic and requirements of the harmonized European Economic
photoelectric technologies. Community and its regulatory agencies.
4
MAN-MACHINE SAFETY
THE SCHMERSAL SYSTEM: CHANGING MAN-MACHINE

A 360° APPROACH SAFEGUARDING RULES
For more than 50 years SCHMERSAL has dedicated Today worker safety is an issue of major concern to man-
itself to understanding machine safety hazards. We have ufacturers worldwide. OSHA guidelines, more stringent
made it our mission to develop defeat-resistant, fail-to- ANSI standards, and the recently (1996) adopted
safe solutions using advanced safety switch tech- European Machinery Directive (EMD) are evidence
nology. This catalog-handbook is a compila- of the increased emphasis being given to
tion of information that addresses the lat- employee safety in the workplace.
est and most stringent industry safety
Selected industry standards and
standards and regulations matched
guidelines aimed at achieving high-
with a broad selection of depend-
er levels of safety are reviewed in
able solutions.
the section of this Handbook/
The day-to-day study of mod- Catalog entitled “Safety Stan-
ern workplace safety is filled dards.” Each defines minimum
with the minutiae of industry safety requirements to which
regulations and standards. But manufacturers and employees
philosophically we look to a must comply.
higher standard in the work of
In so doing, they present new
one of the world’s greatest
challenges to the plant safety
engineers, Leonardo da Vinci. A
specialist and equipment designer
true Renaissance genius, he was
…especially where safety guards
a man whose fascination for the
ancillary to the production equip-
human body and the principles of
ment’s functional design are required.
physics resulted in his meticulous
anatomical drawings, numerous intricate
machines, and even a robotic knight that con-
sisted of a system of cables and pulleys that controlled NEW SAFETY CONCEPTS AND
the movement of articulated limbs. Arguably the world’s TECHNIQUES
first ergonomic engineer, Leonardo truly understood man
and his physiological relationship to machinery. The goal of these new and emerging guidelines is to pro-
vide heightened levels of protection to machine opera-
Like Leonardo, we at SCHMERSAL take a 360-degree tors, helpers, and maintenance personnel. Toward this
approach to safety. We evaluate from every angle the goal they have embraced several new safety system
potential for accidents and their prevention. We recog- concepts including:
nize the wide differences in each work station. We take
into account specific guard design, as well as the envi- • positive-break contacts
ronmental and physical considerations necessary to • greater tamper-resistance
support machinery operation and provide maintenance. • positive-guided controllers
We even understand the frustrations and all-too-human • fault detection
temptation some machine operators feel to override • single component failure control reliability
(bypass) the safety system. Conventional limit switches, proximity sensors, magnet
Different dynamics mean different solutions. Different switches and other classical position-sensing and control
markets are subject to different regulations. Our system devices traditionally used as safety interlocks do not
of more than 100 interlock, magnetic and rope-pull meet contemporary requirements. Consequently, when
switches has earned SCHMERSAL a world-wide reputa- used in such applications, they are regarded as unsafe.
tion for reliability, flexibility, and dependable quality.
5
INTRODUCTION
SELECTING THE OPTIMAL In designing a machine guarding safety system, the fol-
lowing objectives should be considered:
CONTROLLER . Design to suit the working environment
Some form of safety controller is required to meet higher . Achieve the desired degree of protection
risk categories of the European safety standards, to . Do not interfere with machine operation
meet OSHA/ANSI requirements for Control Reliability, . Do not encourage manipulation/bypassing
and when using coded-magnet switches as safety inter- . Make it difficult to override
locks. This guide is intended to help you properly select . Do not cause any additional dangers/hazards
and apply Schmersal Safety Controllers.
It is impossible to correctly select and apply a Safety
It is common for all of us to want to look at safety issues Controller without performing some type of quantitative
in black and white terms (“Here is Application Number risk assessment. “Guesstimating” a control category may
116 and I can find the solution in my Safety Handbook lead to excessive expense and/or to an inadequate or
under Solution Number 116”). Unfortunately, this is sel- unsafe system. There are a number of approaches to risk
dom possible. You are forced to look at safety issues in assessment, most of which use some form of decision
various shades of gray. For any given situation, there tree to determine the appropriate safety control catego-
may be a number of correct solutions depending on total ry. One such approach is discussed in the next section.
system design.
A simplistic approach that can initially point you in the
A safe machine is generally achieved through the com- right direction, but which must not be substituted for a
bination of safety measures incorporated by design and formal risk assessment is:
taken by the machine operator. Ideally such measures
should be addressed during the design phase. In addi- . If a machine can cause an injury that will heal with-
tion proper training of machine operators and mainte- out permanent damage or disability, you most likely
nance personnel is critical for safe operation. can satisfy your needs with a Category 1 safety con-
trol system.
While individual component suppliers can provide gener-
al guidance and technical information related to their . If a machine can cause permanent damage or dis-
products, it is the responsibility of the machine designer ability, you probably require at least a Category 3
or retrofitter to ensure the safety system is designed to safety control system.
meet the appropriate standards.
To minimize the possibility of worker injury and address Note: For additional background material, you may wish
industry safety standards/guidelines, it is recommended to review Schmersal’s “Man-Machine Safeguarding
that the machine designer follow these general steps: Requirements & Techniques.” This tutorial booklet pro-
vides an overview of basic machine safeguarding con-
1) Familiarize himself with the pertinent safety stan- cepts and terminology.
dards
2) Specify the limits of the machine
3) Identify the hazards and assess the risks
4) Remove the hazards or limit the risk by design
5) For remaining hazards, install necessary protective
devices
6) Inform and warn the operator of any remaining
risks/hazards.
6
RISK ASSESSMENT
Different machines and processes have different levels of The levels of risk and related safety control system
relative risk. Determining this relative risk level involves requirements are defined in Figure 2.
evaluating three major factors. These include:
These safety control system categories are not to be
(1) Severity of the potential injury.
regarded as a hierarchy. The goal is to reduce the ulti-
(2) Frequency of exposure to the potential hazard. mate risk of all machines to acceptable levels regardless
of initial assessed risk.
(3) Possibility of avoiding the hazard if it occurs.
One approach to risk assessment provides guidelines for
determining the safety control system requirements based
upon five levels of risk. These levels range from the lowest
Safety Control
risk (level B) in which the severity of injury is slight and/or Category
there is relatively little likelihood of occurrence, to the high- B 1 2 3 4
est risk (level 4) in which the likelihood of a severe injury S1
(if the safety control system fails) is relatively high. P1
F1
This particular method is depicted in Figure 1, in which the Starting Point P2
following qualitative definitions apply: S2
P1
S: Severity of potential injury F2
P2
S1: slight injury (bruise)
S2: severe injury (amputation or death)
Selection of the Safety Control Category:
F: Frequency of exposure to potential hazard A brief overview of these safety control categories is
F1: infrequent exposure provided in Figure 2.
F2: frequent to continuous exposure Preferred categories
P: Possibility of avoiding the hazard if it occurs (general- Possible categories, which require additional
ly related to the speed/frequency of movement of measures
hazard point and distance to hazard point) Excessive measures for the relevant risk
P1: possible
P2: less possible FIGURE 1
FIGURE 2
º Safety General Safety General Safety Safety General Safety General Safety
Cat. System Requirements System Behavior Cat. System Requirements System Behavior
B Safety system designed to meet operational A single fault or failure in 3 Safety system must meet the requirements of Here a single fault or fail-
requirements and withstand expected external the safety system can lead Category B. In addition the safety control system ure in the safety system will
influences. to the loss of the safety must be designed such that a single fault will not not lead to the loss of the
(This category is usually satisfied by selecting function. lead to the loss of the safety function. And, where safety function and, where
components compatible with the application condi- practical, the single fault will be detected. possible, will be detected.
tions … e.g. temperature, voltage, load, etc.) (This requires redundancy in the safety circuit
monitoring module and the use of dual-channel
1 Safety system must meet the requirements of A single fault or failure in monitoring of the input and output devices such as
Category B, but must use “well-tried” safety princi- the safety system can lead machine guard interlock switches, E-stop pushbut-
ples and components. to the loss of the safety tons, safety relays, etc.)
“Well-tried” principles and components include function. However, the use
those which: of “well tried” safety princi-
• avoid certain faults … e.g. short circuits. ples and safety compo-
4* Safety system must meet the requirements of Here a single fault or fail-
Category B. In addition the safety control system ure in the safety system will
• reduce probability of faults … e.g. over-rating nents results in a higher must be designed such that a single fault will not not lead to the loss of the
selected components, over-dimensioning for struc- level of safety system relia- lead to the loss of the safety function and will be safety function, and it will
tural integrity. bility. detected at or before the next demand on the be detected in time to pre-
• detect faults early … e.g. ground fault protec- safety system. If this is not possible, then the vent the loss of the safety
tion. accumulation of multiple faults must not lead to function.
• assure the mode of the fault … e.g. ensure an the loss of the safety function.
open circuit when it is vital that power be interrupt- (This also requires redundancy in the safety cir-
ed should an unsafe condition arise. cuit and the use of dual-channel monitoring of the
• limit the consequences of the fault. input and output devices such as machine guard
interlock switches, E-stop pushbuttons, safety
2 Safety system must meet the requirements of Here, too, a single fault relays, etc. Here the number of allowable faults
Category B. In addition the machine shall be pre- or failure in the safety sys- will be determined by the application, technology
vented from starting if a fault is detected upon tem can lead to the loss of used, and system structure.)
application of machine power, or upon periodic the safety function between
checking during operation. the checking intervals. *Category/Level 4 safety requirements are usually associated with extremely high-risk
(This suggests the use of a safety relay module However, periodic checking applications. Since general machine design practice respects classic safety hierarchy, in
with redundancy and self-checking. Single-chan- may detect faults and per- which most machine hazards are either:
nel operation is permitted provided that the input mit timely maintenance of • designed out,
devices … such as machine guard interlocks, E- the safety system. • guarded against (if they cannot be designed out), and,
stop pushbuttons, et al … are tested for proper • (as a last resort) warned against,
operation on a regular basis.) Level 4 requirements may arise relatively infrequently.
7
ACHIEVING “CONTROL RELIABILITY”
“Control Reliability” as defined by ANSI/OSHA essential- . Successive machine cycles shall be prevented until
ly states that the safety system be designed, construct- the fault is corrected. This means the fault must be
ed and installed such that the failure of a single compo- detected. This is achieved by cross-monitoring of the
nent within the device or system should not prevent nor- redundant safety circuits.
mal machine stopping action from taking place — but
shall prevent a successive machine cycle from being ini- . The device that is cross-monitoring (safety controller)
tiated until the failure is corrected. must also be checked to prevent a loss of the safety
system due to a fault in this device.
Note that this definition closely follows the definitions of
a safety control category 3 as defined by European Thus the following are required to achieve “Control
machinery safety standard EN954-1. Reliability”:
It is helpful to break down the definition of Control . Redundancy

Reliability in order to better understand how it might be . Fault Detection
achieved. . Cross-Monitoring
. Self-checking of the monitoring device
. Any single fault shall not lead to a loss of the safety
function. This strongly implies redundancy in the safe- Let’s look at a basic safety system and develop it to a
ty circuit. control reliable level.
Assuming the components are selected with

appropriate electrical ratings and agency MCR
approvals, this system will generally meet cat-
E-STOP CONVENTIONAL MASTER
egory B requirements per European stan- LIMIT SWITCH CONTROL
dards. RELAY
FIGURE 3
Basic Safety Control System (Category B)
We can improve the safety system reliability by

using an E-Stop and a safety interlock switch MCR
with positive-break contacts. This will general- POSITIVE-BREAK POSITIVE-BREAK

MASTER
ly meet category 1 requirements per the refer- E-STOP SAFETY INTERLOCK SWITCH
CONTROL
RELAY
enced European standards. However, it does
not yet meet the requirements for control relia- FIGURE 4:
bility. Basic Safety Control System (Category 1)
8
MCR
To increase the reliability, let’s next add addi-
tional positive-break contacts to our E-Stop
and safety interlock switch (Figure 5).
MCR
POSITIVE-BREAK POSITIVE-BREAK
We now have redundancy but still lack fault E-STOP WITH SAFETY INTERLOCK MASTER
DUAL CONTACTS SWITCH WITH CONTROL
detection. To provide this fault detection, we DUAL CONTACTS RELAYS
must add additional devices.
FIGURE 5:
Basic Safety Control System with Redundancy
This black box provides safety system fault

detection as well as cross-monitoring and self- MCR
checking. While this can be achieved with a BLACK
complex hard-wired circuit utilizing 3 positive- BOX
guided relays and over 40 wiring points, it is MCR

E-STOP SAFETY
much simpler and less expensive to utilize a GATE MASTER
commercially available safety controller. SWITCH CONTROL
RELAYS
FIGURE 6:
Basic Safety Control System (Category 3 or 4)
with Redundancy and Fault Detection
L1
0 V
Figure 7 shows a typical example of a control

+24 VDC
reliable circuit utilizing a safety controller.
A1 A2 Y1 X1 13 23
100mA
max.
K1
K2
S13 S14 S21 S22 14 24
K3
K4
0 V
M
3
FIGURE 7
9
BASIC FUNCTION
The SCHMERSAL family of safety controllers includes
two basic designs. One utilizes relay logic. The other uses . Welded interlock/E-stop switch contacts
solid-state (microprocessor) logic. Pioneered by SCHM- . Misaligned guard
ERSAL, these “smart” safety controllers provide added . Open circuits, short circuits or ground faults
features and capabilities unachievable with conventional . Welded/stuck contacts in module’s safety relays
safety relay modules. . Fault in the module’s monitoring circuits
. Inadequate supply voltage to module
Both designs feature redundant, dual-channel cross-mon- . Welded/stuck contacts in controlled output motor con-
itoring logic circuits. These continuously check for, and
detect, faults in the system’s safety circuit components . tactor/control relay
Capacitive/inductive interference on module inputs
and interconnection wiring. Modules also detect when a
machine guard interlock/E-stop switch is actuated and, All controllers are designed to increase the level of safety
depending upon the model, are capable of detecting the in the machine guarding and/or E-stop control circuit.
following types of potential safety circuit faults:
SERIES SRB/AZR SAFETY CONTROLLERS SERIES AES MICROPROCESSOR-BASED

SAFETY CONTROLLERS
The SRB/AZR Series safety controllers are conventional
electro-mechanical relay-based units. Many feature the SCHMERSAL’s AES Series features microprocessor-
latest relay technology utilizing only two internal relays to based monitoring logic. In addition to performing the
achieve cross-monitoring, self-checking and redundan- functions provided by traditional relay-based modules,
cy. This results in a smaller, highly cost-effective solution the AES Series “smart” controllers provide added capa-
for up to safety control category 4 system performance bilities typically unavailable in relay-based designs.
per European standards. These include:
Models are available to satisfy most safety application . Fault identification diagnostics … the AES provides a
requirements. They offer a wide variety of important fea- variety of flashing, colored LED patterns which indi-
tures including: cate specific types of faults and their location (thus
minimizing equipment downtime).
. 1 or 2 channel triggering . Auxiliary semiconductor outputs … for alarm and/or
. Crossed wire detection signaling purposes.
. STOP Category 0 & 1 modules . Modular component design … permitting realization of
. Manual monitored reset the most cost-effective monitoring solution.
. Monitoring of non-potential free contacts . “Diverse redundancy” … use of different components
. Feature selection via base mounted dip switches and/or programs in the redundant monitoring circuits
. Output expanders eliminates “common cause” failures and heightens
. Special 12VDC for use on battery power module reliability.
. Dual channel antivalent input circuits for humid envi- • Multiple inputs.
ronments
While initially designed for use with Schmersal coded-
magnet switches, most controllers can also be used with
E-Stop or conventional machine guard safety interlock
switches. These controllers are separated into several
categories for ease of selection.
10
SELECTION CRITERIA
It helps the selection process to view a safety controller as application requirements. This approach can be applied to
having four basic characteristics, each determined by the any safety controller.
FOUR BASIC SAFETY CONTROLLER CHARACTERISTICS
Input
Monitoring Output
Feedback &
Supply Voltage Reset Circuit
SUPPLY VOLTAGE REQUIREMENTS ed contacts. Such feedback is required for safety control
category 3 & 4 systems. A NC auxiliary contact is wired
Select your supply voltage. While many voltages are pos- into the feedback loop (with or without a reset (start) but-
sible (24VDC, 24VAC, 24VAC/DC, 115VAC and 230VAC), ton) to detect welded contacts in these external control
24 VDC gives the most flexibility since virtually all con- devices. The safety controller detects the existence of a
trollers are available in this voltage. Also, since a trans- weld when the relay shuts down due to a power loss or
former and rectifier are not required, this unit generally is open machine guard and prevents a restart.
less expensive and smaller than a 115VAC model.
In order to reset the controller, the feedback loop must be
Regardless of supply voltage, it is always converted by the closed (at least temporarily). If the NC auxiliary contact
controller electronics to 24VDC for internal operation and stays open due to a contact weld, the controller cannot be
for powering monitored input devices. Hence monitored reset.
devices only need to be rated for 24VDC.
Reset can be automatic or be manual monitored/trailing
INPUT MONITORING REQUIREMENTS edge. With automatic reset the controller will automatical-
ly reset (outputs close) when the machine guard is closed.
The first step is to determine whether you need single A reset or start button can be added to the feedback loop
channel (up to control category 2) or dual channel (control if desired. The controller only needs to momentarily see a
category 3 & 4) operation. 24VDC signal at the feedback terminals to reset.
Single-channel systems must monitor one NC positive- With a manual monitored/trailing edge reset, some type of
break contact. Dual-channel systems can monitor manual pushbutton is required. The feedback loop circuit-
1NO/1NC or 2NC contacts. Generally, these need to be ry is designed so that it needs to see a 24V to 0V transi-
isolated dry contacts since most controllers will view C- tion (trailing edge) in order to reset. This method of reset
form contacts as a short circuit. Remember that 24VDC is is generally required when a person can actually get
supplied by the safety controller for monitoring these con- inside a machine guard (where they would be at risk if the
tacts. equipment should automatically restart when the guard
closes).
Safety controllers are available for monitoring non-poten-
tial free contacts (such as PNP outputs from light cur- OUTPUT REQUIREMENTS
tains). Models are also available that allow users to field
select the monitored contact configuration. Determine the number and type of safety controller out-
puts required for machine control elements and signaling.
Another consideration is crossed wire detection (a short Following are the types of safety controller outputs:
between channels). This requires special circuitry in the
safety controllers and is required for category 4 safety A. NO safety enable circuits — either instantaneous or
control systems. timed.
FEEDBACK & RESET CIRCUIT REQUIREMENTS B. NO or NC auxiliary relay contacts — these are not to
be used for safety functions, but only for annuncia-
Safety controllers with feedback capability can also moni- tion/signaling.
tor control relays and motor contactors with positive-guid-
C. Semiconductor outputs for annunciation.
11
SAFETY CONTROLLER SELECTION GUIDE
The following selection charts have been created to help
you select a safety controller that satisfies your applica-
tion requirements. Unlike other selection methods that Safety Controller Key
usually start with identifying the appropriate safety con-
trol category, this method begins with the application Maximum Recommended Safety Control category per
requirements and leads to a possible safety relay solu- EN954:
tion.
To begin, select the application category in the Master Safety Control Category 1/2 CC1
Index Chart below. This will direct you to the appropriate

selection chart. Then starting at the top of the appropri- Safety Control Category 3 CC3
ate chart move through the application selection criteria
until a safety controller(s) is suggested. This selection
should then be examined to ensure it is adequate for the Safety Control Category 4 CC4
assessed level of risk.
Note:
. Models with 4 digits such as 1235 are part of the Under Stop Category 1, Safe Outputs are shown as
AES series.
. Models with a mixed number such as 31R2 are part STOP 0 STOP 1
of the AZR series.
. Models such as C.xx or MO are part of the SRB
series.
MASTER INDEX
Machine Safety Control System
Application
Emergency Stop Area Special Tactile
Category Safeguarding Applications Safeguard
CHART I CHART VI CHART VII
Stop Stop Output 2-Hand Muting

Category 0 Category 1 Expanders Control System
CHART III
Guard Monitoring Output Motion Safe Safety Safety

Monitoring Schmersal Expander Detection Semi- Mat Bumper
BNS
& Conductor
CHART I Coded- CHART III
Magnet Fail-Safe Monitoring
Sensors Timers
CHART V
CHART II CHART IV
12
CHART I
E-Stop and Guard Monitoring
STOP CATEGORY
STOP 0 STOP 1
INPUTS INPUTS
1NC 2NC 1NO/1NC 1NC 2NC
VOLTAGE VOLTAGE VOLTAGE VOLTAGE VOLTAGE
24 VDC AC 24 VDC AC 24 VDC AC 24 VDC 24 VDC
Safe Outputs Safe Outputs Safe Outputs Safe Outputs Safe Outputs
2 3 5 3 2 3 5 3 2 3 4 3 0/3 3/2 0/3 3/2 2/1
Auto C.14 C.15 C.20 C.33 C.14 C.15 C.20 C.33 1235 2335 3535 2335 C.16
1 sec
C.21
0-30 s.
C.16
1 sec
C.21 C.47
Reset PAGE
82
PAGE
86
PAGE
106
PAGE
118
PAGE
82
PAGE
86
PAGE
106
PAGE
118
PAGE
24
PAGE
30
PAGE
38
PAGE
30
PAGE
90
PAGE
110
PAGE
90
PAGE
110
PAGE
146
C.33 C.33 C.19 C.19

0-5 s. 0-5 s.
PAGE PAGE PAGE PAGE
118 118 102 102
Trailing C.17 C.34 C.20 C.17 C.27 C.20 C.34 C.21 C.21 C.47
0-30 s. 0-30 s.
Edge PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE
94 122 106 94 114 106 122 110 110 146
CHART II
Schmersal BNS Coded-Magnet Sensors
STOP CATEGORY
STOP 0
INPUTS
1NO/2NC NO/NC 2NC
VOLTAGE VOLTAGE VOLTAGE
24 VDC AC 24 VDC AC 24 VDC AC
Safe Outputs Safe Outputs Safe Outputs Safe Outputs
1 1 1 2 3 4 1 3 3 3
6112 7112 1135 1235 2335 3535 2135 2335 31T2 31T2
Automatic
PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE
Reset 42 44 20 24 30 38 26 30 60 60
1102 1112 C.44

PAGE PAGE PAGE
16 18 138
Trailing Edge C.44 31R2 31R2

Reset PAGE
138
PAGE
52
PAGE
52
13
CHART III
Output Expander
STOP CATEGORY
STOP 0 STOP 1
VOLTAGE VOLTAGE
24 VDC AC 24 VDC AC
Safe Outputs Safe Outputs Safe Outputs Safe Outputs
4/0 6/0 4/0 6/0 0/6 0/6
C.EW Mo LV 62A2 63V2 63V2

0-30s 0-30s
PAGE PAGE PAGE PAGE PAGE PAGE
150 162 154 66 68 68
CHART IV
Motion Detectors and

Fail-Safe Timers
STANDSTILL MONITOR FAIL-SAFE TIMER
INPUTS INPUTS
1 PULSED 2 PULSED 3-PH TAP NO/NC
VOLTAGE VOLTAGE VOLTAGE VOLTAGE
24 VDC 24 VDC AC 24 VDC AC 24 VDC AC
Safe Outputs Safe Outputs Safe Outputs
1 1 3 3 3 3 3 3
1106 1105 2316 2316 31S1 31S1 2305 2305

PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE
76 74 78 78 56 56 72 72
14
CHART V CHART VI
Safe Semiconductor*
Monitoring
STOP CATEGORY Special Applications
Stop 0 Stop 1
2-HAND CONTROL MUTING SYSTEM

INPUTS INPUTS
2 PNP 2 PNP INPUTS INPUTS INPUTS
Muting sensors Muting sensors

VOLTAGE VOLTAGE 2NC/2NO
2/4 PNP 2/4 NO
24VDC 24VDC VOLTAGE VOLTAGE VOLTAGE
Safe Outputs Safe Outputs 24 VDC AC 24 VDC 24VDC
2 3 0/3 3/1 3/2 Safe Outputs Safe Outputs
2 3 2 3 (2) (2)
Automatic C.18 C.33 C.19
0-5s.
C.38
0-30
Reset PAGE PAGE PAGE PAGE
98 118 102 134
ZHK 31R2 ZHK 31R2 MSK MSK
166 52 166 52 158 158
Trailing Edge C.36 C.27 C.35 C.38

0-30 0-30
Reset PAGE
130
PAGE
114
PAGE
126
PAGE
134
*i.e. PNP outputs from light curtains or proximity switches
CHART VII
Tactile Safeguard
SAFETY MAT SAFETY EDGE
STOP CATEGORY STOP CATEGORY
STOP 0 STOP 0
INPUTS INPUTS
2NC 1 NC + RESISTOR 2NC
VOLTAGE VOLTAGE VOLTAGE
24 VDC AC 24 VDC AC 24 VDC AC
Safe Outputs Safe Outputs Safe Outputs
1 3 3 1 1 1 3 3
Automatic 11RT2 31T2 31T2 2103 2103 11RT2 31T2 31T2

PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE
Reset 46 60 60 70 70 46 ???60 60
Trailing Edge 11RT2 31R2 31R2 11RT2 31R2 31R2

Reset 46 52 52 46 52 52
15
Guard Door and E-Stop Safety Controllers Safety Category (EN954-1): CC1
AES 1102 to Monitor Several Devices Stop Category (EN60204-1): 0
Features • Control Category 1 to EN 954-1

• 1 enabling path
• Monitoring of 1 or a number of guard
devices
• Connection of BNS .. -12z magnetic safety
sensors with 1 NO and 2 NC contacts
• LED function indicators
• Available for various operational voltages
Dimensions 22.5 x 75 x 110 mm
Model AES 1102-24VDC

Designation
AES 1102-24VAC
AES 1102-42VAC
AES 1102-110VAC
AES 1102-230VAC
Approvals BG UL CSA
16
Guard Door and Safety E-Stop Controllers
AES 1102 to Monitor Several Devices
Typical
Application
Typical
WH
GY
GN
Wiring
Diagram
YE
BN
PK
WH
GY
GN
YE
BN
PK
WH
GY
GN
L1
Ue
YE
BN
PK
A1 A2 S22 S32 S14 C 13
K1
24 VDC
K2 AES 1102
K3
14
K4
N 3
M
Notes • AES to secure a number of guard • Monitoring a number of guard

devices using series-parallel cir- devices using BNS 33..-12z-2187
cuits for Control Category 1 to EN range magnetic safety sensors with
954-1. isolated contacts.
• Only suitable for the connection of • The wiring diagram is with guard
magnetic safety sensors. devices closed and shows the de-
energized condition.
Circuit • Monitoring One Guard Device

Options Monitoring one guard devices using
a BNS .. -12z Series coded-magnet
safety sensor.
17
AES 1112 to Monitor Two Devices Stop Category (EN60204-1): 0

• 1 enabling path
• Monitoring of 1 or 2 guard devices or multi-
ple devices using BNS .. -12z
magnetic safety sensors with 1 NO and 2
NC contacts
• LED function indicators
• Designed to DIN VDE 0660-209

Designation
AES 1112-24VAC
AES 1112-42VAC
AES 1112-110VAC
AES 1112-230VAC
Approvals BG UL CSA
18
Guard Door and E-Stop Safety Controllers
AES 1112 to Monitor Two Devices
Typical
Application
Typical
Wiring
Diagram
Notes • AES to monitor a two guard • Monitoring a number of two guard • The wiring diagram is with guard
devices for Control Category 1 to devices each fitted with one devices closed and shows the de-
EN 954-1. BNS 33..-12z range magnetic energized condition.
• Only suitable for the connection of safety sensors.
magnetic safety sensors.
Circuit • Monitoring One Guard Device • Series-Parallel Circuits

Options When only one magnetic safety Further guard devices can be moni-
sensor is connected, the terminals tored using BNS 33-12z-2187
S22, S32, S14 and C of S1 are Series coded-magnet safety sensor
used and jumper connections must in series-parallel circuits.
be wired between the terminals
S22, S32 and C of S2.
19
AES 1135, AES 1136, AES 1145 and AES 1146
Stop Category (EN60204-1): 0
to Monitor One Device

• 1 enabling circuit
• Enable delay time can be modified
• Monitoring of mechanical position switches,
safety switches, solenoid interlocks, coded
magnet sensors or E-stops
• Can be used as emergency-stop controller
for Category 0 to EN 60204-1
• Monitoring for short-circuit between
connections with NO-NC contact
combination
• Connection of input expansion modules
possible
ISD The following faults are recognized by the safety Note The ISD tables (Integral System Diagnostics)
controller and indicated by means of ISD for analysis of the fault indications and their
• Failure of door contacts to open or close causes are shown in the appendix.
• Short-circuits on or between the switch connections
• Interruption of the switch connections
• Failure of the unit’s internal safety relay to pull-in or
drop-out
• Faults on the input circuits or on the relay control
of the guard door monitor
Model AES 1135-24VDC (For unit with optional start-up test specify AES 1136-24VDC)
Designation
AES 1145-24VDC (For unit with optional start-up test specify AES 1146-24VDC)
Function Additional semi- Function of output Y Switching Condition

Table conductor output Y
AES 1135/6 Y1 Enable Enable circuit closed

Y2 No enable Enable circuit open
AES 1145/6 Y1 Guard device open Enable circuit open

Y2 Fault Enable circuit open
Approvals BG UL CSA
20
AES 1135, AES 1136, AES 1145 and AES 1146 to Monitor One Device
Typical
Application
Typical
Wiring AZM 415-22
Diagram
A1 A2 11 12 13 14 21 22 23 24
L1
+24 VDC
A1 S13 S14 S21 S22 13
K1
max.
AES 1145/1146
100mA
K2
A2 Y1 Y2 X1 14 14
K3
0V M K4
N N
3
M
CC3 CC1
Notes • AES to achieve up to Control of “faults due to breakage or contactors” can be substantiated
Category 3. loosening of the actuator or in the and is documented, e.g. by using
• Monitoring a sliding, hinged or solenoid interlock”. reliable de-rated contactors. A sec-
removable guard device using • If the load is directly switched by ond contactor leads to an increase
a solenoid interlock. the AES, the complete system can in the level of security by redundant
be classified in Control Category 3 switching of the load.
• The NC contact must have positive
opening function when the guard to EN 954-1. If one or two external • The wiring diagram is with guard
device is opened. relays or contactors are used to device closed and shows the
switch the load, the system can de-energized condition.
• Control Category 3 to EN 954-1 then only be classified in Control
can be achieved by substantiation Category 3 to EN 954-1 if exclusion
and documentation of exclusion of the fault “Failure of the external
Circuit • Extension of Enable Delay Time

Options The enable delay time can be
increased from 0.1 s to 1 s by
changing the position of a jumper
link connection under the cover of
the unit.
21
AES 1165 and AES 1166 to Monitor Two Devices Stop Category (EN60204-1): 0

• To monitor 2 guard devices for Control
Category 3
• NO-NC contact combination can be
connected
connections
• ISD Integral System Diagnostics
• Operational voltage 24 VDC
possible
drop-out
Designation
Approvals BG UL CSA
22
AES 1165 and AES 1166 to Monitor Two Devices
Typical
Application
Typical
Wiring
Diagram
L1
+24 VDC
A1 S13 S14 S21 S22 13
S1
K1
max. AES 1165/1166
K2
100mA
S2
A2 S13 S14 S21 S22 14 14
0V
K3
M K4
N M
SK3
CC3 SK1
CC1 3
Notes • AES to achieve up to Control • The NC contacts must have “Failure of the external contactors”
Category 3 to EN 954-1. positive opening function when the can be substantiated and is docu-
• For the monitoring of two sliding guard devices are opened. mented, e.g. by using reliable
guard devices, each with two posi- • If the load is directly switched by de-rated contactors. A second
tion switches with safety function the AES, the complete system can contactor leads to an increase in
(A and B, C and D). be classified in Control Category 3 the level of security by redundant
to EN 954-1. switching of the load.
• Monitoring of two hinged guard
devices, each with two hinge safety • If one or two external relays or • The wiring diagram is with guard
switches (A and B, C and D). contactors are used to switch the devices closed and shows the
load, the system can then only be de-energized condition.
• Monitoring of two removable guard
devices, each with two safety classified in Control Category 3 to
switches with separate actuators. EN 954-1 if exclusion of the fault

increased from 0.1 s to 1 s by
changing the position of a jumper
link connection under the cover of
the unit.
23
AES 1235 and AES 1236 to Monitor One Device Stop Category (EN60204-1): 0

• 2 enabling circuits
connected
combination
• Short-circuit proof additional transistor
output
• Feedback circuit to monitor external relays
• Start function
possible
ISD The following faults are recognized by the safety • Additional contact by means of output
controller and indicated by means of ISD expansion modules
• Failure of door contacts to open or close
• Failure of the unit’s internal safety relay to pull-in or Note The ISD tables (Integral System Diagnostics)
drop-out for analysis of the fault indications and their
• Faults on the input circuits or on the relay control causes are shown in the appendix.
Designation

AES 1235 Y1 Enable Enable circuit closed
Approvals BG UL CSA
24
AES 1235 and AES 1236 to Monitor One Device
Typical
Application
L1
Typical
Wiring 0V
Diagram +24 VDC
A1 A2 Y1 X1 13 23
max. 100mA
K1 AES 1235
AES 1236
K2
S13 S14 S21 S22 14 24
K3
K4
0V
SK3
CC3 3
M
Notes • AES achieve Control Category 3 to • If only one external relay or con- contactor. A second contactor leads
EN 954-1. tactor is used to switch the load, to an increase in the level of securi-
• Monitoring a sliding, hinged or the system can be classified in ty by redundant switching of the
removable guard device, each Control Category 3 to EN 954-1 if load.
using a coded magnet sensor A. exclusion of the fault “Failure of • The wiring diagram is with guard
the external contactor” can be devices closed and shows the de-
• The feedback circuit monitors posi- substantiated and is documented,
tions of the contactors K3 and K4. energized condition.
e.g. by using a reliable de-rated
Circuit • Start Pushbutton s • Feedback Circuit • Extension of Enable Delay Time

Options A start pushbutton (NO) can option- A feedback circuit is shown con- The enable delay time can be
ally be connected to the inputs in nected in the wiring diagram. If no increased from 0.1 s to 1 s by
the feedback circuit. With the guard feedback circuit is used, input X1 changing the position of a jumper
device closed, the enabling circuits must be connected to 24 VDC link connection under the cover of
are then not closed until the start supply or a jumper between output the unit.
pushbutton has been operated. Y1 and input X1.
25

• Can be changed from NO-NC to NC-NC
contact combination
combination
possible
Dimensions 55 x 75 x 110 mm
drop-out
Model AES 2135-24VAC (For unit with optional start-up test specify AES 2136-24VAC)
Designation
AES 2135-110VAC (For unit with optional start-up test specify AES 2136-110VAC)
Approvals BG UL CSA
26
Typical
Application
Typical
Wiring
Diagram
CC3 CC1
Notes • AES to achieve Control Category 3 • If one or two external relays or con- the level of security by redundant
to EN 954-1. tactors are used to switch the load, switching of the load.
• Monitoring a sliding, hinged or the system can then only be • The wiring diagram is with guard
removable guard device, each classified in Control Category 3 to devices closed and shows the de-
using a safety coded magnet A. EN 954-1 if exclusion of the fault energized condition.
“Failure of the external contactors”
• If the load is directly switched by can be substantiated and is docu-
the AES, the complete system can mented, e.g. by using reliable
be classified in Control Category 3 de-rated contactors. A second
to EN 954-1. contactor leads to an increase in
Circuit • Modification for 2 NC Contacts • Extension of Enable Delay Time

Options The controller can be modified to The enable delay time can be
monitor two normally closed con- increased from 0.1 s to 1 s by
tacts by jumping between the termi- jumping between the terminals X5
nals X1 and X2. The short circuit and X6.
monitoring between connections
then becomes inoperative.
27

• To monitor 2 guard devices for Category
0 to EN 60204-1
connected
connections
possible
drop-out
Designation
Approvals BG UL CSA
28
Guard Door and E-Stop Safety Controller
Typical
Application
Typical
Wiring
Diagram
CC3 CC1
Notes • AES to achieve Control Category 3 • If one or two external relays or con- level of security by redundant
to EN 954-1. tactors are used to switch the load, switching of the load.
• Monitoring of two guard devices, the system can then only be • The wiring diagram is with guard
each with a coded magnet sensor classified in Control Category 3 to devices closed and shows the de-
(A and B). EN 954-1 if exclusion of the fault energized condition.
“Failure of the external contactors”
• If the load is directly switched by can be substantiated and is docu-
the AES, the complete system can mented, e.g. by using reliable
be classified in Control Category 3 de-rated contactors. A second con-
to EN 954-1. tactor leads to an increase in the

increased from 0.1 s to 1 s by a
jumper between the terminals X5
and X6.
29

connected
connections
outputs
• Start function
possible
• Additional contact by means of output
ISD The following faults are recognized by the safety expansion modules
controller and indicated by means of ISD
• Failure of or functional fault on the safety controller
Designation


Y2 No enable Enable circuit open
Approvals BG UL CSA
30
Typical
Application
Typical L1
+24 VDC/
Wiring S13/S21
Diagram 0V
Ue
A1 A2 Y1 Y2 X1 13 23 33
max. 100mA
K1
AES 2335
24 VDC
K2
PE S13 S14 S21 S22 14 24 34
0V
13 14 21 22 1 2 3 4 5 6
K3
K4
AZM 160-22yp N
SK1 3
M
CC1
Notes • The wiring diagram shown achieves is to be substantiated and docu- and is documented, e.g. by using a
Control Category 1 to EN 954-1. mented. reliable de-rated contactor. A sec-
• Monitoring a sliding, hinged or • The NC contact A must have posi- ond contactor leads to an increase
removable guard device. tive opening function when the in the level of security by redundant
guard device is opened. switching of the load.
• To achieve Control Category 3 to
EN 954-1, the feedback circuit must • If only one external relay or contac- • The wiring diagram is with guard
be connected. tor is used to switch the load, the device closed and shows the de-
system can be classified in Control energized condition.
• In addition, exclusion of faults due
to breakage or loosening of the Category 3 to EN 954-1 if exclusion
actuator or in the solenoid interlock of the fault “Failure of the external
contactor” can be substantiated
Circuit • Start Pushbutton s • Feedback Circuit with 24 VDC from terminal S13 or
Options A start pushbutton (NO) can option- For this purpose, the positive-drive S21.
ally be connected to the inputs in contacts of the external contactors
the feedback circuit. With the guard can be connected to input X1. The
device closed, the enabling circuits power supply to this feedback
are then not closed until the start circuit is either from semiconductor
pushbutton has been operated. output Y2 or, if this is already used, 31

contact combination
combination
• Operational voltage of 24 VDC
outputs
• Feedback circuit to monitor external
contactors
Dimensions 99.7 x 75 x 110 mm • Start function
possible
ISD The following faults are recognized by the safety
controller and indicated by means of ISD • Additional contact by means of output
expansion modules
Designation
Function Additional semi- Function of output Y X5 and X6

AES 3335/6 Y1 Enable Without jumper

Y2 No enable Without jumper
Y1 Door Open With jumper

Y2 Fault With jumper
Approvals BG UL CSA
32
Typical
Application
Typical 0V
Wiring L1
Diagram
+24 VDC
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33
max. 100mA
K1
K2
A2 X3 X4 X5 X6 X7 X8 14 24 34
0V K3
AES 3335/3336
K4
N
SK3
CC3 3
M
Notes • AES to achieve up to Control positive opening function when the substantiated and documented.
Category 3 to EN 954-1. guard device is opened. • The feedback circuit monitors the
• Monitoring a sliding guard door • Control Category 3 to EN 954-1 positions of the positive-drive NC
using two position switches with can also be achieved using only contacts on the contactors K3 and
safety function (A and B). one safety switch with one NO and K4.
• Monitoring a hinged or removable one normally closed contact. • Contactor K4 increases the level of
guard device using two safety Exclusion of faults due to breakage security but is not essential
switches with separate actuators or loosening of the actuating ele-
ment or the operating head as well • The wiring diagram is with guard
(A and B). device closed and shows the de-
as releasing, dismantling or sliding
• The NC contact A must have of the position switches is to be energized condition.
Circuit • Start Pushbutton s • Modification for 2 NC Contacts • Extension of Enable Delay Time
Options A start pushbutton (NO) can option- The controller can be modified to The enable delay time can be
ally be connected into the feedback monitor two normally closed con- increased from 0.1 s to 1 s by a
circuit. With the guard device tacts by a jumper between the ter- jumper between the terminals X7
closed, the enabling circuits are minals X3 and X4. The monitoring and X8.
then not closed until the start push- of short-circuit between connec-
button has been operated. If neither tions then becomes inoperative.
start button nor feedback circuit are
connected, a jumper must be wired
between X1 and X2.
33
AES 3335 AC to Monitor One Device Stop Category (EN60204-1): 0

contact combination
• 2 potential-free indication contacts
(NO-NC)
connections
• Available in various operational voltages
• Start function
possible
Designation
Function of output Y X5 and X6

Function Additional semi-
AES 3335/6 43/44 Enable Without jumper

51/52 No enable Without jumper
43/44 Door open With jumper

51/52 Door closed With jumper
Approvals BG UL CSA
34
AES 3335 AC to Monitor One Device
Typical
Application
Typical
Wiring
Diagram
CC3
Notes • AES to achieve up to Control • If only one external relay or contac- in the level of security by redundant
Category 3 to EN 954-1. tor is used to switch the load, the switching of the load.
• Monitoring a sliding, hinged or system can be classified in Control • The wiring diagram is with guard
removable guard device using a Category 3 to EN 954-1 if exclusion device closed and shows the de-
coded magnet sensor A. of the fault “Failure of the external energized condition.
contactor” can be substantiated
• The feedback circuit monitors and is documented, e.g. by using a
positions of the positive-drive NC reliable de-rated contactor. A sec-
contacts of the contactors K3 ond contactor leads to an increase
and K4.
ally be connected into the feedback monitor two normally closed con- increased from 0.1 s to 1 s by
circuit. With the guard device tacts by placing a jumper between placing a jumper between the
closed, the enabling circuits are the terminals X3 and X4. The moni- terminals X7 and X8.
then not closed until the start push- toring of short-circuit between con-
button has been operated. If neither nections then becomes inoperative.
connected, a jumper connection
must be wired between X1 and X2.
35

Category 3
connected
connections
output
• Start function
possible
expansion modules
Designation


Approvals BG UL CSA
36
Typical
Application
Typical
Wiring
Diagram
CC3
Notes • AES to achieve Control Category 3 connected, a jumper must be and is documented, e.g. by using a
to EN 954-1. placed between the inputs X1 and reliable de-rated contactor. A sec-
• Monitoring of two guard devices, X2. ond contactor leads to an increase
each with a coded magnet sensor • If only one external relay or contac- in the level of security by redundant
of the BNS range (A and B). tor is used to switch the load, the switching of the load.
• The feedback circuit monitors system can be classified in Control • The wiring diagram is with guard
the positions of the positive-drive Category 3 to EN 954-1 if exclusion device closed and shows the de-
NC contacts on the contactors of the fault “Failure of the external energized condition.
K3 and K4. If no feedback circuit is contactor” can be substantiated
Circuit • Start Pushbutton s • Extension of Enable Delay Time

Options A start pushbutton (NO) can option- The enable delay time can be
ally be connected between the increased from 0.1 s to 1 s by
input X1 and X2 or in the feedback placing a jumper between the
circuit. With the guard device terminals X7 and X8.
closed, the enabling circuits are
then not closed until the start push-
button has been operated. If neither
start button nor feedback circuit is
used, a jumper must be placed
between X1 and X2.
37

contact combination
• 1 potential-free indication contact (NC)
combination
• Operational voltage of 24 VDC
• 2 short-circuit proof additional transistor
outputs
Dimensions 99.7 x 75 x 110 mm contactors
• Start function
ISD The following faults are recognized by the safety • Available with or without start-up test
controller and indicated by means of ISD • Connection of input expansion modules
• Failure of door contacts to open or close possible
• Short-circuits on or between the switch connections • Additional contact by means of output
expansion modules
Designation
Function Additional semi- Function of output Y X5 and X6

AES 3335/6 Y1 Enable Without jumper

Y2 No enable Without jumper
Y1 Door Open With jumper

Y2 Fault With jumper
Approvals BG UL CSA
38
Typical
Application
Typical 0V
Wiring L1
Diagram
+24 VDC
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33 43 51
max. 100mA
K1
K2
A2 X3 X4 X5 X6 X7 X8 14 24 34 44 52
0V K3
AES 3535/3536
K4
N
SK3 3
M
CC3
Notes • AES to achieve up to Control positive opening function when the substantiated and documented.
Category 3 to EN 954-1. guard device is opened. • The feedback circuit monitors the
• Monitoring a sliding guard door • Control Category 3 to EN 954-1 positions of the positive-drive NC
using two position switches with can also be achieved using only contacts on the contactors K3 and
safety function (A and B). one safety switch with one NO and K4.
• Monitoring a hinged or removable one normally closed contact. • Contactor K4 increases the level of
guard device using two safety Exclusion of faults due to breakage security but is not essential
switches with separate actuators or loosening of the actuating ele-
ment or the operating head as well • The wiring diagram is with guard
(A and B). device closed and shows the de-
as releasing, dismantling or sliding
• The NC contact A must have of the position switches is to be energized condition.
ally be connected into the feedback monitor two normally closed con- increased from 0.1 s to 1 s by a
circuit. With the guard device(s) tacts by placing a jumper between jumper between the terminals X7
closed, the enabling circuits are the terminals X3 and X4. The moni- and X8.
then not closed until the start push- toring of short-circuit between con-
button has been operated. If neither nections then becomes inoperative.
connected, a jumper must be
placed between X1 and X2.
39

Category 3 to EN 954-1
connected
• 1 potential-free indication contact (NC)
combination
• Short-circuit proof semiconductor outputs
• Start function
Dimensions 99.7 x 75 x 110 mm • Connection of input expansion modules
possible
Designation
Function Additional semi- Function of output Y Switching condition


Approvals BG UL CSA
40
Typical
Application
Typical 0V
Wiring L1
Diagram
+24 VDC
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33 43 51
S1
max. 100mA
K1
S2 K2
A2 S13 S14 S21 S22 X7 X8 14 24 34 44 52
0V AES 3565/3566
K3
K4
N
SK3 3
M
CC3
Notes • AES to achieve Control Category 3 • Monitoring of two hinged guard tor is used to switch the load, the
to EN 954-1. devices, each with two hinge safety system can be classified in Control
• Control Category 3 to EN 954-1 switches (A and B, C and D). Category 3 to EN 954-1 if exclusion
can also be achieved without the • Monitoring of two removable guard of the fault “Failure of the external
second safety switches B and D. devices, each with two safety contactor” can be substantiated
Exclusion of the faults “breakage switches with separate actuators. and is documented, e.g. by using a
or loosening of the actuating ele- reliable de-rated contactor. A sec-
• The NC contacts A and C must ond contactor leads to an increase
ments or actuator and loosening, have positive opening function
dismantling or sliding of the safety in the level of security by redundant
when the guard devices are switching of the load.
switch” is to be substantiated and opened.
documented. For this purpose, both • The wiring diagram is with guard
a NO and NC contact must be con- • The feedback circuit monitors the devices closed and shows the de-
nected from each of the safety positions of the positive-drive NC energized condition.
switches A and C. contacts on the contactors K3 and
K4. If no feedback circuit is con-
• For the monitoring of two sliding nected, a jumper must be placed
guard devices, each with two posi- between the inputs X1 and X2.
tion switches A and B, C with safety
function (A and B, C and D). • If only one external relay or contac-
Circuit • Start Pushbutton s then not closed until the start push- • Extension of Enable Delay Time
Options A start pushbutton (NO) can option- button has been operated. If neither The enable delay time can be
ally be connected between the start button nor feedback circuit is increased from 0.1 s to 1 s by
input X1 and X2 or in the feedback used, a jumper must be placed placing a jumper between the
circuit. With the guard device between X1 and X2. terminals X7 and X8.
closed, the enabling circuits are 41
AES 6112 to Monitor Several Devices Stop Category (EN60204-1): 0

• 1 enabling path
• Monitoring of 1 or a number of guard
devices
• Connection of BNS .. -12z magnetic safety
sensors with 1 NO and 2 NC
contacts
• LED function indications
• Operating voltage 24 VDC

Designation
Approvals BG UL CSA
42
AES 6112 to Monitor Several Devices
Typical
Application
Typical
WH
GY
GN
Wiring
Diagram
YE
BN
PK
WH
GY
GN
L1
+24 VDC
YE
BN
PK
A1 S22 S32 S14 C 13

S1
K1
K2 AES 6112
K3
S2
A2 S22 S32 S14 C 14
0V
K4
N 3
M
Notes • AES to monitor a number of guard • Monitoring a number of guard • The wiring diagram is with guard
devices using series-parallel cir- devices using BNS 33..-12z-2187 devices closed and shows the de-
cuits for Control Category 1 to EN range magnetic safety sensors with energized condition.
954-1. isolated contacts.
• Only suitable for the connection of • Monitoring one guard device using
magnetic safety sensors. a BNS .. -12z range magnetic
safety sensor.
Circuit • Monitoring of Further Devices

Options Further magnetic safety sensors
can be connected to the terminals
S22, S32, S14 and C of S2 in a
similar way to those on S1.
43
AES 7112 to Monitor Two Devices Stop Category (EN60204-1): 0

• 1 enabling path
• Monitoring of one or two guard devices
• Connection of BNS ..-12z magnetic safety
sensors with 1 NO and 2 NC contacts
• LED function indications
• Available for various operating voltages
Model AES 7112-24VAC

Designation
AES 7112-110VAC
AES 7112-230VAC
Approvals BG UL CSA
44
AES 7112 to Monitor Two Devices
Typical
Application
Typical
Wiring
Diagram
CC1
Notes • AES to monitor two guard devices • Monitoring of two guard devices • The wiring diagram is with guard
for Control Category 1 to EN 954-1. each fitted with one BNS .. -12z devices closed and shows the de-
• Only suitable for the connection of range magnetic safety sensor. energized condition.
magnetic safety sensors.
Circuit • Monitoring One Guard Device • Series-Parallel Circuits

Options When only one magnetic safety Further guard devices can be
sensor is connected, the terminals monitored using BNS 33..-12z-
S22, S32, S14 and C of S1 are 2187 range magnetic safety sen-
used and jumper connections must sors by using series-parallel
be wired between the terminals circuits.
S22, S32 and C of S2.
45
AZR 11 RT2 to Monitor One Device Stop Category (EN60204-1): 0

magnet sensors, switching mats or E-stops
connected
for stop Category 0 to EN 60204-1
connections on 2 channel circuit
• 1 or 2 channel operation possible
• Manual or automatic reset function
• Additional short-circuit proof semiconductor
output
• Start function
• 2 LED’s to show operating conditions
Dimensions 22.5 x 82 x 98.8 mm
• Additional outputs by means of output
expansion modules
Model AZR 11 RT2-24VDC

Designation
Approvals BG UL CSA
46
AZR 11 RT2 to Monitor One Device
Typical
Application
Typical
+24 V L1
Wiring 0
S
Diagram R
A1 S44 X1 X4 S13 13
K1 K2
K2
AZR 11 RT2
K1
A2 S14 S34 S24 Y1 14
0V
N M
3
CC4
Notes • AZR 11 RT2 to achieve up to • Monitoring of a sliding and hinged • The wiring diagram is with guard
Control Category 4 guard device with a safety switch devices closed and shows the de-
to EN 954-1. or a removable guard cover energized condition, whereby the
• The wiring diagram shown is with a safety switch with separate normally closed contacts connect-
however only to Control Category 3 actuator A. ed must be closed.
to EN 954-1. • The NC contact of A must have
positive opening function when the
guard device is opened.
Circuit • Start Pushbutton s • Feedback Circuit

Options A start pushbutton (NO) can option- In the wiring diagram, a feedback
ally be connected to the input X1. circuit is connected. If the feedback
With the guard device(s) closed, circuit is not used, a jumper must
the enabling circuits are then not be placed between input X1 and
closed until the start pushbutton terminal S13.
has been operated.
47
Typical
Application
Typical
Wiring
Diagram
0 CC1
Notes • The safety controller fulfills stop • Without short-circuit monitoring • The reset pushbutton R must be
Category 0 to EN 60 204-1 between connections AZR safety operated to close the enabling
• The wiring diagram shown controller being used for single- circuits if a jumper is not placed
only achieves Control Category 1 to channel monitoring of an emer- between X1 and X4.
EN 954-1, gency-stop command device such • The diagram is shown for the
because it is only single channel. as a switch or ZS range pull-wire de-energized condition.
unit and power contactors.
• However, by using two-channel
circuits, AZR 11 RT 2 can
achieve Control Category 4.
48
Typical
Application
Typical
Wiring
Diagram
0 CC4
Notes • The safety controller fulfills • AZR safety controller being used • The diagram is shown for the
Category 0 to EN 60 204-1. for two-channel monitoring of an de-energized condition.
• Achieves Control Category 4 emergency-stop command device
to EN 954-1. such as a switch or ZS range pull-
wire unit and power contactors.
• Without short-circuit monitoring
between connections. • Reset pushbutton R
49
Safety Controlers for Special Applications
Monitoring Safety Switching Mats Using AZR 11 RT2
Typical
Application
Typical
Wiring
Diagram
CC3
Notes • Achieves Control Category 3 to EN • Monitoring a safety switching • The wiring diagram shows the
954-1 mat and power contactors using de-energized condition and is
the AZR safety controller without feedback circuit.
with manual or automatic reset.
Circuit • Reset R or Start s Pushbutton • Connection of Several Safety

Options A reset or start pushbutton can be Switching Mats
connected to terminals X1 and X4. For monitoring of a large area,
If no pushbutton is connected, a using the modular mat system, the
jumper connection must be wired safety switching mats are connect-
between X1 and X4. ed in series.
50
Safer
by
Design
51
AZR 31 R2 to Monitor One Device Stop Category (EN60204-1): 0

magnet sensors, switching mats and strips
or E-stops
• 2 NC contacts can be connected
• Is also suitable for use as safety controller
for two-hand operation
• With monitored manual reset for increased
security
• 1 auxiliary contact (NC)
• Cross-wire monitoring
• Removable terminal block
• Start-stop function
contactors
Dimensions 45 x 73.2 x 121 mm
Model AZR 31 R2-24VAC

Designation
AZR 31 R2-24VDC
AZR 31 R2-110VAC
AZR 31 R2-230VAC
Approvals BG UL CSA
52
AZR 31 R2 to Monitor One Device
Typical
Application
L1
Typical
Wiring
Diagram 0 0
L+
L1
A1 S13 S24 X2 41 13 23 33
AZR 31 R2
K1 R
L1 L2 L3
K2
A2 S14 S23 X3 42 14 24 34
K3
K4
L-
N N M
3
SK4
CC4
Notes • NC contacts must have positive • The wiring diagram is with guard
opening function when the guard devices closed and shows the de-
device is opened. energized condition, whereby the
• The feedback circuit monitors the normally closed contacts connect-
positions of the positive-drive NC ed must be closed.
contacts on the contactors K3 and
K4. If the feedback circuit is not
needed, the reset button must be
directly connected between the
inputs X2 and S13.
Circuit • Reset Pushbutton R

Options A reset pushbutton (NO) must be
connected to the input X2 and ter-
minal S13. With the guard device
closed, the enabling circuits are not
closed until the reset pushbutton
has been operated.
53
Safety Controllers for Special Applications
Monitoring Two-Hand Operating Consoles Using AZR 31 R2
Typical
Application
Typical
L1
Wiring
Diagram 0 0
L+
L1
A1 S13 S24 X2 41 13 23 33
K1
L1 L2 L3
K2
AZR31R2
A2 S14 S23 X3 42 14 24 34
L-
N N M
3
SK4
CC4
Notes • To achieve Control Category 4 • Monitoring for simultaneous opera- • The wiring diagram shows the
to EN 954-1 tion, i.e. both pushbuttons must be de-energized condition.
• Monitoring a two-hand operating operated within 0.5s of each other,
console and power contactors otherwise the enabling circuits are
using the AZR safety controller. not closed.
54
Monitoring Safety Switching Mats Using AZR 31 R2
Typical
Application
Typical
Wiring
Diagram
CC3
Notes • To achieve Control Category 3 to • Monitoring a safety switching • The wiring diagram shows the
EN 954-1 mat and power contactors using de-energized condition.
the AZR safety controller with
manual reset.
Circuit • Connection of Several Safety • Reset Pushbutton R

Options Switching Mats A reset pushbutton (NO) is con-
For monitoring of a large area, nected in the feedback circuit.
using the modular mat system, the
safety switching mats are connect-
ed in series.
55
Fail-to-Safe Standstill Monitors Safety Category (EN954-1): CC4
AZR 31 S1
Features • Sensor-free registration of standstill

by monitoring e.m.f.
• Direct connection to three-phase motors
• Control Category 4 to EN 954-1
• 1 auxiliary contact
• Feedback circuit to monitor external relay
• 5 LED’s to indicate operating conditions
• No required-value setting needed
• Wire-breakage monitoring of measuring
inputs
• Self-test with fault memory
• Cyclic self-monitoring

controller and indicated by means of the LED’s
• Wire-breakage monitoring of measurement inputs
• Error indication after 9 self-test cycles
Model AZR 31 S1-24VDC

Designation
AZR 31 S1-24VAC
AZR 31 S1-110VAC
AZR 31 S1-230VAC
Approvals BG UL CSA
56
Fail-to-Safe Standstill Monitors
AZR 31 S1
Typical
Application
Typical
AZM 170-11z L1
Wiring
Diagram
13 14 21 22 A1 A2 0 0
L1
N E
3
M
L+
L1
A1 S13 S24 X1 41 13 23 33 A1 L1 L2 L3 41 13 23 33
S S1, S2
K1 S1 S2
K1
K2 AZR31T2 K2
AZR31S1
A2 PE X1 X2 42 14 24 34
A2 S14 S23 X2 42 14 24 34
L- N L1 L2 L3
N
SK4
CC4
Notes • The sensor-free standstill monitor • Monitoring of the guard device • After release has taken place,
checks the e.m.f. of the three- using a solenoid interlock and a the guard device must be opened.
phase motor. safety switch with separate • The wiring diagram is with the
• Achieves Control Category 4 to EN actuator. guard device closed and shows
954-1 • Release takes place by means of the de-energized condition.
• AZR range guard door controller the normally open contact only
checks the position of the guard when the run-down movement
device. has come to an end.
57
AZR 31 T0 Stop Category (EN60204-1): 0

• Stop category 0 to EN 60 204-1
• Operational voltage 24 V AC/DC
• Feedback circuit
• Can be used as an output expansion
module
Dimensions 22.5 x 82 x 98.8 mm
Model AZR 31 T0-24VAC/DC

Designation
Approvals BG UL CSA
58
AZR 31 T0
Typical
Application
Typical L+
Wiring
Diagram
0
L1
A1 X1 41 13 23 33
K1
I
AZR31T0
K2
A2 X2 42 14 24 34 L1 L2 L3
L- N M
3
0 SK1
CC1
Notes • The safety controller fulfills stop • AZR safety controller being used
Category 0 to EN 60 204-1. to monitor an emergency-stop.
• The wiring diagram shown achieves • The diagram is shown for the
Control Category 1 to EN 954-1. de-energized condition.
59
AZR 31 T2 to Monitor One Device Stop Category (EN60204-1): 0

magnet sensors, switching mats or E-stops
• 2 NC contacts can be connected
• Cross-wire monitoring
• Automatic reset function
contactors
• Additional contacts by means of output
expansion
Model AZR 31 T2-24VDC

Designation
AZR 31 T2-24VAC
AZR 31 T2-110VAC
AZR 31 T2-230VAC
Approvals BG UL CSA
60
AZR 31 T2 to Monitor One Device
Typical
Application
Typical
L1
L+
Wiring L1
Diagram 0 0
A1 S13 S24 X1 41 13 23 33
K1 AZR 31 T2 S
L1 L2 L3
K2
A2 S14 S23 X2 42 14 24 34
K3
K4
L-
N N M
3
SK4
CC4
Notes • NC contacts must have positive • The wiring diagram is with guard
opening function when the guard devices closed and shows the de-
device is opened. energized condition, whereby the
• The feedback circuit monitors the normally closed contacts connect-
positions of the positive-drive NC ed must be closed.
contacts on the contactors K3 and
K4. If the feedback circuit is not
needed, a jumper connection is to
be fitted between the inputs X1
and X2.
Circuit • Start Pushbutton s

Options A start pushbutton (NO) can option-
ally be connected to the inputs X1
and X2. With the guard device(s)
closed, the enabling circuits are
then not closed until the start push-
button has been operated. If neither
connected, a jumper must be wired
between X1 and X2.
61
Typical
Application
Typical L1
Wiring L+
L1
Diagram
0 0
A1 S13 S24 X1 41 13 23 33
K1 S
L1 L2 L3
AZR31T2
K2
A2 S14 S23 X2 42 14 24 34
L-
N N M
3
0 SK4
CC4
Notes • The safety controller fulfills • AZR safety controller being used
Category 0 to EN 60 204-1. to monitor an emergency-stop.
• Secures to Control Category 4 to • The diagram is shown for the
EN 954-1. de-energized condition.
Circuit • Start Pushbutton s

Option A start pushbutton can optionally
be connected between the termi-
nals X1 and X2. If no start pushbut-
ton is used, a jumper must be wired
between X1 and X2.
62
Typical
Application
Typical L+
Wiring L1
Diagram L1
A1 S13 S24 X1 41 13 23 33
K1
L1 L2 L3
K2
A2 S14 S23 X2 42 14 24 34
L- N
N
3
M
0 CC1
SK1
Notes • The safety controller fulfills stop • AZR safety controller being used • The diagram is shown for the
Category 0 to EN 60 204-1. to monitor two emergency-stop de-energized condition.
• The arrangement shown in the switches (A and B), two ZS pull-
wiring diagram serves to achieve wire switches (C and D) and a
Control Category 1 to EN 954-1. safety switch of the AZ 16 range
with separate actuator (E) as well
as a power contactor.
63
Monitoring Safety Switching Mats Using AZR 31 T2
Typical
Application
Typical
Wiring
Diagram
CC3
Notes • To achieve Control Category 3 to • Monitoring a safety switching • The wiring diagram shows the
EN 954-1 mat and power contactors using de-energized condition.
the AZR safety controller
with automatic reset.
64
Safer
by
Design
65
Safety Controller Expansion Modules Safety Category (EN954-1): CC4
AZR 62 A2 Output Expansion Module Stop Category (EN60204-1): 0

• Stop category 0 to EN 60 204-1
• 2 auxiliary circuits:
2 NC contacts in series
2 NC contacts in parallel
• 1 or 2 channel operation
connections
• LED indication of operating conditions
• To provide additional contacts
Model AZR 62 A2-24VDC

Designation
AZR 62 A2-24VAC
AZR 62 A2-110VAC
AZR 62 A2-230VAC
Approvals BG (pending)
66
Safety Controller Expansion Modules
AZR 62 A2 Output Expansion Module
Typical
Application
AZ
R6
2A
2
AZ
R3
2T
1
Typical L1 L1
Wiring
Diagram L+
L1
0 0
A1 S13 X1 51 41 13 23 33 A1 S13 S23 81 71 13 23 33 43 53 63

K1 K1
L1 L2 L3
AZR32T1 AZR62A2
K2 K2
A2 S14 X2 52 42 14 24 34 A2 S14 S24 Y1 82 72 14 24 34 44 54 64
N N
CC1
SK1 3
M
L-
N
Notes • The output expansion module is • The six enabling circuits serve to • The wiring diagram is with the
suitable to achieve Control switch off machine processes and guard device closed and shows
Category 4 to EN 954-1 and stop sequences. the de-energized condition.
Category 0 to EN 60 204-1. • AZR 32 T1 guard door controller
• The wiring diagram shown achieves to secure a guard device using a
Control Category 1 to EN 954-1. safety switch.
• AZR 62 A2 output expander to • The normally closed contact of the
provide additional contacts for a safety switch (A) must have positive
guard door controller. opening function when the guard
device is opened.
67
Safety Controller Expansion Modules Stop Category (EN60204-1): 1
AZR 63 V2 Output Expansion Module
Features • Stop category 1 to EN 60 204-1

• 3 auxiliary circuits:
1 undelayed NO contact
2 delayed NC contacts in series
2 delayed NC contacts in parallel
• 1 or 2 channel operation
connections
• Off-delay can be set between 0 and 30s in
2 second steps
Model AZR 63 V2-24VDC

Designation
AZR 63 V2-24VAC
AZR 63 V2-110VAC
AZR 63 V2-230VAC
Approvals BG (pending)
68
AZR 63 V2 Output Expansion Module
Typical
Application
AZ
R6
2A
2
AZ
R3
2T
1
Typical L1
Wiring L2
Diagram
L3
L+
L1 0 0
A1 S13 S24 X1 41 13 23 33 A1 S13 S23 93 85 75 17 27 37 47 57 67

K1 K1
L1 L2 L3
AZR 31 T2 AZR 63 V2
K2 K2
A2 S14 S23 X2 42 14 24 34 A2 S14 S24 Y1 94 86 76 18 28 38 48 58 68
L-
N
N
CC1
3
M
Notes • The output expansion module is • The six enabling circuits serve for • AZR 32 T2 safety controller to
suitable for achieving stop the controlled switching off of monitor a two channel emergency
Category 1 to EN 60 204-1. machine processes and stop switch.
• The wiring diagram shown achieves sequences. • The wiring diagram is with the
Control Category 1 to EN 954-1. • The enabling circuits remain active guard device closed and shows
• AZR 63 V2 output extension to pro- in accordance with the preset time. the de-energized condition.
vide additional contacts for a safety • The normally open auxiliary contact
controller for emergency stop appli- 93/94 can be used for visual dis-
cations. play of the beginning of the delay
time.
69
Safety Controllers for Special Applications Safety Category (EN954-1): CC3
Monitoring of Safety Bumpers Types SL & SLS Using ASL 2103

• Requirement Stage 2.2 to DIN V 31 006-2
• Safe evaluation of SL(S) series bumpers
• Monitoring for short-circuit
• Feedback circuit
• Test input
The following faults are registered by the safety

controller
• Short-circuit on the switch connections and
on the safety bumper
• Interruption of the switch connections and in
the safety bumper
drop-out
• Faults on the input circuits or relay control circuits
of the safety controller
Model ASL 2103-24VDC

Designation
ASL 2103-110VAC
ASL 2103-230VAC
Approvals BG
70
Monitoring of Safety Bumpers Types SL & SLS Using ASL 2103
Typical
Application
S
Typical
Wiring
Diagram Ue L1
A1 A2 PE X1 X2 13
Kanal 1 ASL 2103

Kanal 2
S11 S12 X3 X4 14
SL/SLS T
SK3
CC3
N
3
M
Notes • Monitoring a safety bumper using • The resistance shown in series is • The wiring diagram shows the
an ASL 2103 safety controller for integral in the safety switching strip. de-energized condition.
Control Category 3 to EN 954-1.
Circuit • Start Pushbutton s • Test Pushbutton T

Options The start pushbutton is connected By operation of the test pushbutton
to terminals X1 and X2. Optionally, the system is checked. If the test
the feedback circuit can also be pushbutton is not connected, a
used. The enable signal is only jumper must be wired between the
given when the start pushbutton terminals X3 and X4.
has been operated.
71
Fail-to-Safe Timer Safety Category (EN954-1): CC3
AZS 2305
Features • Time can be set between 0.1s and 99min.

• To EN 1088
• Recognition of short-circuit between
connections
• 2 short-circuit proof additional
transistor outputs
• Integral System Diagnostics (ISD)
• 2 channel microprocessor control
• Failure of the unit’s internal safety relay to pull-in or causes are shown in the appendix.
drop-out
• Short-circuits between the input connections
• Interruption of the input connections
• Difference in time setting between channel I and
channel II
• Faults on input or relay control circuits of the timer
Model AZS 2305-24VDC

Designation
AZS 2305-110VAC
AZS 2305-230VAC
Function Additional semi- Function of output Y

AZS 2305 Y1 Enable, enabling circuits closed

Y2 No Enable, enabling circuits open
Approvals BG
72
Fail-to-Safe Timer
AZS 2305
Typical
Application
Typical AZM 160

Wiring
Diagram
13 14 21 22 1 2 3 4 5 6
H1
N
0V
L1
L1
0 0V
+24 VDC +24 VDC
H2 E
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33 S A1 Y1 Y2 13 23 33
100mA max. 100mA

max.
K1 K1
K2 K2
A2 X3 X4 X5 X6 X7 X8 14 24 34 A2 S13 S14 S21 S22 14 24 34

0V
AES 3335/3336 AZS 2305
K3
0V
K4
M
N 3
SK1
CC1
Notes • The arrangement in the wiring dia- • Monitoring of a sliding, hinged or • The coil of the solenoid interlock is
gram fulfills Control Category 1 to removable guard device using an energized by operation of the push-
EN 954-1. AZM range solenoid interlock (A). button E
• Control Category 3 can be • The solenoid interlock releases the • After release has taken place, the
achieved. Exclusion of faults due to guard device only when the set guard device must be opened if H1
“Breakage or release of the actua- time has elapsed. The time begins is not connected.
tor, fault in the solenoid interlock” is to run when the power contactors • The wiring diagram is with the
to be substantiated and document- have dropped out. guard device closed and shows
ed. • The AES range guard door con- the de-energized condition.
troller checks the position of the
guard device.
73
FWS 1105
Features • Confirmation of standstill using 2 impulse

sensors
• Reset input
• 2 short-circuit proof semiconductor outputs
• Customer-specific standstill frequencies
possible
• Interruption of the connections to one of the causes are shown in the appendix.
inductive proximity switches
• Failure of the proximity switches
• Failure of one channel being evaluated
drop-out
• Faults on input or relay control circuits of the safety
controller
Model FWS 1105A-24VDC (Execution A)

Designation
FWS 1105B-24VDC (Execution B)
FWS 1105C-24VDC (Execution C)
Standstill Function Additional Function of

Frequencies Execution A Execution B Execution C Table transistor output Y output Y
Input X1 1Hz 2Hz 1Hz Y1 Enable, Enabling

Input X2 2Hz 2Hz 1Hz circuits closed
Y2 Fault
Approvals BG UL CSA
74
FWS 1105
Typical
Application
Typical AZM 160

Wiring
Diagram
K3
13 14 21 22 1 2 3 4 5 6
K4
N 3
M
0V
0V
L1 L1
+24 VDC +24 VDC
E
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33 A1 X1 X2 13
max. 100mA K1
max.
K1
K2
100mA
K2
A2 X3 X4 X5 X6 X7 X8 14 24 34 A2 Y1 Y2 X3 14
R
K3
0V AES 3335/3336 0V FWS 1105
K4 +24 VDC
N
SK3
CC3
Notes • The solenoid interlock can be • Monitoring of the guard device solenoid interlock” is to be substan-
opened when the FWS 1105 has using a solenoid interlock and a tiated and documented.
registered standstill of the motor by safety switch with separate • Release is only possible when the
means of the two PNP inductive actuator. run-down movement has come to
proximity switches. The coil of the • Control Category 3 can also be an end.
solenoid interlock is then energized achieved without using the safety
by operation of the pushbutton E • After release has taken place, the
switch by connecting the NO and guard device must be opened.
• The AES controller checks the NC contacts of solenoid interlock to
position of the guard device. the guard door monitor. Exclusion • The wiring diagram is with the
of faults due to “Breakage or guard device closed and shows
release of the actuator, fault in the the de-energized condition.
75
FWS 1106
Features • Confirmation of standstill using only 1 or

with 2 impulse sensors
• Uses additional standstill signal, e.g. PLC
as second input channel
• Reset input
possible
• Interruption of the connections to the inductive causes are shown in the appendix.
proximity switches
drop-out
control unit
Model FWS 1106A-24VDC (Execution A)

Designation
FWS 1106B-24VDC (Execution B)
FWS 1106C-24VDC (Execution C)

Frequencies Execution A Execution B Execution C* Table transistor output Y output Y
Input X1 1Hz 2Hz 1Hz Y1 Enable, Enabling

Input X2 2Hz 2Hz 1Hz circuits closed
Y2 Fault, high signal
*Recommended execution when using an impulse sensor.
Other frequencies on request.
Approvals BG UL CSA
76
FWS 1106
Typical
Application
Typical AZM 160

Wiring
K3
Diagram
13 14 21 22 1 2 3 4 5 6 K4
H1
3
M
N
0V 0V
L1
L1
+24 VDC 0 +24 VDC
E
H2
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33 A1 X1 X2 13
max. 100mA K1
max.
K1
K2
FWS 1106
100mA
K2
A2 X3 X4 X5 X6 X7 X8 14 24 34 A2 Y1 Y2 X3 X4 14
AES 3335/3336 R
0V K3 0V
K4 +24 VDC
N H7
CC1
SK1
Notes • The solenoid interlock can be • Monitoring of the guard device • After release has taken place, the
opened when the FWS 1106 has using a solenoid interlock. guard device must be opened if H1
registered standstill of the motor by • To achieve Control Category 3 the is not connected.
means of the PNP inductive prox- exclusion of faults due to “Breakage • The wiring diagram is with the
imity switch and the additional or release of the actuator, fault in guard device closed and shows
standstill signal H7 . The coil of the the solenoid interlock” is to be the de-energized condition.
solenoid interlock is then energized substantiated and documented.
by operation of the pushbutton E
• Release is only possible when the
• The AES controller checks the run-down movement has come to
position of the guard device. an end.
77
FWS 2316

sensors
• Short-circuit recognition by means of
pulsed voltage supply to proximity switches
• Feedback circuit to monitor relays
• Reset input
• Short-circuit proof semiconductor output
possible
proximity switches
• Short-circuit between connections
drop-out
control unit
Model FWS 2361B-24VDC (Execution B) FWS 2361C-24VDC (Execution C)

Designation
FWS 2361B-110VAC (Execution B) FWS 2361C-110VDC (Execution C)
FWS 2361B-230VAC (Execution B) FWS 2361C-230VDC (Execution C)

Frequencies Execution B Execution C Table transistor output Y output Y
Input X3 2Hz 1Hz Y1 Enable, Enabling

Input X5 2Hz 1Hz circuits closed
Approvals BG UL CSA
78
FWS 2316
Typical
Application
+24 VDC/ +24 VDC

Typical S13/S21 L1 (X2/X4) L1
Wiring
Diagram
0V R
+24 VDC 0
E
A1 Y1 Y2 X1 13 23 33 A1 Y1 Y2 X1 13 23 33
max. max.
100mA 100mA
AES 2335 K1 K1 FWS 2316
K2 K2
A2 S13 S14 S21 S22 14 24 34 A2 X2 X3 X4 X5 14 24 34
0V K3
N
3
M
SK1
CC1
13 14 21 22 1 2 3 4 5 6
AZM 160-22yp
Notes • The solenoid interlock can be • Monitoring of the guard device • After release has taken place, the
opened when the FWS 2316 has using a solenoid interlock. guard device must be opened.
registered standstill of the motor by • To achieve Control Category 3 the • The wiring diagram is with the
means of the two PNP inductive exclusion of faults due to “Breakage guard device closed and shows
proximity switches. The coil of the or release of the actuator, fault in the de-energized condition.
solenoid interlock is then energized the solenoid interlock” is to be
by operation of the pushbutton E substantiated and documented.
• The AES guard door controller • Release is only possible when the
checks the position of the guard run-down movement has come to
device. an end.
Circuit • Feedback Circuit

Options A feedback circuit to monitor exter-
nal contactors can be connected to
input X1.
79
FWS 3505-2204

sensors
• Reset input
possible
proximity switches
drop-out
control unit
Model FWS 3505-2204-24VDC

Designation

Frequencies Table transistor output Y output Y
Input X2 1Hz Y1 Enable, Enabling

Input X4 1Hz circuits closed
Y2 Fault
Approvals BG UL CSA
80
FWS 3505-2204
Typical
Application
Typical AZM 160-22yp

Wiring
Diagram
K3
13 14 21 22 1 2 3 4 5 6
K4
N M
3
0V 0V
L1
+24 VDC L1
+24 VDC 0 S
E
A1 S13 S14 S21 S22 X1 X2 Y1 Y2 13 23 33 A1 X1 X2 X3 X4 Y1 Y2 13 23 33 43 51
max. 100mA max. 100mA
K1 K1
K2 K2
A2 X3 X4 X5 X6 X7 X8 14 24 34 A2 X5 X6 X7 X8 14 24 34 44 52
0V AES 3335 0V R FWS 3505

K3
K4
N
Notes • The solenoid interlock can be • Monitoring of the guard device • Release is only possible when the
opened when the FWS 3595-2204 using a solenoid interlock and a run-down movement has come to
has registered standstill of the safety switch with separate an end.
motor by means of the PNP induc- actuator. • After release has taken place, the
tive proximity switches. The coil of • Control Category 3 can also be guard device must be opened.
the solenoid interlock is then ener- achieved without using the safety
gized by operation of the push- • The wiring diagram is with the
switch B. Exclusion of faults due to guard device closed and shows
button E “Breakage or release of the actua- the de-energized condition.
• The AES controller checks the tor, fault in the solenoid interlock” is
position of the guard device. to be substantiated and document-
ed.
81
Guard Door and Emergency-Stop Safety Controllers Safety Category (EN954-1): CC4
SRB-NA-R-C.14 Stop Category (EN60204-1): 0
Features • 2 NO relay outputs

• Input for reset
• Feedback loop
• Input for E-stop or door monitoring
• LED’s for K1, K2, Ui
• Housing 22.5 mm, made of thermoplastic in
accordance with UL-94-V-0, red RAL 3000
• DIN rail mounting, DIN EN 50 022-35
• Not for use with BNS Series coded
magnet switches
Front View
C C1 23
Dimensions 82 x 22.5 x 98.8 mm 13 S1 24
K1
SRB- UB
NA-R
-C.14 K2
X2 S2 X1
14 D1 D
Model Enabling Outputs Operating Voltage

Designation
SRB-NA-R-C.14-24VDC 2 NO 24VDC
SRB-NA-R-C.14-24VAC 2 NO 24VAC
SRB-NA-R-C.14/UC 2 NO 24VDC/VAC
Approvals BG UL CSA
82
Guard Door and Emergency-Stop Safety Controllers
SRB-NA-R-C.14
L1
Typical ****
Example for Dual Channel Door
ON
Wiring OFF
Monitoring using two limit switches (one
Diagram KB with positive opening contacts) and
Reset external reset button.
KA
Dual-channel output, suitable for contact
C C1 S1 X1 X2 13 23 reinforcement or contact multiplication,
using relays or contactors with positively
guided contacts.
F1**
**** = Feedback loop
K2 K1 K1 K2
K1 KA Wiring breakage and earth leakage in

the Monitoring circuits are detected.
K2 KB
** Fuse M 0.5 A
K1 K2 (an external leading fuse M 0.25A is
D D1 S2 14 24
recommended)
KA KB
Technical Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10%; 24 VAC -15% / +6%
Data
Frequency 50/60 Hz (for AC operating)
Fuse (Power Supply) M 0.25 A (internal M 0.5 A/250V)
Power Consumption 2.5 VA
Switching Capacity (Enabling Contacts) 230 VAC, 6 A resistive (inductive with suitable suppression)
Fuse (Enabling Contacts) 6 A slow blow
Application Category AC 15/DC 13, DIN VDE 0660 Part 200
Pick-Up Delay ≤ 10 ms
Drop-Out Delay ≤ 30 ms
Contact Materials / Contacts AgSnO self cleaning, positively driven
Contact Resistance max. 100 mOhm when new
Air and Creeping Distances DIN VDE 0110 Part 1 and 2, 4 kV/2
Connections Self lifting terminals min. 0.6 qmm, max 2.5 qmm
Dimensions (H/W/D) 82 mm / 22.5 mm / 98.8 mm
Weight 190 g
Ambient Operating Temperature -25˚ C … +45˚ C (derating curve available)
Mechanical Life 107 switching cycles
Terminal Labeling DIN EN 60 445 / DIN 40 719 Part 2
83
SRB-NA-R-C.14
Wiring example: Wiring example:

Input level Input level
L+(A1) C1 D1 X1 L+(A1) L-(A2) C1 D1 X1
Single-Channel Emergency Dual-channel Emergency-
Stop switch according to Stop switch in accordance
EN 60 204-1. with EN 60 204-1.
Wire breakage and earth Wire breakage and earth
leakage in the Emergency Emergency Reset
Stop circuits are detected. switch off Stop circuits are detected. switch off
With external Reset button. Earth leakage at input A2 is

detected in non-grounded
Safety category 2 in accor-
mains only!
dance with EN 954-1.
Cross shorts in the E-stop
circuits are detected.
With external reset button.
C S1 S2 X2 C D S1 S2 X2

C1 D1 X1 L+(A1) C1 D1 X1
Dual-Channel Emergency Single-Channel Door
Stop switch according to Monitoring according to EN
EN 60 204-1. 1088 one limit switch with ON
positive opening contact. OFF
Wire breakage and earth
leakage in the Emergency Reset Wire breakage and earth Reset
Emergency
Stop circuits are detected. switch off leakage in the Door
Monitoring circuits are
Cross-shorts in the
detected.
Emergency Stop circuits
are detected. With external reset button
for increased safety
With external Reset button.
requirements.
Safety category 3 or 4 in
accordance with EN 954-1.
S1 S2 X2 C S1 S2 X2
Wiring example:
Input level
C1 D1 X1
Dual-Channel Door
Monitoring according to EN
ON
1088 one limit switch with
OFF
positive opening contact.
Wire breakage and earth ON
leakage in the Door
detected.
Cross-shorts in the
are detected.
With external Reset button
requirements.
Safety category 3 or 4 in S1 S2 X2
84
SRB-NA-R-C.14

Power level Power level
Single-Channel output. Dual-Channel output.
L1 L1
Suitable for contact rein- Suitable for contact rein-
forcement or contact multi- KA * KB forcement or contact multi- KA * KB
plication, using relays or X1 X2 13 plication, using relays or X1 X2 13 23
contactors with positively contactors with positively KB
KA
guided contacts. guided contacts.
14 KB 14 24 KA
KA KB KA KB
N N
*Reset button wired in *Reset button wired in
series to feedback loop. series to feedback loop.
85
SRB-NA-R-C.15, SRB-NA-R-C.15/1 Stop Category (EN60204-1): 0
Features • 3 NO relay outputs, 1 NC auxiliary output

(NC auxiliary contact for monitoring only,
must not be used in safety enabled circuits)
• Input for reset
• Feedback loop
• NC contacts for monitoring
(SRB-NA-R-C.15/1: in series)
(SRB-NA-R-C.15: in parallel)
magnet switches
Front View
Dimensions 82 x 22.5 x 98.8 mm
13 23 33
14 24 34
K2
UB SRB-
NA-R
K1 -C.15
41 X1 C
42 X2 D

Designation
SRB-NA-R-C.15-24VDC 3 NO / 1 NC 24VDC
SRB-NA-R-C.15-24VAC 3 NO / 1 NC 24VAC
SRB-NA-R-C.15/1-24VDC 3 NO / 1 NC 24VDC
SRB-NA-R-C.15/UC 3 NO / 1 NC 24VDC/VAC
Approvals BG UL CSA
86
SRB-NA-R-C.15, SRB-NA-R-C.15/1
Typical L-(A2) L+(A1) L1 Example for Dual Channel Door

Wiring ON Monitoring using two limit switches (one
OFF
****
KA Dual-channel output, suitable for contact
C X1 X2 13 23 33 41 41* reinforcement or contact multiplication,
guided contacts.
F1** **** = Feedback loop
K2 K1 K1 K2
K1 KA
Wiring breakage and earth leakage in
Earth leakage at input D is detected
K2 KB
K1 K2 only in mains with insulation leakage
monitoring.
D 14 24 34 42 42
* Monitoring contacts in series at bei
KA KB SRB-NA-R-C.15/1
N ** Fuse M 0.5 A
(an external leading fuse M 0.25A is
recommended)
Data
Fuse (Enabling Contacts) 6 A slow blowing
Switching Capacity (Monitoring Contacts) 24V, 2 A resistive (inductive with suitable suppression)
Fuse (Monitoring Contacts) 2 A slow blow
Weight 190 g
87

L+(A1) L-(A2) X1 L+(A1) L-(A2) X1
Single-Channel Emergency Dual-Channel Emergency
Stop switch according to Stop switch according to
EN 60 204-1. EN 60 204-1.
leakage in the Emergency Emergency Reset leakage in the Emergency Emergency Reset
With external Reset button. Cross-shorts in the

are detected.
C D X2 C D X2

L+(A1) L-(A2) X1 L+(A1) L-(A2) X1
Single-Channel Door Dual-Channel Door
Monitoring according to EN Monitoring according to EN
ON ON
1088 one limit switch with 1088 one limit switch with
positive opening contact. OFF positive opening contact. OFF
Wire breakage and earth Reset Wire breakage and earth Reset
leakage in the Door leakage in the Door
Monitoring circuits are Monitoring circuits are
detected. detected.
With external Reset button With external Reset button
for increased safety for increased safety
requirements. requirements.
Safety category 2 in accor- Safety category 3 in accor-
dance with EN 954-1. dance with EN 954-1.
C D X2 C D X2
88

L1 L1
forcement or contact multi- KA * KB forcement or contact multi- KA * KB
KA
14 14 24
KB KA
KA KB KA KB
N N

89
SRB-NA-R-C.16, SRB-NA-R-C.16/1 Stop Category (EN60204-1): 1

• Input for reset
• Feedback loop
• NC contacts for monitoring
(SRB-NA-R-C.16/1: in series)
(SRB-NA-R-C.16: in parallel)
magnet switches
Front View
13 23 33
14 24 34
K2
UB SRB-
NA-R
K1 -C.16
41 X1 C
42 X2 D

Designation
SRB-NA-R-C.16-24VDC 3 NO / 1 NC 24VDC
SRB-NA-R-C.16/1-24VDC 3 NO / 1 NC 24VDC
Approvals BG UL CSA
90
L-(A2) L+(A1) L1
Typical Example for Dual Channel Door
ON
Wiring OFF
Reset
**** external reset button.
KA
C X1 X2 13 23 33 41 41*
reinforcement or contact multiplication,
guided contacts.
K2 K1 K1 K2
KA Wiring breakage and earth leakage in
K1 the Monitoring circuits are detected.
KB Earth leakage at input D is detected
K1 K2 K2 only in mains with insulation leakage
D 14 24 34 42 42
monitoring.
An external leading fuse 0.5A is recom-
KA KB
mended.
N
* Monitoring contacts in series at SRB-
NA-R-C.16/1
Data
Switching Capacity (Monitoring Contacts) 24V, 2 A resistve (inductive with suitable suppression)
Drop-Out Delay 1,1 s -20% / +20% (for UB = 24VDC)
Weight 190 g
91

L+(A1) L-(A2) X1 L+(A1) L-(A2) X1
EN 60 204-1. EN 60 204-1.
Cross-shorts in the Cross-shorts in the

Emergency Stop circuits Emergency Stop circuits
are detected. are detected.
With external Reset button. With external Reset button.
Safety category 2 in accor- Safety category 3 in accor-
dance with EN 954-1. dance with EN 954-1.
C D X2 C D X2

L+(A1) L-(A2) X1 L+(A1) L-(A2) X1
ON ON
positive opening contact. positive opening contact. OFF
OFF
detected. detected.
With external Reset button Cross-shorts in the Door
for increased safety Monitoring circuits are
requirements. detected.
Safety category 2 in accor- With external Reset button
dance with EN 954-1. for increased safety
requirements.
C D X2
Safety category 3 in accor- C D X2
92
Wiring example:
Power level
Single-Channel output.
L1
Suitable for contact rein-
forcement or contact multi- KA * KB
plication, using relays or X1 X2 13
contactors with positively KA
guided contacts.
Drop-out delay: Safety
category 1 in accordance
with EN 954-1.
14 KB
KA KB
*Reset button wired in

series to feedback loop.
93

• Input for reset
• Feedback loop
• LED’s for K1, K2
magnet switches
Front View
13 23 X1
Dimensions 82 x 22.5 x 98.8 mm 14 24 X2
K1
SRB-
NA-R
-C.17 K2
S1 S2 C
S11 S21 D

Designation
Approvals BG UL CSA
94
SRB-NA-R-C.17
L1
Typical ON
Wiring OF **** Monitoring using two limit switches (one
KB with positive opening contacts) and
Diagram
Reset
external reset button.
KA
C S2 S1 S11 S21 X1 X2 13 23
guided contacts.
Trigger K1 KA Wiring breakage and earth leakage in
circuit the Monitoring circuits are detected.
K2 KB
** internal electronic fuse
K1 K2
D 14 24
KA KB
Technical Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10%
Data
Fuse (Power Supply) Internal electronic fuse, breaking current > 0.6 A, reset time approx. 1 second
Power Consumption max. 2.5 VA
Weight 190 g
Ambient Operating Temperature 0˚ C … +45˚ C (derating curve available)
95
SRB-NA-R-C.17

S1 S2 C D S1 S2 C D
Dual-Channel Emergency Dual-Channel Door
leakage in the Emergency Emergency Reset Wire breakage and earth Reset
Cross-shorts in the
detected.
are detected. Cross-shorts in the
are detected.
requirements.
Safety category 3 or 4 in S11 S21 X1 X2
S11 S21 X1 X2
Advice:
Change over from mode
“External Reset with trailing A1 (+) A2 (-) A1 (+) A2 (-)
edge” to mode “Automatic
Reset” is achieved by alter-
ing the polarity of the sup-
ply voltage.
In “Automatic Reset” the
reset button is eliminated.
C D D C
Trailing Edge Automatic Reset
96
SRB-NA-R-C.17

L1 L1
* *
forcement or contact multi- KA KB forcement or contact multi- KA KB
plication, using relays or D X2 13 plication, using relays or D X2 13 23
KA
14 KB 14 24 KA
KA KB KA KB
N N
97

• Input for reset
• Feedback loop
• LED’s for K1, K2, UB
magnet switches
Front View
C C1 23
Dimensions 82 x 22.5 x 98.8 mm 13 S1 24
K1
SRB- UB
NA-R
-C.18 K2
X2 S2 X1
14 C1.1 D

Designation
Approvals BG UL CSA
98
SRB-NA-R-C.18
L1
Typical **** Example for Dual Channel Door
ON Reset
Wiring OFF
KA Dual-channel output, suitable for contact
C C1.1 C1 S1 X1 X2 S2 13 23 reinforcement or contact multiplication,
guided contacts.
K2 K1 K1 K2
K1 KA
** Fuse M 0.5 A
K2 KB
K1 K2 (an external leading fuse M 0.25A is
recommended)
D 14 24
KA KB
Data
Weight 190 g
99
SRB-NA-R-C.18

L+(A1) C1 C1.1 X1 L+(A1) L-(A2) C1 C1.1 X1
EN 60 204-1. EN 60 204-1.
Cross-shorts in the Earth leakage at input A2 is

Emergency Stop circuits detected in non-grounded
are detected. mains only.
are detected.
C S1 S2 X2 dance with EN 954-1. C D S1 S2 X2

C1 C1.1 X1 L+(A1) C1 C1.1 X1
Cross-shorts in the
detected.
are not detected. With external Reset button
requirements.
S1 S2 X2 C S1 S2 X2

C1 C1.1 X1 C1 C1.1 X1
Dual-Channel Door Dual-Channel triggering
Monitoring according to EN using P-switching semicon-
ON
1088 one limit switch with ductors.
Wire breakage and earth Reset leakage in the monitoring Reset
leakage in the Door circuits are detected.
detected.
Cross-shorts in the
are not detected.
requirements.
Safety category 3 or 4 in S1 S2 X2 S1 S2 X2
100
SRB-NA-R-C.18

L1 L1
* *
forcement or contact multi- KA KB forcement or contact multi- KA KB
KA
14 KB 14 24
KA
KA KB KA KB
N N

101

• Input for reset
• Feedback loop
• LED’s for K1, K2, K4, Ui
• Housing 45 mm, made of thermoplastic in
DIN EN 50 022
magnet switches
Front View
13 23 33
A1 T11 Y2 Y1 S11
Dimensions 83 x 45 x 140 mm SRB-NA-R-
C.19-24V Ui
Fuse K2 K3
K4
A2 S1 S2 S22 V1
14 24 34

Designation
Approvals UL CSA BG
102
SRB-NA-R-C.19
L1
Typical ON
**** Example for Dual Channel Door
Wiring OFF KB Monitoring using two limit switches (one
Diagram with positive opening contacts) and
Reset K A
A1 T11 Y1 Y2 S1 S11 S2 S22 V1 13 23 33
F2 F1 F3 F1 using relays or contactors with positively
K2 K1
K1
K2 K1 K3 guided contacts.
K1
K2
KA
K3 K4 K4 Wiring breakage and earth leakage in
K1 K2 K3 K4 K3
KB
Cross-shorts in the Door Monitoring cir-
cuits are not detected.
A2 14 24 34
KA KB
Data
Fuse (Power Supply) F2: M 0.25 A/250V (internal M 0.5 A/250V; F3: T 0.1 A/250V)
Power Consumption max 3 VA
Drop-Out Delay Refer to chart two pages further on
Dimensions (H/W/D) 83 mm / 45 mm / 140 mm
Weight 390 g
Terminal Labeling DIN EN 50 005 / DIN 50 013
103
SRB-NA-R-C.19

T11 S1 S11 T11 T11 S11
EN 60 204-1. EN 60 204-1.
With external Reset button. Earth leakage at input A2 is

detected in non-grounded
mains only!
Cross-shorts in the
are not detected.
S1 S2 Y1 accordance with EN 954-1. S1 S2 Y1

T11 S1 S11 T11 T11 S11
1088 one limit switch with ON 1088 one limit switch with ON
OFF
Wire breakage and earth Reset
detected. detected.
With external Reset button. Cross-shorts in the Door
Monitoring circuits are not
detected.
requirements.
S1 S2 Y1 S1 S2 Y1
Advice:
For “Automatic Reset” S11
apply jumper S11-Y1.
When using external Reset
button (S11-Y2) and
jumper Y1-Y2, unit is trig-
gered by trailing edge func- Reset
tion.
Reset button wired in
If the time between channel
1 and 2 exceeds ca. 20
msec. when connecting a
Safety Limit Swith or
Interlocking Device, a lock
function can be achieved
by triggering channel 2
(T11-S2) prior to channel 1 Y2 Y1
(T11-S1). The time differ-
ence is then extended to
infinite.
104
SRB-NA-R-C.19

L1 L1
Suitable for contact rein- Suitable for contact rein- *
KA * KB KA KB
forcement or contact multi- forcement or contact multi-
plication, using relays or S11 Y1 13 plication, using relays or S11 Y1 13 23
KA
14 KB 14 24
KA
KA KB KA KB
N N

Advice: Advice:
Enagling outputs 23/24 and A1 14 It is possible to shorten the A1 14
33/34 correspond to STOP- drop-out delay time via an
category 1 in accordance external NC between termi-
with EN 60 204-1. nals 14 and V1.
The safety relay module S1
has no safety function if
connector V1 is triggered
externally.
13 V1 13 V1
Set to On Time in Seconds

S1, S4 ca. 0.7
S2, S5 ca. 1.4
S1, S2, S4, S5 ca. 2.1
S6
S5
S4 S3, S6 ca. 3.2
S3
S2
S1 S1, S3, S5, S6 ca. 3.9
S2, S3, S5, S6 ca.4.6
S1, S2, S3, S4, S5, S6 ca. 5.3
Tolerance ± 30%
105

• Input for reset
• Feedback loop
• LED’s for K1, K2, K3,K4, UB, Ui
magnet switches
Front View
13 23 33 43 53
C C1 S1 X1 X2
C.20-24V UB U i
Fuse K1 K3
K2 K4
D D1 S2 X2.1 L62
14 24 34 44 54

Designation
SRB-NA-R-C.20-24V 5 NO / 1 NC 24VAC/VDC
Approvals BG UL CSA
106
SRB-NA-R-C.20
L1
ON
Wiring **** Monitoring using two limit switches (one
OFF

Reset
KA
C C1 X2 X2.1 S1 X1 S2 13 23 33 43 53
guided contacts.
K1 K2
F2 **** = Feedback loop
* Trigger K1
F1 circuit
K3 K4
K1
K3
K2
K1 K3 K2 K4
K2 KB * Fuse F2 (front cover) 1 A, Fuse F1
K4
(internal) 1.25 A
D D1 L62 14 24 34 44 54
KA KB
Data
Fuse (Power Supply) T 1.0 A/250 V (internal T 1.25 A/250V)
Power Consumption max 3 VA, plus monitoring output L62
NO 43/44, 53/54: DC 13: 24 VDC/2 A; AC 15: 230 VAC/3 A
Switching Capacity (Monitoring Contacts) L62: max. 500 mA
Weight 460 g
Terminal Labeling DIN EN 60 445 / DIN 40 719 Part2
107
SRB-NA-R-C.20

C1 S1 X1 C1 C1 X1
EN 60 204-1. EN 60 204-1.
are not detected.
QS accordance with EN 954-1. QS
1 0 1 0
S1 S2 X2 S1 S2 X2

C1 D1 X1 C1 S1 X1
Cross-shorts in the
detected.
are detected. With external Reset button
To enable cross-short mon-
requirements.
itoring: Set switch QS (bot-
tom of housing) to 1. Safety category 2 or 4 in
QS QS
1 0 1 0
accordance with EN 954-1. S1 S2 X2 S1 S2 X2
Wiring example:
Input level
C1 D1 X1
Dual-Channel Door Monitoring
according to EN 1088 one limit
ON
switch with positive opening
contact. OFF
Wire breakage and earth leak- Reset

age in the Door Monitoring cir-
cuits are detected.
Cross-shorts in the
Emergency Stop circuits are
detected.
To enable cross-short monitor-
ing: Set switch QS (bottom of
QS
housing) to 1.
1 0
With external Reset button for
increased safety requirements.
S1 S2 X2
108
SRB-NA-R-C.20

L1 L1
Suitable for contact rein- Suitable for contact rein- *
forcement or contact multi- KA * KB forcement or contact multi- KA KB
KA
14 14 24
KB KA
KA KB KA KB
N N

Advice:
For “Automatic Reset” apply X1
jumper X1-X2.
button (connect to X1-X2.1),
unit is triggered by trailing
edge function. Reset
Reset button wired in series

to feedback loop.
X2.1
109
Features • 3 NO relay outputs, 2 NO time delayed con-

tacts, 1 NC auxiliary output (NC auxiliary
contact for monitoring only, must not be
used in safety enabling circuits)
• Input for reset
• Feedback loop
DIN EN 50 022
magnet switches
Front View
47 57
13 23 33 (43) (53)
C C1 S1 X1 X2
SRB-NA-R- t ...... s
C.21-24V UB U i
Fuse K1 K3
K2 K4
D D1 S2 X2.1 L62
48 58
14 24 34 (44) (54)

Designation
SRB-NA-R-C.21-24V 3 NO / 2NO / 1 NC 24VAC/VDC
Approvals BG UL CSA
110
SRB-NA-R-C.21
L1
Typical ON
****
Wiring OFF Monitoring using two limit switches (one
KB
Reset
KA
C C1 X2 X2.1 S1 X1 S2 13
47 57
23 33 (43) (53)
K1 K2
guided contacts.
F2
* Trigger K1 **** = Feedback loop
F1 circuit
K1 KA
K3 K4
TIMER TIMER
K3 Wiring breakage and earth leakage in
K2 KB
K1 K3 K2 K4 K4 * Fuse F2 (front cover) 1 A, fuse F1
D D1 L62 14 24 34 48 58
(internal) 1.25 A
(44) (54)
KA KB
Data
Power Consumption max 4 VA, plus monitoring output L62
NO 43/44, 53/54: DC 13: 24 VDC/2 A; AC 15: 230 VAC/3 A
Switching Capacity (Monitoring Contacts) L62: max. 500 mA
Weight 480 g
111
SRB-NA-R-C.21

C1 S1 X1 C1 C1 X1
EN 60 204-1. EN 60 204-1.

are not detected.
1 0 1 0
S1 S2 X2 S1 S2 X2

C1 D1 X1 C1 S1 X1
ON
EN 60 204-1. 1088 one limit switch with
Cross-shorts in the
detected.
requirements.
itoring: Set switch “QS”
(bottom of housing) to 1. Safety category 2 or 4 in
QS QS
1 0 1 0
accordance with EN 954-1. S1 S2 X2 S1 S2 X2

C1 D1 X1 C1 C1 X1
Dual-Channel Door Dual-Channel Door
ON ON
OFF OFF
positive opening contact. positive opening contact.
detected. detected.
are detected. are not detected.
With external Reset button QS With external Reset button QS
for increased safety for increased safety
requirements. 1 0 requirements. 1 0
accordance with EN 954-1. accordance with EN 954-1.
112
SRB-NA-R-C.21

L1 L1
Suitable for contact rein- KB Suitable for contact rein-
KA KA
* KB
forcement or contact multi- KC forcement or contact multi-
*
plication, using relays or 13 43 plication, using relays or S11 S12 13 23
contactors with positively KA contactors with positively KB
X1 X2
14 44 KB 14 24 KA
KA KB KC KA KB
N N
Advice: Advice:
47 57
For “Automatic Reset” X1 Drop-out delay of the (43) (53)
apply jumper X1-X2. enabling outputs 43/44 and
53/54 correspond to STOP-
button (X1-X2.1), unit is
with EN 60 204-1.
triggered by trailing edge
function. Reset Enabling outputs 13/14,
23/24 and 33/34 corre-
spond to STOP-category 1
in accordance with EN 60
204-1.
X2.1 (44) (54)

48 58
Time in S1 = 1 S1 = 0 S1 = 1 S1 = 0
Seconds S2 = 1 S2 = 1 S2 = 0 S2 = 0
S3 = 1 S3 = 0 S3 = 1 S3 = 0
S4 = 1 S4 = 1 S4 = 0 S4 = 0
II
III
IV V
VI Max
I 0.44 2.30 3.5 18
Min I
1 0 II 0.62 2.45 5.0 20

QS S4
1 0 S3 III 0.87 2.70 7.0 22
S2
S1
IV 1.05 2.85 8.5 23
V 1.27 3.05 10.2 25
VI 1.77 3.55 14.2 29
Tolerance ± 5%
113

• Monitoring outputs for K1, K2/K3
• Input for reset
• Feedback loop
• LED’s for K1, K2, K3,QS, UB, Ui
magnet switches
Front View
41 13 23 33 L11
Dimensions 83 x 45 x 140 mm C C1 S11 S12 L13
SRB-NA-R-
C.27-24V UB U i
Fuse K1 K3
K2 Qs
D S13 S21 S41 L14
42 14 24 34 D2

Designation
SRB-NA-R-C.27-24V 3 NO / 1 NC 24VAC/VDC
Approvals BG UL CSA
114
•Guard Door and Emergency-Stop Safety Controllers
SRB-NA-R-C.27
L1
ON
Wiring OFF **** Monitoring using two limit switches (one
KB
Diagram Reset
with positive opening contacts) and
KA
C C1 S11 S12 S13 S21 S41 13 23 33 41 Dual-channel output, suitable for contact
F2 S5 K1 using relays or contactors with positively
F1
S1 K2 K1 K1 K2 K1 K3 guided contacts.
K1 K2 KA
Querschlufl-
K3 K2 K3
erkennung
S4 Wiring breakage and earth leakage in
K3 KB the Monitoring circuits are detected.
K1 K2 K3
D L13 L11 D2 L14 14 24 34 42
KA KB
Technical Operating Voltage 24 VDC -15% / +20%, residual ripple max. 10%, 24 VAC -15% / +6%
Data
Switching Capacity (Monitoring Contacts) 41/42: 24VDC, 2 A; L11, L14: max. 100mA
Fuse (Monitoring Contacts 41/42: 2 A slow blow; L11, L14: 100mA slow blow
Weight 460 g
115
SRB-NA-R-C.27

C1 S21 C1 S11 C1 C1 S41 S11
EN 60 204-1. EN 60 204-1.
leakage in the Emergency Enabling Reset leakage in the Emergency Enabling Reset

are not detected.
S4 accordance with EN 954-1. S4
1 0 1 0
S21 S41 S13 S12 S21 S41 S13 S12

C1 D C1 S11 C1 S21 C1 S11
Cross-shorts in the
detected.
requirements.
itoring: Set switch QS (bot-
tom of housing) to 1. Safety category 2 in accor-
S4 S4
1 0 1 0
accordance with EN 954-1. S21 S41 S13 S12 S21 S41 S13 S12

C1 D C1 S11 C1 D C1 S11
Dual-Channel Door Monitoring Dual-Channel Door
according to EN 1088 one limit Monitoring according to EN ON
ON
switch with positive opening 1088 one limit switch with
OFF OFF
contact. positive opening contact.
Wire breakage and earth leak- Reset Wire breakage and earth Reset
age in the Door Monitoring cir- leakage in the Door
cuits are detected. Monitoring circuits are
detected.
Cross-shorts in the Emergency
Stop circuits are detected. Cross-shorts in the Door
Monitoring circuits are not
detected.
ing: Set switch QS (bottom of
housing) to 1. S4 With external Reset button S4
With external Reset button for 1 0 1 0
requirements.
increased safety requirements.
Safety category 3 or 4 in S21 S41 S13 S12
Safety category 3 or 4 in S21 S41 S13 S12
116
SRB-NA-R-C.27

Single-Channel output. Dual-Channel output. L1
L1
Suitable for contact rein- * Suitable for contact rein- *
KA KB KA KB
plication, using relays or S11 S12 13 plication, using relays or S11 S12 13 23
contactors with positively KA contactors with positively KB
14 KB 14 24 KA
KA KB KA KB
N N
*Feedback loop. *Feedback loop.
Advice: Advice:
For “Automatic Reset” C1 Semiconductor outputs L11 24 VDC 0V
apply jumper C1-S13. and L14 are galvanically
separated from the other
sections of the SRB-NA-R-
button (switch S1 is set to
C.27.
“1”), unit is triggered by
trailing edge function. Reset Provide power supply
through inputs L13 and D2.
If the time difference
between input channel 1 Semiconductor output L11
and 2 of the safety relay is linked to Relay K1
exceeds ca. 100 msec. (Reset). Semiconductor
when connecting a safety output L14 is linked to
limit switch or interlocking Relays K2 and K3.
device, a self-locking func-
tion can be achieved by
setting switch S5 to “1”. The
time difference is then
extended to infinite. S13 L13 D2
Setting
S1 ON = Trailing edge function off OFF = Trailing edge function on
S4 ON = Cross-short recognition off OFF = Cross-short recognition on
1 0 S5 S5 ON = Time delay between input OFF = Time delay between input

1 0 S4 channel 1 and 2 infinite channel 1 and 2 ca. 100 msec.
1 0 S1
117

• Input for reset
• Feedback loop
• LED’s for K1, K2, UB, Ui
magnet switches
Front View
41 33 23 13 A1
T11 T12 T12 T22
C.33 UB U i
Fuse K1 K2
T33 T34 PE X1 X2
42 34 24 14 A2

Designation
SRB-NA-R-C.33-24V 3 NO / 1 NC 24VDC/VAC
SRB-NA-R-C.33-115VAC 3 NO / 1 NC 115VDC
Approvals BG UL CSA
118
SRB-NA-R-C.33
L1
Typical ON
Wiring Reset OFF Monitoring using two limit switches (one
KB
KA
A1 X1 T34 T33 T11 X2 T12 T12 T22 13 23 33 41
K1
F2 guided contacts.
F1 K2 K1 K2 K1 K3 **** = Feedback loop
K3 KB
K1 K2 K3
A2 PE 14 24 34 42
KA KB
Data
24 VAC, 48 VAC, 115 VAC, 230 VAC -15% / +6%
Fuse (Power Supply) F2: T 0.25 A/250 (internal F1: TM 0.25 A/250V)
Switching Capacity (Monitoring Contacts) 24V, 2 A resistive (inductive with suitable suppression)
Weight 190 g (280g at 115 VAC and 230 VAC versions)
119
SRB-NA-R-C.33

T11 T12 T33 X1 T11 T11 T33 X1
EN 60 204-1. EN 60 204-1.

are not detected.
T12 T22 T34 X2 T12 T22 T34 X2

T11 T12 T33 X1 T11 T11 T33 X1
Monitoring according to EN ON Monitoring according to EN ON
1088 one limit switch with 1088 one limit switch with OFF
OFF
detected. detected.
for increased safety Monitoring circuits are not
requirements.
T12 T22 T34 X2 Safety category 3 or 4 in T12 T22 T34 X2

120
SRB-NA-R-C.33

L1 L1
forcement or contact multi- KA
* KB forcement or contact multi-
*
KA KB
KA
14 KB 14 24 KA
KA KB KA KB
N
N
121
Features • 3 NO relay outputs, 2 NO/ NC auxiliary out-

puts (NO/NC auxiliary contacts for monitor-
ing only, must not be used in safety
enabling circuits)
• Input for reset
• Feedback loop
• LED’s for K1, K2, UB, Ui
DIN EN 50 022
magnet switches
Front View
13 23 33 41 53
Dimensions 83 x 45 x 140 mm A1 T11 T12 T22 X5
SRB-NA-R-
C.34-24V UB U i
Fuse K2 K3
T33 T34 X3 X4 A2
14 24 34 42 54

Designation
SRB-NA-R-C.34-24V 3 NO / 1 NC / 1 NO 24VDC/VAC
Approvals BG UL CSA
122
SRB-NA-R-C.34
L1
ON
Wiring Reset OFF Monitoring using two limit switches (one
KA
A1 X1 T34 T33 T11 X2 T12 T12 T22 13 23 33 41 reinforcement or contact multiplication,
F2 K1 guided contacts.
F1 K2 K1 K2 K1 K3 **** = Feedback loop
K3 KB
K1 K2 K3
A2 PE 14 24 34 42
KA KB
Data
Fuse (Power Supply) F2: T 0.25 A/250 (internal F1: T 0.5 A/250V)
Power Consumption max. 5 VA
DC 13: 24 V/2 A; AC 15: 230 VAC/3 A
Switching Capacity (Monitoring Contacts) max. 24 VDC/2 A resistive (inductive with suitable suppression)
Fuse (Monitoring Contacts) 2 A slow blow; 0.5 A slow blow
Contact Materials / Contacts AgCdO self cleaning, positively driven
Weight 200g
123
SRB-NA-R-C.34

T11 T12 T33 X3 T11 T11 T33 X3
EN 60 204-1. EN 60 204-1.

are not detected.
T12 T22 T34 X4 T12 T22 T34 X4

T11 T12 T33 X3 T11 T11 T33 X3
Monitoring according to EN ON Monitoring according to EN ON
1088 one limit switch with OFF
1088 one limit switch with OFF
detected. detected.
With external Reset button Cross-shorts in the
for increased safety Emergency Stop circuits
requirements. are not detected.
requirements.
T12 T22 T34 X4 Safety category 3 or 4 in T12 T22 T34 X4

Advice: Wiring example:

Input level
Time window infinite chan- T 33 X3 T 33 X3
nel 1 and channel 2 via Start with trailing edge
cable link between X3/X4 function.
and T33/T34.
Module is activated after
For external Reset connect release of the Reset button.
Reset button to X3/X4. Reset
This prevents tampering of
the Reset button which
could lead to an automatic
reset.
T 34 X4 T 34 X5 X4
124
SRB-NA-R-C.34

L1 L1
forcement or contact multi- KA * KB forcement or contact multi- KA
* KB
contactors with positively contactors with positively
KA KB
14 KB 14 24
KA
KA KB KA KB
N N
125
Features • 4 NO relay outputs, 1NC auxiliary output,

1 NO time-delayed output (NC auxiliary
contact for monitoring only, must not be
used in safety enabling circuits)
• Input for reset
• Feedback loop
• LED’s for K2, K3, K4, K5, UB, Ui
DIN EN 50 022
magnet switches
Front View
13 23 33 47 51
Dimensions 83 x 45 x 140 mm A1 T11 T12 T22 X5
SRB-NA-R-
C.35 t ...... s
UB U i
Fuse K2 K3
K4 K5
A2 A2.1 T33 T34 UT
14 24 34 48 52

Designation
SRB-NA-R-C.35/WE-24V 3 NO / 1 NO / 1 NC 24VDC/VAC
SRB-NA-R-C.35KE-24V 3 NO / 1 NO / 1 NC 24VDC/VAC
SRB-NA-R-C.35/WE-QS-24V 3 NO / 1 NO / 1 NC 24VDC/VAC
SRB-NA-R-C.35/KE-QS-24V 3 NO / 1 NO / 1 NC 24VDC/VAC
WE — Time setting at factory (recommended)

KE — Time setting by customer
Approvals BG UL CSA
126
SRB-NA-R-C.35
L1
Typical ON
Wiring **** OFF Monitoring using two limit switches (one
Diagram KB
KA
A1 T11 T33 T34 X5 T12 T22 UT 13 23 33 47 51 reinforcement or contact multiplication,
F1 K2 K1
abfallende
guided contacts.
F2 Flanke
K3 K1 K2 K1 K4 **** = Feedback loop
K2
K4 K2
K3
K5 TIMER TIMER
K4
K4
K1 K2 K3 K4 K5
K5
KB
A2 A2.1 14 24 34 48 52
KA KB
Data
Fuse (Power Supply) F2: T 0.25 A/250 (internal F1: T 0.5 A/250V)
DC 13: 24 V/2 A; AC 15: 230 VAC/3 A
Switching Capacity (Monitoring Contacts) max. 24 VDC/2 A resistive (inductive with suitable suppression)
Weight 280g
127
SRB-NA-R-C.35

T11 T12 T33 T33 T11 T11 T33 T33
EN 60 204-1. EN 60 204-1.

are not detected.
T12 T22 T34 UT T12 T22 T34 UT

T11 T12 T 33 T33 T11 T11 T33 T33
ON ON
1088 one limit switch with OFF 1088 one limit switch with OFF
Reset Reset
detected. detected.
requirements.
T12 T22 T34 UT Safety category 3 or 4 in T12 T22 T34 UT


T11 A2.1 T33 T33 T11 A2.1 T 33 T33
(Type QS) (Type QS)
ON
Stop switch according to Monitoring according to EN OFF
EN 60 204-1. 1088 one limit switch with
Reset
Emergency positive opening contact.
switch off
leakage in the Emergency Wire breakage and earth
Stop circuits are detected. leakage in the Door
Cross-shorts in the
detected.
are detected. Cross-shorts in the Door
detected.
requirements.
T12 T22 T34 UT T12 T22 T34 UT
128
SRB-NA-R-C.35

L1 L1
KB KB
forcement or contact multi- KA KC
forcement or contact multi- KA KC
plication, using relays or * plication, using relays or *
13 47 13 23 47
T33 T34 KB T33 T34 KB
14 48 KA 14 24 48 KA
KA KB KC KA KB KC
N N

Advice: Wiring example:

Input level
The supply for the electron- T33 T33
ic timers of the delayed Start with trailing edge
enabling output 47/48 is on function.
terminal UT.
Module is activated after
For a controlled operation release of the Reset button.
in case of power loss, sup- Reset
This prevents tampering of
ply external power to termi-
the Reset button which
nal UT.
could lead to an automatic
Warning: If external voltage reset.
(24V DC, no ripple) is
applied on a terminal UT, a
fuse 0.1 A quick blow shall
be provided.
T34 X5
UT
Advice:
Drop-out delay of the 47
enabling output 47/48
adjustable 0…30 sec.
Enabling output 47/48 cor-
responds to Stop-category
1 in accordance with EN 60
204-1.
Enabling output 13/14,
23/24 and 33/34 corre-
sponds to Stop-category 0
204-1.
48
129

• Input for reset
• Feedback loop
• No cross-short recognition
magnet switches
Front View

13 23 X1
14 24 X2
K2
SRB-
NA-R-
K1 C.36
S1 S2 C
C1 X3 D

Designation
Approvals BG UL CSA
130
SRB-NA-R-C.36
L1
ON
Wiring OFF
**** Monitoring using two limit switches (one
Diagram KB
KA
C C1 S1 S2 X1 X2 X3 13 23 reinforcement or contact multiplication,
guided contacts.
F1
** **** = Feedback loop
K1 K2
K1 Wiring breakage and earth leakage in
KA
Trigger circuit the Monitoring circuits are detected.
K2 ** internal electronic fuse
K1 K2 KB
D 14 24
KA KB
Data
Fuse (Power Supply) Internal electronic fuse, breaking current > 0.6 A, reset time approx. 1 second
Power Consumption max. 2.5 W
Pick-Up Delay ≤ 330 ms / 720 ms (reset / auto reset)
Weight 190 g
Ambient Operating Temperature 0˚ C … +45˚ C (derating curve available)
131
SRB-NA-R-C.36

C1 S1 X1 C1 C1 X1
EN 60 204-1. EN 60 204-1.

are detected. are not detected.
With external Reset button. With external Reset button.
Safety category 2 in accor- Safety category 3 or 4 in
dance with EN 954-1. accordance with EN 954-1.
S1 S2 X2 S1 S2 X2

C1 S1 X1 C1 C1 X1
ON ON
OFF
detected. detected.
requirements.
S1 S2 X2 Safety category 3 or 4 in
S1 S2 X2
Wiring example: Advice:

Input level
C1 C1 X1 For “Automatic Reset” X1 X1
Dual-Channel triggering apply jumper X1-X3.
using P-switching semicon-
ductors.
button (connected to X1-
Wire breakage and earth X2), unit is triggered by
leakage in the Door Reset trailing edge function. Reset
detected.
With external Reset. KA KA
KB KB
S1 S2 X2 X2 X3
132
SRB-NA-R-C.36

L1 L1
forcement or contact multi- KA * KB forcement or contact multi- KA
* KB
KA
14 KB 14 24 KA
KA KB KA KB
N N

133
Features • 3 NO relay outputs, 2 NO time-delayed

outputs
• Input for reset
• Feedback loop
DIN EN 50 022
magnet switches
Front View
13 23 33 47 57
A1 T11 T12 T33 T34
Dimensions 83 x 45 x 140 mm SRB-NA-R- t: .... s
C.38-24V UB Ui
Fuse K1 K3
K2 K4
A2 T21 T22 T35 RT
14 24 34 48 58

Designation
SRB-NA-R-C.38-24V 3 NO / 2NO 24VAC/VDC
Approvals BG UL CSA
134
SRB-NA-R-C.38
L1
ON
Wiring OFF ****
KA
A1 T11 T34 T35 T33 T12 RT T22 13 23 33 47 57 reinforcement or contact multiplication,
guided contacts.
F2 K1 K2 **** = Feedback loop
Trigger
F1 circuit K1 KA Wiring breakage and earth leakage in
K3 K4 K3
TIMER TIMER
K2 KB * Fuse F2 (front cover) 1 A, fuse F1
K1 K3 K2 K4 K4 (internal) 1.25 A
A2 T21 14 24 34 48 58
KA KB
Data
NO 43/44, 53/54: DC 13: 24 VDC/2 A; AC 15: 230 VAC/3 A
Weight 480 g
135
SRB-NA-R-C.38

T11 T12 T33 T11 T11 T33
EN 60 204-1. EN 60 204-1.

are not detected.
1 0 1 0
T12 T22 T34 T12 T22 T34

T11 T21 T33 T11 T12 T33
Dual-Channel Door Single-Channel Door
ON
Wire breakage and earth Emergency Reset Wire breakage and earth Reset
leakage in the Door switch off leakage in the Door
detected. detected.
Cross-shorts in the With external Reset button
Emergency Stop circuits for increased safety
are detected. requirements.
To detect cross-short moni- QS Safety category 2 in accor- QS
toring: Set switch “QS” (bot- dance with EN 954-1.
tom of housing) to 1. 1 0 1 0
With external Reset button. T12 T22 T34 T12 T22 T34

T11 T21 T33 T11 T11 T33
Dual-Channel Door Monitoring Dual-Channel Monitoring
according to EN 1088 one limit according to EN 1088 one ON
ON
switch with positive opening limit switch with positive
OFF OFF
contact. opening contact.
Wire breakage and earth leak- Reset Wire breakage and earth Reset
age in the Door Monitoring cir- leakage in the Door
cuits are detected. Monitoring circuits are
detected.
Stop circuits are detected. Cross-shorts in the
are not detected.
ing: Set switch “QS” (bottom of
housing) to 1. QS With external Reset button. QS
With external Reset button for 1 0 Safety category 3 or 4 in 1 0
increased safety requirements. accordance with EN 954-1.
Safety category 3 or 4 in accor- T12 T22 T34 T12 T22 T34
136
SRB-NA-R-C.38

L1 L1
Suitable for contact rein- KB
Suitable for contact rein- KB
forcement or contact multi- KA forcement or contact multi- KA KC
* KC *
plication, using relays or 13 47 plication, using relays or 13 23 47
T33 T34 KB T33 T34 KA
14 48 KA 14 24 48 KB
KA KB KC KA KB KC
N N

Advice: Advice:
For “Automatic Reset” T33 Drop-out delay of the 47 57
apply jumper X1-X2. enabling outputs 43/44 and
53/54 adjustable from 0-30
sec.
button (X1-X2.1), unit is
triggered by trailing edge Enabling outputs 43/44 and
function. Reset 53/54 correspond to STOP-
with EN 60 204-1.
Enabling outputs 13/14,
23/24 and 33/34 corre-
spond to STOP-category 1
204-1.
T35 48 58
Time in S1 = 1 S1 = 0 S1 = 1 S1 = 0
Seconds S2 = 1 S2 = 1 S2 = 0 S2 = 0
S3 = 1 S3 = 0 S3 = 1 S3 = 0
S4 = 1 S4 = 1 S4 = 0 S4 = 0
II
III
IV V
VI Max
I 0.44 2.30 3.5 18
Min I
1 0 II 0.62 2.45 5.0 20

QS S4
1 0 S3 III 0.87 2.70 7.0 22
S2
S1
IV 1.05 2.85 8.5 23
V 1.27 3.05 10.2 25
VI 1.77 3.55 14.2 29
Tolerance ± 5%
137
SRB-C.44 Stop Category (EN60204-1): 0
Features • Suitable for E-Stop, door monitoring or

BNS Series coded magnet switches
• 3 enabling outputs and 1 monitoring output
• Current limitation at input circuits
• Voltage limitation at input circuits
• Selectable trailing edge function and auto
reset
• 22.5 mm housing
Front View

Designation
SRB-C.44 3 NO 24VAC/DC
Approvals BG UL (pending) CSA (pending)
138
SRB-C.44

Wiring Monitoring using two limit switches (one
Diagram with positive-opening contacts) and
Suitable for contact reinforcement or
contact multiplication, using relays or
contactors with positively guided con-
tacts.
** Fuse M 0.5A (an external leading
fuse M 0.25 A is recommended)
Data
Fuse (Power Supply) T 0.25 A/250V (internal TM 0.5 A/250V)
Switching Capacity (Monitoring Contacts) 24VDC, 100mA
Fuse (Monitoring Contacts) 100 mA slow blow
Current- & Voltage-Limitation of Input Circuits 26 VDC, 100 mA
Pick-Up Delay ≤ 120 ms / ≤ 30 ms (auto start, reset button)
Dimensions (H/W/D) 90 mm / 2.25 mm / 121 mm
Weight 200g
139
SRB-C.44

Dual-Channel Emergency Dual Channel Door
EN 60 204-1. 1088, one limit switch with
positive-opening contact.
leakage in the Emergency- Wire breakage and earth
detected.
Safety category 3 or 4
Cross-shorts in the Door
according to EN 954-1.
detected.
Wiring example:
Input level
Dual Channel Door
Monitoring with safety mag-
net switch and initial start
test.
leakage in the door
detected.
140
SRB-C.44

plication, using relays or plication, using relays or
contactors with positively- contactors with positively-
*Feedback loop *Feedback loop
Advice:
For “Automatic Reset” con-
tact feedback loop to X1-X3
or apply jumper X1-X3 if no
feedback loop is used.
button (feedback loop con-
nected to X1-X2), unit is
function.
Note: When operated at 24VAC only and when wired for trailing edge reset, loss of an internal capacitor
will result in the reset function not being fail safe.
141

safety magnet switched
• 3 enabling outputs and 1 monitoring output
• Suitable for monitoring semiconductor
outputs
• With electronic short-circuit protection
“Hybrid Fuse”
• Reset-feedback loop
• Selectable trailing edge function, auto reset
and cross-short recognition
• 22.5 mm housing
magnet switches
Front View

Designation
142
SRB-C.46

Diagram with positive-opening contacts) and
contactors with positively-guided con-
tacts.
** Hybrid fuse – Electronic fuse,
however it resets only when power
is cycled.
Data
Fuse (Power Supply) Internal electronic fuse, triggering current > 0.6A, reset after power down
Switching Capacity (Monitoring Contacts) 24VDC, 2 A
Weight 200g
143
SRB-C.46

Single-Channel Emergency Single Channel Door
Stop switch according to Monitoring according to
EN 60 204-1. EN1088, one limit switch
with positive-opening con-
tact.
leakage in the Emergency
Stop circuits are detected. Wire breakage and earth
leakage in the Door
Safety category 2 in accor- detected.
Safety category 2 accord-
ing to EN954-1.

Dual-Channel Emergency Dual Channel Door Monitoring
Stop switch according to according to EN1088, one
EN 60 204-1. limit switch with positive-open-
ing contact.
leakage in the Emergency Wire breakage and earth leak-
Stop circuits are detected. age in the Door Monitoring cir-
cuits are detected.
Cross-shorts in the
Emergency Stop circuits Cross-shorts in the Door
are not detected. Monitoring circuits are detect-
ed.
Activating Cross-Short moni-
toring: Set switch “QS” (bottom
of housing) to “1”.
Safety category 3 or 4 accord-
ing to EN954-1.

Input level
Dual-Channel Emergency Stop nect feedback loop to X1-
switch according to EN 60 204- X3 or apply jumper X1-X3 if
1. no feedback loop is used.
Wire breakage and earth leak- When using external Reset
age in the Emergency Stop cir- button (feedback loop con-
cuits are detected. nected to X11-X1) unit is
function.
Stop circuits are detected.
Safety category 3 or 4 in accor-
144
SRB-C.46

145

safety magnet switched
• 3 enabling outputs, 1 drop out delayed:
1… 30 second
• Suitable for monitoring semiconductor
outputs
• With electronic short-circuit protection
“Hybrid Fuse”
• Reset-feedback loop
• LED’s for K1, K2, K3/K4, Ui
• Selectable trailing edge function, auto reset
and cross-short recognition
• 22.5 mm housing
magnet switches
Front View

Designation
146
SRB-C.47

contactors with positively guided con-
tacts.
** Hybrid fuse – Electronic fuse,
however it resets only when power
is cycled.
Data
Fuse (Power Supply) Internal electronic fuse, triggering current > 0.6A, reset after power down
Power Consumption max. 4 VA, plus output L42
Switching Capacity (Monitoring Contacts) L42: 24VDC, 100 mA
Fuse (Monitoring Contacts)
Weight 200g
147
SRB-C.47

Single-Channel Emergency Single-Channel Door
leakage in the Emergency Wire breakage and earth
Stop circuits are detected. leakage in the Coor
detected.
Safety category 2 accord-
ing to EN 954-1.

leakage in the Emergency- Wire breakage and earth
Cross-shorts in the
detected.
are not detected. Activating Cross-Short
monitoring: Set switch “QS”
(bottom of housing) to “1”.

Input level
Dual-Channel Emergency Stop nect feedback loop to X1-
switch according to EN 60 204- X3 or apply jumper X1-X3 if
1. no feedback loop is used.
Wire breakage and earth leak- When using external Reset
age in the Emergency Stop cir- button (feedback loop con-
cuits are detected. nected to X1-X2) unit is
function.
Stop circuits are detected.
When Cross-Short monitor-
ing is deactivated (QS to 0)
mark filed “Ohne QS” in
front of housing.
Safety category 3 or 4 accord-
ing to EN 954-1.
148
SRB-C.47

Advice:
The safety enabling contact
37/38 is drop out delayed.
Delay time adjustable from
1 to 30 seconds.
The safety enabling contact
37/38 complies with Stop-
category 1 according to EN
60 204-1.
The enabling contact 13/14
and 23/24 comply with
Stop-category 0 according
to En 60 204-1.
149
SRB-NA-R-C.EW Output Expansion Module

• Feedback circuit X1, X2
Front View
13 23 33
Dimensions 82 x 22.5 x 98.8 mm X2 X1 A1
K2
SRB-NA
-R-C.EW
K1
14 24 34
A2 43 44

Designation
SRB-NA-R-C.EW-24V 4 NO 24VDC/VAC
Approvals UL CSA BG
150
Typical A1 X1 13 23 33 43
Wiring
Diagram K1
K1
K1
K2
K2 K2
K1 K2
A2 X2 14 24 34 44
Data
Fuse (Power Supply) M 0.25 A/250V
Weight 190g
151
Wiring example:
Input level
24 V
Single-Channel control of
the expansion module
SRB-NA-R-C.EW via one
enabling output of the base
module.
A fault in the expansion
module is not detected by X1 X2 13 23 A1 X1 X2
the base module. SRB-NA-... SRB-NA-R-C.EW
Connect terminals X1 and
14 24 A2
X2 to the feedback loop of
the base module.
0V
152
Safer
by
Design
153
SRB-LV Output Expansion Module

(NC auxiliary contacts for monitoring only,
must not be used in safety enabling
circuits)
• Feedback circuit X1, X2
Front View
A1
(+) U K1 X1 13 23 33 43 51
Dimensions 83 x 90 x 127 mm SRB-LV
K1 K2
A2
(–) U PE K2 X2 14 24 34 44 52

Designation
SRB-LV-24V 4 NO / 1 NC 24VDC/VAC
SRB-LV-115V 4 NO / 1 NC 115VAC
SRB-LV-230V 4 NO / 1 NC 230VDC
Approvals UL CSA BG
154
Typical A1 U U K1 K2 X1 13 23 33 43 51
Wiring
K1
Diagram
K1
K1
K2
K2 K2
K1 K2
A2 PE X2 14 24 34 44 52
Data
24 VAC, 115 VAC, 230 VAC -15% / +6%
Switching Capacity (Monitoring Contacts) 24VDC/ 2 A
Weight 420 g (500g at 115 VAC and 230 VAC versions)
155
Wiring example:
Input level
L (L+)
SRB-LV via one enabling
output of the base module.
module is not detected by
X1 X2 13 23 U U X1 X2
the base module. A1
SRB-NA-...
Connect terminals X1 and A2 SRB-LV
14 24 K1 K2
the base module.
N (L-)
Wiring example:
Input level
L (L+)
Dual-Channel control of the
expansion module SRB-LV
via two enabling outputs of
the base module.
module is not detected by
X1 X2 13 23 U U X1 X2
the base module. A1
Connect terminals X1 and SRB-NA-...

A2 SRB-LV
14 24 K1 K2
the base module.
N (L-)
156
Safer
by
Design
157
Safety Controller for Muting Safety Category (EN954-1): CC4
SRB-MSK
Features • 2 muting outputs

• Monitored output for muting lamp function
• Output for monitoring the simultanety of
muting sensors
• Integrated fuse
• Green LED’s for K1, K2, K3, K4, K5, Ub and
Ui
Front View
LA1 L54
Dimensions 83 x 90 x 140 mm SRB-MSK
L84
L84 LA2

Designation
SRB-MSK-24VDC 2 24VDC
SRB-MSK/QS-24VDC 2 24VDC
Approvals BG
158
Safety Controller for Muting
SRB-MSK
Typical
Wiring L84 L54 LA1
Diagram
LA2
Data
Fuse (Power Supply) F2: T 1.0 A/250V (internal F1: T 1.25 A/250V)
Power Consumption max. 3.2 W plus power consumption of sensors and muting lamps
Switching Capacity (Auxiliary Contacts) Y1/Y2: max. 250 mA; M1/M/2: 24V/250 mA - 2.5 A
Fuse (Auxiliary Contacts) F2: T 1.0 A (internal F1: T 1.25 A); M1/M2; 2 x T 2.5 A (internal)
Connections Self lifting terminals min. 0.6 qmm2, max 2.5 qmm2
Weight 460g
Mechanical Life 50 x 105 switching cycles
159
SRB-MSK
Wiring
Example:
Input Level
MSK-QS
Light Curtain
SRB
L84
LA1 LA2
SRB-MSK
Light Curtain
SRB
L84
LA1 LA2
With SRB-MSK connect S2/S4 to S21 & S22
160
SRB-MSK
Wiring example:
Input level
(S21-MSK)
Wiring muting sensor.
Detects wire breakage and
earth leakage in the moni-
toring circuit.
(S22-MSK)
MSK-QS
Time Charts
L84
LA1 / LA2
L84
161
SRB-ZB-Mo Output Expansion Module

• LED’s for B1, B2, B10, B20
• Feedback circuit X1, X2 and X11, X12
Front View
B1 B2 X1 X11 13 23 33 43 53 63
B1 B2
SRB-ZB-Mo
B10 B20
A B12 X2 X12 14 24 34 44 54 64

Designation
SRB-ZB-Mo-24VDC 6 NO 24VDC
Approvals UL CSA BG
162
Typical B1 B2 B12 X1 X11 13 23 33 43 53 63

Wiring
Diagram
B1 B10
B1 B10
B2 B20 B2 B20
B1 B2 B10 B20
A X2 X12 14 24 34 44 54 64
Data
Weight 870 g
163
Wiring example:
Input level
L (L+)
SRB-NA-R-C.EW via one
enabling output of the base
module.
module is not detected by X1 X2 13 23 X1 X2 X11 X12
the base module. SRB-NA-...
A SRB-ZB-Mo
Connect terminals X1 and
14 24 B1 B2 B12
the base module.
N (L–)
Wiring example:
Input level
L (L+)
Dual-Channel control of the
expansion module SRB-
NA-R-C.EW via two
enabling outputs of the
base module.
module is not detected by X1 X2 13 23 X1 X2 X11 X12
the base module. SRB-NA-... SRB-ZB-Mo
A
Connect terminals X1, X2
14 24 B1 B2 B12
and X11, X12 to the feed-
back loop of the base mod-
ule.
N (L–)
164
Safer
by
Design
165
Two-Hand Control Safety Controller Safety Category (EN954-1): CC4
SRB-ZHK
Features • 3 enabling paths, 1 auxiliary contact

• Green LED’s for K1 and K2
31
32
DC
Model SRB-ZHK
S11 S21
S12 S22
Dimensions 82 x 22.5 x 98.8 mm DC Front Views

83 x 45 x 140 mm AC
13 23 31 A1
S11 S23 S12 S24 X1
SRB-ZHK (AC)
AC K1 Ui UB
Model
K2 Fuse
S43 S31 S32 S44 X2

14 24 32 A2

Designation
SRB-ZHK-24VDC 2 NO 24VDC
SRB-ZHK-115VAC 2 NO 115VAC
Approvals BG UL CSA
166
Two-Hand Control Safety Controller
SRB-ZHK
Typical
Wiring
Diagram
DC
Model
A1 D C C1 D1
AC
Model
A2 32
Data
115/230 VAC -15% / +6%
Fuse (Power Supply) M 0.25 A/250V (internal M 0.5 A/250V)
Switching Capacity (Monitoring Contacts) 24VDC/ 2 A resistive (inductive with suitable suppression)
Dimensions (H/W/D) 82 mm / 22.5 mm / 98.8 mm (83 mm / 45 mm / 40 mm AC)
Weight 420 g (360 g AC)
167
SRB-ZHK
Wiring example:
Input level C C1 D1 C1
Two-hand control according
to EN 574 and EN 60 204-
1.
Faults in each pushbutton
contact as well as earth
faults and cross-shorts are
detected.
Feedback circuit: The safe-
ty function of external posi-
tively driven contactors is
monitored by a series con-
nection of NC contacts with
the terminals X1 and X2.
This circuit must be closed
in release state.
Safety category III/C
according to EN 574.
DC Model AC Model
Time Chart Note: Do not use pushbuttons with overlapping contacts.
.
SRB-ZHK

Suitable for relays or con- Suitable for relays or con-
tactors with positive guided tactors with positive guided
contacts. contacts.
169
Safer
by
Design
170
Appendices
Contents
Topic Page
• AES / AZR Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
• AES Series “Integral System Diagnostic” Charts . . . . . . . . . . . . . . . . . . . . . . . 186
• AES / AZR Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
• Selected Machine Safeguarding Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 193
• Machine Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
171
Technical Data
AES 6112/7112 AES 1102/1112
Standards: IEC/EN 60204-1/VDE 0113 part 1; EN 1088; EN 954-1; DIN VDE 0660-209;
BG-GS-ET-14; BG-GS-ET-20
Control Category: 1
Start-up test: No
Enclosure material: Glass-fibre reinforced plastic
Fixing: Snaps onto standard DIN rail to DIN EN 50022
Screw terminals: Max. 1.5 mm2 (incl. conductor ferrules) Max. 2.5 mm2 (incl. conductor ferrules)
Protection class: Terminals IP 20; Enclosure IP 40 to IEC/EN 60529/DIN VDE 0470-1
Operating voltage Ue: AES 6112: 24 VDC ± 15 %; AES 1102, AES 1112: 24 VDC ± 15 %
AES 7112.1: 110 VAC; AES 1102.1, AES 1112.1: 110 VAC
AES 7112.2: 230 VAC; AES 1102.2, AES 1112.2: 230 VAC
AES 7112.3: 24 VAC AES 1102.3, AES 1112.3: 24 VAC
AES 1102.4, AES 1112.4: 42 VAC
Operating current Ie: AES 6112: 0.1 A AES 1102: 0.1 A
Power consumption: AES 7112: 1.5 VA AES 1112: 0.7 VA
Inputs: C/S14/S22/S32:
auxiliary contacts
Max. length of lead: 1000 m of 0.75 mm2 conductor
Outputs: 1 enabling path
Utilization category: AC-15; DC-13
Rated operating
current / voltage Ie / Ue: – –
Switching voltage: Max. 250 VAC
Load current: Max. 5 A (cos ϕ = 1) Max. 4 A (cos ϕ = 1)
Switching capacity: Max. 1250 VA Max. 1000 VA
Max. fuse rating: 5 A (quick blow) 4 A (quick blow)
Additional transistor outputs: –
Indications: LED
Immunity to noise: To EMC guidelines –
Max. switching frequency: 10 Hz
Overvoltage category: II to DIN VDE 0110
Degree of pollution: 3 to DIN VDE 0110
Resistance to vibration: 10 … 55 Hz / amplitude 0.35 mm ± 15%
Resistance to shock: 30 g / 11 ms –
Ambient temperature: 0 °C … + 55 °C
Storage and transport temp.: – 25 °C … + 70 °C
Note: Inductive loads (e.g. contactors, relays, etc.) are to be suppressed by means of a suitable circuit.
172
Technical Data
AES 1235/1236 AES 1135/1136 / AES 1145/1146
DIN VDE 0801/-A1; BG-GS-ET-14; BG-GS-ET-20
Control Category: 3
Start-up test: No/Yes
Screw terminals: Max. 2.5 mm2 (incl. conductor ferrules)
Operating voltage Ue: 24 VDC ± 15 %
Operating current Ie: 0.2 A

Inputs: S14/S22, X1: S1-S14/S22, X1:
Input resistance: Approx. 2 kΩ to earth
Input signal „1“: 10 … 30 VDC
Outputs: 13-14/23-24: 13-14:

2 enabling paths 1 enabling path
Rated operating
current / voltage Ie/Ue: 2 A/250 VAC; 2 A/24 VDC
Load current: Max. 4 A (cos ϕ = 1)
Switching capacity: Max. 1000 VA
Max. fuse rating: 4 A (quick blow)
Additional transistor outputs: Y1:Ue – 4 V; 100 mA, Y1, Y2: AES 1145/1146 min. Ue – 4 V;
short-circuit proof, switching p Y1+Y2 = Max. 100mA, short-circuit proof, switching p
Indications: ISD
Immunity to noise: To EMC guidelines
Resistance to vibration: 10 … 55 Hz / amplitude 0.35 mm ± 15% at the regulation point
Resistance to shock: 30 g / 11 ms
173
Technical Data
AES 1165 / 1166
Control Category: 3
Screw terminals: Max. 2.5 mm2 (incl. conductor ferrules)
Operating voltage Ue: 24 VDC ± 15 %
Operating current Ie: 0.2 A

Power consumption: –
Inputs: S1-S14 / S22, S2-S14 / S22:
Outputs: 13-14:
1 enabling path

Rated operating
current / voltage Ie / Ue: 2 A/250 VAC; 2 A/24 VDC
Additional transistor outputs:
–
Additional contacts: –
Indications: ISD
174
Technical Data
AES 2335/2336 AES 2135/2136
Control Category: 3
Screw terminals: Max. 4 mm2 (incl. conductor ferrules)
Operating voltage Ue: AES 2335 / 2336: 24 VDC ± 15 %; AES 2135.1 / 2136.1: 110 VAC
AES 2335.1 / 2336.1: 110 VAC; AES 2135.2 / 2136.2: 230 VAC
AES 2335.2 / 2336.2: 230 VAC AES 2135.3 / 2136.3: 24 VAC
Operating current Ie: 0.2 A (DC-Version) –
Power consumption: 5.8 VA 5 VA
Inputs: S13-14 / S21-22, X1: S1-S14 / S22, X2, X4, X6:
Max. length of lead: 1000 m of 0.75 mm2 conductor 1000 m of 1.5 mm2 conductor
Outputs: 13-14/23-24/33-34: 13-14:
Rated operating
current / voltage Ie/Ue: 2 A/250 VAC; 2 A/24 VDC
Additional transistor outputs: Y1, Y2: Ue – 4 V; –
Y1 + Y2 = Max. 100 mA short-circuit proof, switching p
Indications: ISD
Max. switching frequency: 5 Hz 1 Hz
175
Technical Data
AES 3535/6 / AES 3335/6 AES 3335/3336 AC-Versions
Control Category: 3
Operating voltage Ue: 24 VDC ± 15 % 3335.1/3336.1:110 VAC; 3335.2/3336.2: 230 VAC
Operating current Ie: 0.3 A –
Power consumption: – 5.8 VA
Inputs: S1-S14/S22, X2, X4, X6, X8 S14,S22, X2, X4, X6, X8
Outputs: AES 3535 /3536: 13-14 / 23-24 / –
33-34 / 43-44: 4 enabling paths
AES 3335 / 3336: AES 3335 / 3336 AC version:
13-14 / 23-24 / 33-34: 3 enabling paths 13-14 / 23-24 / 33-34: 3 enabling paths
Rated operat. current / voltage Ie/Ue: 3 A/250 VAC; 2 A/24 VDC
Additional outputs: 51-52: 43-44 / 51-52:
NO and NC contacts not suitable for safety functions
Utilization category: – AC-15; DC-13
Rated operat. current / voltage Ie/Ue: – 2 A/250 VAC; 2 A/24 VDC
Load current: – Max. 2 A (cos ϕ = 1)
Switching capacity: – Max. 500 VA
Max. fuse rating: – 2 A (quick blow)
Transistor-Additional outputs: Y1, Y2: min. Ue – 4 V; Y1 + Y2 = Max. 100 mA –
Indications: ISD
Resistance to vibration: 10 … 55 Hz / amplitude 0.35 mm ± 15 % at the regulation point
Storage and transport temperature: – 25 °C … + 70 °C
176
Technical Data
AES 3565/3566 / AES 3365/3366 AES 2165/2166
Control Category: 3
Operating voltage Ue: 24 VDC ± 15 % AES 2165.1/2166.1 110 VAC;
AES 2165.2/2166.2 230 VAC;
AES 2165.3/2166.3 24 VAC
Operating current Ie: 0.3 A –
Power consumption: 5 VA
Inputs: S1-S14 / S22, X2, X4, X6, X8: S1-S14 / S22, S2-S14 / S22, X6:
Outputs: AES 3565/3566 13-14 / 23-24 / 13 / 14:
33-34 / 43-44: 4 enabling paths 1 enabling path
51-52: NC contacts not suitable for safety function
AES 3365, AES 3366 13-14/23-24/33-34 –
3 enabling paths
Rated operating
current / voltage Ie/Ue: 3 A/250 VAC; 2 A/24 VDC 2 A/250 VAC; 2 A/24 VDC
Additional transistor outputs: Y1, Y2: Ue – 4 V; –
Y1 + Y2 = Max. 100 mA short-circuit proof, switching p
Indications: ISD
Resistance to vibration: 10 … 55 Hz / amplitude 0.35 mm ± 15 % at the regulation point
177
Technical Data
AZR 31 T0
Standards: IEC 60204-1 / EN 60204-1 / VDE 0113 Part 1; EN 954-1; EN 1088; BG-GS-ET-20
Control Category: 4
Start-up test: –
Enclosure material: Polycarbonate
Fixing: Snaps onto standard DIN rail to EN 50 022
Screw terminals: Max. 1.5mm2 (incl. end thimbles)
Protection class: Terminals IP 20; Enclosure IP 40 to IEC 60529 / EN 60529 / DIN VDE 0470-1
Operational voltage Ue: 24V AC / DC ± 15%
Operational current Ie: –

Power consumption: <2W
Inputs: S13/S14/S23/S24
Potential-free contact in lead to A1
for 1 channel connection or 1 contact
each in leads to A1 and A2 for
2 channel connection max. 150 Ω;
Feedback X1 and X2 potential free
Input resistance: –
Input signal “1”: –
Max. length of lead: –
Outputs: 3 enabling circuits
1 signal circuit
(2 relay NC contacts in parallel)
2 NC contacts in series)
Utilization category: AC 15; DC 13
Rated operational
current / voltage Ie/Ue: 6A / 250V AC; 3A / 24V DC
Switching voltage: Max. 400V AC
Load current: Max. 6A (cos ϕ = 1)
Switching capacity: 1,500VA
Max. fuse rating: 6A (quick-acting)
Switch-on time: <25ms
Switch-off time: <150ms
Indications: Green LED’s for control voltage and output

Max. switching frequency:1Hz
Resistance to vibration: 10 to 55Hz / Amplitude 0.35mm ± 15% at the regulation point
Resistance to shock: 30g / 11ms
Ambient temperature: 0°C to +50°C
Storage and transp. temp.: –25°C to +70°C
178
Technical Data
AZR 31 T2 / AZR 31 R2 AZR 11 RT2
Standards: IEC/EN 60204-1/VDE 0113 part 1; EN 954-1; EN 1088; BG-GS-ET-20
Control Category: 4
Start-up test: –
Screw terminals: Max. 2.5 mm2 (incl. conductor ferrules) Max. 2 x 1.5 mm2 (incl. conductor ferrules)
Operating voltage Ue: 24 VAC; 24 VDC; 110 VAC ± 15 %; 230 VAC ± 15 % 24 VDC ± 15 %
Operating current Ie: 0.15 A (DC version) –
Power consumption: <3W < 0.5 W
Inputs: S13 = 24V, S23 = GND, S14/S24 = Relay –
Max. current on short-circuit 85 mA (leads to drop-out),
Reset (AZR 31 R2): 24 VDC (from S13-S23),
Test (AZR 31 T2): Potential-free contact
Input resistance: Between S13-S14/S23-S24: 150Ω –
Input signal „1“: – –
Input signal „0“: – –
Max. length of lead: 1000 m of 0.75 mm conductor
2
–
Outputs: 13-14/23-24/33-34: 13-14:
1 signal path (2 relay NC contacts in parallel) 1 signal path (Semi-conductor output)
Rated operating
current / voltage Ie / Ue: 2.5 A/400 VAC; 3 A/24 VDC 2.5 A/250 VAC; 2.5 A/24 VDC
Switching voltage: Max. 400 VAC Max. 250 VAC
Load current: Max. 6.2 A (cos ϕ = 1) Max. 4 A (cos ϕ = 1)
Max. fuse rating: 6 A (slow blow) 4 A (slow blow)
Additional outputs: – Semi-conductor output: 24 VDC; 15 mA DC
Switch-on time: < 80 ms ≤ 35 ms
Response time: < 15 ms (< 130 ms on supply failure) ≤ 15 ms
Indications: green LED’s for control voltage, inputs and outputs green LED’s for control voltage and inputs
179
Technical Data
AZR 62 A2 AZR 63 V2
Standards: IEC 60204-1 / EN 60204-1 / VDE 0113 Part 1; EN 954-1; EN 1088; BG-GS-ET-20
Control Category: 4
Start-up test: –
Screw terminals: Max. 2.5mm2 (incl. end thimbles)
Operational voltage Ue: 24V DC; 24V AC; 110V AC ± 15%; 230V AC ± 15%
Operational current Ie:
Inputs: S 13/14 and S 23/24
Potential-free NC contacts
Input resistance: Max. 150Ω
Max. length of lead: 1,000m of 0.75mm2 conductor
Outputs: 6 enabling circuits 6 enabling circuits, off delay,
1 NC contact for feedback input to other 1 NC contact for feedback input to other
safety control units; 1 NC aux. contact safety control units and 1 NC aux. contact
with off delay, 1 NO aux. contact without delay
Rated operational
current / voltage Ie / Ue: 6A / 250V AC; 3A/ 24V DC
Load current: Max. 6A
Switching capacity: Max. 1,500VA
Switch-on time: <30ms <30ms to max. 3s
Switch-off time: <150ms <150ms to max. 15s
(Setting 0 to 30s in 2 second steps)
Indications: Green LED’s for control voltage, output
Max. switching frequency: 1Hz
Storage and transport temperature: –25°C to +70°C
180
Technical Data
ASL 2103
Standards: IEC 60204-1 / EN 60204-1 /
VDE 0113 Part 1; EN 954-1;
DIN V 31006-2
Control Category: 3
Start-up test:
Screw terminals: Max. 4mm2 (incl. end thimbles)
Protection class: Terminals IP 20; Enclosure IP 40 to IEC IEC 60529 / EN 60529 / DIN VDE 0470-1
Operational voltage Ue: 224V DC ± 15%, 24V AC, 110V AC
230V AC
Operational current Ie: –
≤300 mA
Inputs: Potential-free switching strips/
switching mats with
1.5k Ω ± 300 Ω internal resistance
(leads to drop-out)
Reset X2/X3: Potential-free contact
Input resistance: –
Test and feedback: Potential-free contact
Outputs: 1 enabling circuit
Rated operational
current / voltage Ie/Ue: 2A / 250V AC; 2A / 24V DC
Load current: 4A
Max. fuse rating: 4A
Switch-on conditions: Switch-on time ≤35ms
between A and Bl
Switch-off time : Response time: ≤60ms <2%
Indications: Green LED’s for channel 1
channel A/B, output; Yellow LED’s and channel 2
for sync. and reset; Green LED’s
for control voltage and inputs
Note: Inductive loads (contactors, relays, etc.) are to be suppressed by a suitable circuit.
181
Fail-to-Safe Timer
Technical Data
AZS 2305
Standards: IEC 60204-1 / EN 60204-1 / VDE 0113 Part 1; EN 1088; EN 954-1;
DIN VDE 0801/-A1; BG-GS-ET-20
Control Category: 3
Start-up test: –
Screw terminals: Max. 4mm2 (incl. end thimbles)
Operational voltage Ue: AZS 2305 24V DC ± 15%
AZS 2305.1 110V AC
AZS 2305.2 230V AC
Operational current Ie: 0.1A at 24V DC
Power consumption:
Inputs: S1(S14), S1(S22):
Input resistance: Approx. 2kΩ to Earth
Input signal “1”: 10 to 30V DC
Outputs: 13-14, 23-24, 33-34:
3 enabling circuits, each with 2 NO contacts in series
Rated operational
current / voltage Ie / Ue: 2A / 250V AC; 2A / 24V DC
Load current: Max. 3A
Switching capacity: Max. 750VA
Additional transistor outputs Y1, Y2: Min. Ue - 4V; Y1 + Y2 = 100mA short-circuit proof, p-switching
Time setting:
Minimum time tmin: 0.1s
Maximum time tmax: 99min
Timing tolerance: <2%
Indications: ISD
Storage and transport temperature: –25°C to +70°C
Note: Inductive loads (e.g. contactors, relays, etc.) are to be suppressed by a suitable circuit.
182
Technical Data
FWS 2316 FWS 1105 / FWS 1106
Standards: IEC 60204-1 / EN 60204-1 / VDE 0113 Part 1; EN 1088; EN 954-1; DIN VDE 0801/-A1; BG-GS-ET-20
Control Category: 3
Start-up test: –
Screw terminals: Max. 4mm2 (incl. end thimbles) Max. 2.5mm2 (incl. end thimbles)
Operational voltage Ue: 24V DC ± 15%
Operational current Ie: 0.3A 0.2A
Power consumption:
Inputs: X2, X4, X6, X8: X1, X2
Input resistance: Approx. 2kΩ to Earth
Max. length of lead: 100m of 0.75mm2 conductor
Standstill frequency: Execution C: Input X2/X4: 1Hz/1Hz Execution A: Input X1/X2: 1Hz/2Hz
Other executions: On enquiry Execution B: Input X1/X2: 2Hz/2Hz
Execution C: Input X1/X2: 1Hz/1Hz
Other executions: On enquiry
Hysteresis: 10% of standstill frequency
Max. input frequency: 1000Hz 4000Hz
Min. pulse duration: 500µs 125µs
Outputs: 13/14; 23/24; 33/34; 43/44; 51/52: 13-14:
Rated operational
current / voltage Ie /Ue: 3A / 250V AC; 2A / 24V DC 2A / 250V AC; 2A / 24V DC
Load current: Max. 6A (cos ϕ = 1) Max. 4A (cos ϕ = 1)
Switching capacity: Max. 1,500VA Max. 1,000VA
Max. fuse rating: 6A (quick-acting) 4A (quick-acting)
Additional transistor Min. Ue - 4V; Y1 + Y2 = 100mA short-circuit proof,
outputs Y1, Y2: open collector, p-switching
Switch-on time:
Switch-off time:
Indications: ISD

183
Technical Data
AZR 31 S1 FWS 3505-2204
Standards: IEC 60204-1 / EN 60204-1 / VDE 0113 Part 1; IEC 60204-1 / EN 60 204-1 / VDE 0113 Part 1;
EN 1088; EN 954-1; BG-GS-ET-20 EN 1088; EN 954-1; DIN VDE 0801/-A1; BG-GS-ET-20
Control Category: 4 3
Start-up test: No No
Enclosure material: Polycarbonate Glass-fibre reinforced thermoplastic
Screw terminals: Max. 2.5mm2 (incl. end thimbles) Max. 4mm2 (incl. end thimbles)
Operational voltage U : e 24V DC; 24V AC; 110V AC ± 15%; 230V AC ± 15% 24V DC ± 15%
Operational current Ie: – 0.3A
Power consumption: <3W –
Inputs: Channel A, B: Terminals for 3 phase motor 400V AC Inputs X2, X4, X6, X8
Feedback X1/X2: Potential-free contact
Input resistance: – Approx. 2kW to Earth
Input signal “1”: – 10 to 30V DC
Input signal “0”: – 0 to 2V DC
Max. length of lead: – 100m of 0.75mm2 conductor
Standstill frequency: – Execution C: Input X2/X4: 1Hz/1Hz
Other executions: On enquiry
Hysteresis: – 10% of standstill frequency
Max. input frequency: – 1000Hz
Min. pulse duration: – 500µs
Outputs: 13/14; 23/24; 33/34: 3 enabling circuits 13/14; 23/24; 33/34; 43/44; 51/52:
1 signal circuit (2 relay NC contacts in parallel) –
Rated operational
current / voltage Ie/Ue: 6A / 250V AC; 3A / 24V DC 3A / 250V AC; 2A / 24V DC
Switching voltage: Max. 400V AC Max. 250V AC
Load current: Max. 6A (cos ϕ = 1)
Switching capacity: Max. 1,500VA
Additional transistor – Min. Ue - 4V; Y1 + Y2 = 100mA short-circuit proof,
outputs Y1, Y2: open collector, p-switching
Switch-on time: <3s after motor comes to standstill –
Switch-off time: <15ms (<130ms on supply failure) –
Indications: Green LED’s for control voltage and output, ISD
red LED for fault, yellow LED’s for channels A and B
184
Safer
by
Design
185
ISD - Integral System Diagnostics
AES 1135 to 1166, AES 1185, AES 1235/1236, AES 2135 to 2166,
AES 2335 and AES 3335 to 3566
Indication Explanation of switching conditions

LED on green • Enabling circuits closed
LED flashing green • Enable delay time running,

enabling circuits open,
only for AES 1185
LED flashing yellow • Guard device open

(short pulses approx. 0.5Hz)
LED flashing yellow • Guard device closed

(short pulses approx. 2Hz) but no enable.
Possible cause: Faulty operation
(only one contact actuated when
opening the guard)
• Voltage drop
• Feedback circuit not closed
• Start-up test not carried out,
only for AES ...6
Indication (yellow) Explanation of switching conditions Only valid for: AES 1165/1166, AES 1185,
LED one pulse • Guard device 1 open AES 2165/2166 and AES 3365/3566
LED two pulses • Guard device 2 open
LED three pulses • Guard device 3 open,

only for AES 1185
186
AES 1135 to 1166, AES 1185, AES 1235/1236, AES 2135 to 2166,
AES 2335 and AES 3335 to 3566
Indication (orange) Fault Cause * Partial actuation

LED one pulse • Inputs S1 • Incoming connection Switch position in which only one con-
to switch defective tact has been actuated
• Switch defective or fitted incorrectly
• Switch at least 5s only Cancellation of fault indication
partially actuated* The fault indication is cancelled when
• Short-circuit between connections its source has been eliminated and the
connected switch has been actuated
LED two pulses • Inputs S2, only for AES 1165/1166, • See fault inputs S1 to check all functions
AES 2165/2166, AES 3365/3566 • Defective incoming connection (Open and re-close guard device)
and AES 1185 to relay or relay contact
• Defective relay
LED three pulses • Inputs S1 + S2, only for • See fault inputs S2
AES 1165/1166, AES 2165/2166 • Defective incoming connection
and AES 3365/3566 to relay or relay contact
• Inputs S3, only for AES 1185 • Defective relay
LED four pulses • Fault signals on the inputs, • Excessive capacitive or inductive
no secure evaluation, coupling on the switch leads or
not for AES 1185 incoming power supply leads
LED five pulses • One or both relays not pulled in • Operational voltage Ue too low
within a monitored time • Defective relay
LED six pulses • Relay not dropped out on • Welded relay contact
actuation of switch
LED seven pulses • Dynamic monitoring of both • Fault on one channel

channels (Cross-Monitoring) • Error in internal data transmission
not operating correctly • Excessive capacitive or inductive
• Fault signals on the inputs, coupling on input signal leads,
no secure evaluation, only for AES 1185
only for AES 1185
187
AES-E 3035

LED on green • Enable Y14 “low”, Y22 “high”,
only for AES-E 3035
• Enable Y14 and Y24 “high”,
only for AES 3075
LED flashing green • Enable delay time running
LED on yellow • At least one guard device

open
LED flashing yellow • Feedback circuit is open
• Enable input X4 is open,
only for AES 3075
Indication (orange) Fault Cause * Partial actuation

LED one pulse • Guard device 1 • Incoming connection Switch position in which only one con-
to switch defective tact has been actuated
• Switch at least 5s only Cancellation of fault indication
partially actuated* The fault indication is cancelled when
• Short-circuit between connections its source has been eliminated and the
connected switch has been actuated
LED two pulses • Guard device 2 • Incoming connection to check all functions
to switch defective (Open and re-close guard device)
• Switch at least 5s only
partially actuated*
LED three pulses • Guard device 3 • Incoming connection

to switch defective
partially actuated*
LED four pulses • Guard device 4 • Incoming connection

to switch defective
partially actuated*
LED five pulses • Enable outputs Y14 and Y24, • Short-circuit between connections
only for AES 3075 • Short-circuit
• Enable outputs Y14 and Y22,
only for AES-E 3035
LED six pulses • Additional transistor outputs • Short-circuit

Y1 to Y5
LED seven pulses • Fault signals on the inputs, • Excessive capacitive or inductive
no secure evaluation coupling on the switch leads or
incoming power supply leads
LED eight pulses • Feedback circuit, • Feedback of external contactors

only for AES 3075 defective, incorrect wiring of
feedback circuit
188
AZS 2305

LED on red • Comparison of channel 1 and
channel 2 time values faulty
(setting of coding and DIP switches)
LED on green • Enabling circuits are closed
LED flashing green • Input signal in base position

(short pulses approx. 0.5Hz) • Enabling circuits are not closed
LED flashing yellow • Time measurement carried out,

maximum remaining time value
can be seen from table below
Number of pulses n 1 2 3 4 5 6
Minimum remaining time T/2 T/4 T/8 T/16 T/32 T/64
Indication (orange) Fault Cause * The signal change occurred either

LED one pulse • Input signal S14/S22 on S1 • Connection for signal only on one input or on both inputs
input S1 defective with a time interval of more than 5
• Fault occurred on signal change* seconds
LED two pulses • Time processing • Channel 1 time value too long Cancellation of fault indication
The fault indication is cancelled when
its source is eliminated and the input
signal S1 has been switched to the
LED three pulses • Time processing • Channel 2 time value too long base position to check all functions.
no secure evaluation coupling on the input signal leads or
within the monitoring time • Defective relay
LED six pulses • Relay not dropped out • Welded relay contact
on signal change
LED seven pulses • Dynamic monitoring • Fault on the internal

(Cross-Monitoring) data transmission
not operating correctly
Legend T: Time setting
189
FWS 1105, FWS 1106, FWS 2316 and FWS 3505-2204

LED on green • The enabling circuits are closed
LED flashing yellow • Motor running, the limiting

(short pulses approx. 2 Hz) frequency is exceeded, the enabling
circuits are open
LED flashing yellow • With two proximity

(short pulses approx. 0.5 Hz) switches connected, only one
switch is below the limiting frequency,
the enabling circuits are open
Indication (orange) Fault Cause Cancellation of fault indication

LED one pulse • Sensor 1 frequency too low • Defective incoming connection The fault indication is cancelled when
• Input X1, or defective proximity switch its source has been eliminated and all
only for AES 1105/1106 input signals have been checked, e.g.
• Input X2, whether machine turning. Operation of
only for FWS 3505-2204 the Reset pushbutton also cancels all
• Input X3, fault indications.
only for FWS 2316
LED two pulses • Sensor 2 frequency too low • Defective incoming connection
• Input X2, or defective proximity switch
only for AES 1105/1106 • With only one proximity switch,
• Input X4, jumper X1/X2 missing,
only for FWS 3505-2204 only for FWS 1106
• Input X5,
only for FWS 2316
LED three pulses • Voltage X2/X4, • One or both proximity switches

only for FWS 3505-2204 supply no output voltage:
• Short-circuit between connections, Proximity switch defective,
only for FWS 2316 not fitted or leads interrupted,
only for FWS 2316, FWS 3505-2204
• Short-circuit between the output
connections of the proximity
switches, only for FWS 2316
no secure evaluation coupling on the inputs or
within a monitored time • Defective relay
LED six pulses • Relay not dropped out • Welded relay contact
on actuation of switch
LED seven pulses • Fault signals on internal • Fault on the internal

data connections data transmission due to excessive
capacitive or inductive coupling on
the internal data connections
LED eight pulses • Additional standstill signal, • The condition of the additional
only for FWS 1106 standstill signal does not agree with
the deduced frequencies, e.g. the
additional signal shows standstill but
the proximity switch indicates
190 limiting frequency exceeded
Dimensional Drawings
Safety Controllers
22.5 22.5
82
75 A1
X1 13
23 33
A1+ 13 41
A2- Y1 23
X1
AES ON
1235 OUT
S13 S21 S22 X2 24
S14 14 24 A2 14 42
34
.8
110
98
22.5 x 75 x 110 mm 22.5 x 82 x 96.8 mm
55
37.5 45
4.5
73.2
A1 S13 X1 51
62.5
60
75
41 13 23 33
A1 Y1 Y2 X1
13 23 33
ON
Made in Germany
Wuppertal OUT
Funktion
A2 S14 X2 52
121
S1 42 14 24 34
A2 S13 S14 S21
S22 14 24
110
34
55 x 75 x 110 mm 45 x 73.2 x 121 mm
191
Dimensional Drawings
Safety Controllers
99.7
100 85
4.5
73.2
A1 A2 S13 S23
13 23 33 43 A1 S1Y S1X S21
62.5
60
75
53 63 71 81 S22 S31 S32
S1 X1 X2
OUT A 13 23 33
41
ON
OUT B Funktion
Made in Germany
Reset Wuppertal
A2/PE S14 S24 Y1 14

24 34 44 54 A2 S1Y S1X S21
121
64 72 82 S22 S31 S32

Y1 Y2
14 24 34
110
42
100 x 73.2 x 121 mm 99.7 x 75 x 110 mm
105
48
A1
A1
A2
S22
S2
2
S32 S1
S3 S1
S14
2
Ma
de
S14
C
in
Ge
Mad
rm
C
an
e in
y
Ger
13
man
13
Fu
y
nk
tio
Fun
n
58.1
Wu
Wup
ktio
pp
per
n
A2
ert
tal
al
42
42
S2
S22
58.1
S2 S14
2
S32
S2 S14
S3
2
C
C
14
14
96
96
48 x 96 x 58.1 mm 105 x 96 x 58.1 mm
192
SELECTED MACHINE SAFEGUARDING
TERMINOLOGY
Authorized Output: an output from a safety controller’s CSA (Canadian Standards Association): an inde-
positive-guided relays (used to “authorize” or “enable” a pendent Canadian testing and standards-
machine’s start circuit when safety system conditions making organization similar to
exist). Also known as “safety output.” Underwriters Laboratories (UL) in the U.S.
“CSA-certified” products meet relevant
Automatic Reset: a safety controller reset circuit that CSA electrical and safety standards.
automatically resets the safety controller when safe
system conditions (no system faults) exist. A manual Declaration of Conformity: a manufacturer’s self-certi-
reset button is optional. fied document, signed by a highly-positioned technical
manager, which lists all the Standards and Directives to
Auxiliary output: a non-safety related contact closure which a product conforms. A Declaration of Conformity
or semiconductor output primarily used for signaling is mandatory for all CE-marked products, and for
component or system status to a PLC, audible alarm or machine components which, if they fail, could lead to a
visual indicator (such as a stack light). Also called a dangerous or hazardous situation on a machine.
“signaling contact” or “auxiliary monitoring contact”.
Defined Area: a predetermined area scanned by a light
ANSI (American National Standards Institute): an beam within which the presence of an opaque object of
association of industry representatives who, working specified minimum size will result in the generation of a
together, develop safety and other technical standards. control signal.
Auxiliary monitoring contact: See “auxiliary output”. Direct-Action Contacts: See “positive-break” contacts.
BG (Berufgenossenschaft): an independent German Diverse Redundancy: the use of different components

insurance agency whose legislative arm and/or different microprocessor instruction sets written
recommends industry safety practices. by different programmers in the design and construction
One of many “notified bodies” authorized of redundant components/circuits. Its purpose is to
to certify that safety products comply with increase system reliability by minimizing the possibility
all relevant standards. of common-mode failure (the failure of like components
used in redundant circuits).
CE (Conformité Europeéne) mark: a symbol (CE)
applied to finished products and machinery indicating it Dual-Channel Safety System: a safety control system
meets all applicable European Directives. For electrical characterized by two inputs; each connected to one of
and electronic “finished products”, such as a safety two independent safety circuits. Dual-channel systems
relay module, these include the Low are typically capable of detecting interconnection wiring
Voltage Directive and, where relevant, the faults such as open circuits, short-circuits and ground
Electromagnetic Compatibility (EMC) faults. As such they provide a higher level of safety than
Directive. single-channel systems.
Coded-Magnet Sensor: a two-piece position sensor E-Stop (Emergency Stop): the stopping of a machine
consisting of an array of reed switches and a multiple by actuation of an “emergency stop” switch (such as a
magnet array-actuating element. Such devices will only safety interlock switch, emergency push button switch,
deliver an output signal when the reed switch element rope-pull switch, foot switch, or other actuating device.
is in the presence of a matched, multiple-magnetic field
array. Coded-magnet sensors cannot be actuated using European Machinery Directive (EMD) 98/392/EEC: a
a simple magnet. Hence they are far more difficult to set of machine safety design requirements which must
defeat/bypass than a simple magnetic switch or proxim- be satisfied to meet the Essential Health and Safety
ity sensor. standards established by the European Economic
Community. This Directive, and other relevant European
Control Reliability: A term applied to safety devices or Directives (such as the Low Voltage Directive, EMC
systems which are designed constructed and installed Directive, et al) must be satisfied for the machine to
such that the failure of a single component within the bear the CE mark.
device or system does not prevent normal machine
stopping action from taking place…but does prevent a
successive machine cycle from being initiated.
193
Fail-to-Danger: a component or system failure which Hard Guarding: the use of screens, fences, or other
allows a machine to continue operating, exposing per- mechanical barriers to prevent access of personnel to
sonnel to a hazardous or unsafe condition. hazardous areas of a machine. “Hard guards” generally
allow the operator to view the point-of-operation.
Fail-to-Safe: “Fail-to-Safe” safety devices are designed
such that a component failure causes the device/sys- Hazardous Area: an area of a machine or process
tem to attain rest in a safe condition. which presents a potential hazard to personnel.
Fault Detection: the monitoring of selected safety sys- Interlock: an arrangement in which the operation of
tem components whose failure would compromise the one device automatically brings about or prevents the
functioning of the safety system. The detection of such operation of another device.
failures is known as “fault detection.” Examples are:
. a short-circuit in the safety circuit’s interconnection Interlocked Barrier Guard: a fixed or movable guard
wiring which, when opened, stops machine operation.
. an open-circuit in the safety circuit’s interconnec-
tion wiring Machine Primary Control Element (MPCE): an elec-
. a welded contact in the safety controller’s positive- trically powered component which directly controls a
guided relays machine’s operation. MPCE’s are the last control com-
. an open machine guard ponent to operate when a machine’s motion is initiated
or stopped.
Fault Exclusion: the ability to minimize known possible
component failures (“faults”) in a safety system by Machine Secondary Control Element (MSCE): a
design criteria and/or component selection. Simple machine control element (other than an MPCE) capable
examples of “excluded faults” are: of removing power from the hazardous area (s) of a
. The use of an overrated contactor to preclude the machine.
possibility of contact welding.
. Design of a machine guard such that the safety Manual Start-Up Test: a term applied to safety con-
interlock switch actuator cannot be damaged. trollers designed such that at least one of the system’s
. Selection of a suitable safety interlock switch. interlocked machine guards must be manually-opened
. Use of positive-break safety interlock switches and closed (after applying power) before machine oper-
together with a self-monitoring safety relay mod- ation is authorized. All SCHMERSAL’S even numbered
ule, such that the possibility of a contact weld Series AES microprocessor--based safety controllers
resulting in the loss of the safety function is elimi- (e.g. AES 1136, AES 1146, AES 1156, AES 3366, et
nated. al) are designed to require a manual start-up test.
The elimination of such faults are generally a compro- Manually-monitored Reset: a safety controller reset
mise between the technical safety requirements and the circuit requiring the presence of a discrete “trailing-
theoretical probability of their occurrence. Design engi- edge” signal (24V to 0V) to activate the controller’s
neers are permitted to exclude such faults when con- authorized outputs. A reset button is mandatory.
structing the machine’s safety system. However, each
“fault exclusion” must be identified, justified, and docu- Muting: the ability to program a monitoring and/or con-
mented in the Technical File submitted to satisfy the trol device to ignore selected system conditions.
European Machinery Directive.
Negative Mode Mounting: the mounting of a single-
Feedback Loop: an auxiliary input on a safety con- piece safety interlock switch (e.g. a limit switch) such
troller designed to monitor and detect a contact weld in that the force applied to open the normally closed (NC)
the primary machine-controlled device (e.g. motor con- safety contact is provided by an internal spring. (See
tactor, relay, et al) having positive-guided contacts. Figure 1.)
In this mounting mode the NC contacts may not open
Force-Guided Contacts: See “Positive-Guided when the safety guard is “open”. Here welded/stuck
Contacts”. contacts, or failure of a contact-opening spring, may
result in exposing the machine operator to a haz-
Fixed Barrier Guard: See “Hard Guarding”. ardous/unsafe area.
Guard: a barrier that prevents entry of an individual’s When mounted in the “negative-mode”, single-piece
hands or other body parts into a hazardous area. safety interlock switches can be easily
circumvented/defeated by the operator…simply by tap-
ing down the switch actuator when the safety guard is
open.
194
Point-of-Operation: the area(s) of a machine where
Safety Safety material or the workpiece is positioned and a process is
Guard Guard
Closed Open
performed.
Point-of-Operation Guarding: a device or guard
installed at the interface between the operator and the
point-of-operation which is intended to protect person-
nel from hazardous areas.
Positive-Break Contacts: normally-closed (NC) con-

Contacts Contacts open
by internal tacts which, upon actuation, are forced to open by a
Closed
spring force non-resilient mechanical drive mechanism. Also called
“positive-opening” or “direct-action” contacts. (See
Figure 1 Figure 2.)
NEGATIVE-MODE INSTALLATION
Positive-Guided Contacts: Normally-open (NO) and
OSHA (Occupational Safety Health Administration): normally-closed (NC) contacts which operate interde-
a U.S. Department of Labor Federal agency responsible pendently such that the NO and NC contacts can never
for monitoring and regulating workplace safety. OSHA be closed at the same time. They are designed such
enforcement may reference their own regulations, as that if one of the contacts welds/sticks closed, the other
well as those of other industry standards-making contacts cannot change state. (See Figure 3.)
groups (e.g. ANSI, NFPA, UL, et al).
POSITIVE-GUIDED CONTACTS CONVENTIONAL CONTACTS
UN-ENERGIZED STATE
CONVENTIONAL SPRING-DRIVEN
CONTACTS Actuator
Actuator
Gap Tolerance
Normally- Normally- Normally- Normally-
Closed Open Gap Tolerance Closed Open
Contacts Contacts Contacts Contacts
MACHINE GUARD CLOSED MACHINE GUARD OPEN (for monitoring) (for machine control) (for monitoring) (for machine control)
ENERGIZED STATE
MOVABLE
MACHINE GUARD
ACTUATING A Actuator
CONVENTIONAL Actuator
LIMIT SWITCH
Normally- Normally- Normally- Normally-
WITH Closed Open Closed Open
SPRING-DRIVEN Contacts Contacts Contacts Contacts
Open Closed Open Closed
NC CONTACTS
UN-ENERGIZED STATE
WELD WELD
Normally-Closed Normally-Open Normally-closed Normally-

Contacts will Contact Contacts will Open Contact
remain open, welded return to Welded
maintaining a minimum closed N.C. state Closed
gap of 0.5mm
CONVENTIONAL NORMALLY-CLOSED CONTACTS
OPEN BY RESILIENT MECHANICAL MECHANISM.
CONTACTS MAY NOT OPEN DUE TO SPRING FAILURE
OR WELDED CONTACTS. Figure 3
The interdependent operation between NO and NC
®
CONTACTS contacts permits self-checking/monitoring of the func-
tioning of relays and contactors featuring positive-guid-
MACHINE GUARD CLOSED MACHINE GUARD OPEN
ed contacts. Hence they are desirable in machine safe-
MOVABLE
ty circuits where “fail-to-safe” or “control reliability” is
MACHINE GUARD desired. Also called “force-guided contacts”.
ACTUATING A
SAFETY INTERLOCK
OR LIMIT SWITCH
WITH POSITIVE- Positive Linkage: a term applied to roller lever, rocking
OPENING OR
POSITIVE-BREAK lever and other switch actuating members designed
CONTACTS
such that the integrity of the linkage between the actua-
tor and the shaft is heightened (beyond a set screw on
a smooth shaft) by its mechanical design. Examples of
positive-linkages are pinned, square and serrated
shafts. (See Figure 4.)
POSITIVE-BREAK NORMALLY-CLOSED CONTACTS
FORCED TO OPEN BY A NON-RESILIENT MECHANICAL MECHANISM.
Figure 2
CONVENTIONAL VERSUS POSITIVE-OPENING
CONTACTS
195
the early stages of the machine’s design to permit such
hazards to be designed-out or alternatively determine
the scope of the safety system needed to protect per-
sonnel from possible injury. One approach suggested in
EN954-1 is summarized in Figure 6.
Figure 6
Safety Category
B 1 2 3 4
S1
P1
F1
Starting Point P2
Pinned Square Serrated S2
P1
F2
Actuator Positive Linkage P2
Figure 4
Positive-Mode Mounting: the mounting of a singe- Selection of the Safety Category:
A brief overview of these safety categories is provided
piece safety interlock switch (e.g. a limit switch) such in Figure 7.
that the non-resilient mechanical mechanism which
Preferred categories
forces the normally-closed (NC) contacts to open is
directly driven by the interlocked machine safety guard. Possible categories, which require additional
measures
In this mode (as opposed to “negative-mode mounting”)
the safety guard physically forces the NC contacts to Over-dimensioned measures for the relevant risk
open when the guard is opened. (See Figure 5.)
Here the safety • F Frequency • P Possibility of

Safety Safety category is and/or exposure avoiding the
Guard Guard determined by the time to the hazard hazard
Closed Open following parameters: • ■ F1 Seldom to • ■ P1 Possible
• S Severity of injury quite often under specific
• ■ S1 Slight injury • ■ F2 Frequent to conditions
• ■ S2 Serious injury continuous • ■ P2 Scarcely
possible
Safeguarding: protecting personnel from hazards

Contacts forced using guards, barriers, safety devices and/or safe work-
Contacts open by non-
resilient
ing procedures.
Closed
mechanical member
Safety Controller: an electronic and/or electromechan-
Figure 5 ical device designed expressly for monitoring the
integrity of a machine’s safety system. Such controllers
Positive-Opening Contacts: See “Positive-Break are designed using positive-guided (force-guided)
Contacts”. relays. Depending upon the model, SCHMERSAL’s
safety controllers are capable of detecting the following
types of potential safety system faults:
Push/Pull Operation: a term applied to emergency
. Machine guard(s) open
rope-pull switches designed to actuate when the
. Guard monitoring switch/sensor failure
rope/trip-wire is pulled and when it is pushed (goes
. Interconnection wiring “open circuit”
slack). Such rope-pull switches provide a higher level of
. Interconnection wiring “short circuit”
safety than units which only actuate when the trip-
. Interconnection wiring “short-to-ground”
wire/rope is pulled.
. Welded contact in controlled output device
Redundancy: the duplication of control circuits and/or
. Failure of one of the safety controller’s positive-
guided relays
components such that if one component/circuit should
. Fault in the safety controller’s monitoring circuit
fail the other (redundant) component/circuit will ensure
safe operation.
. Insufficient safety controller operating voltage
Upon detection of a system fault, the safety controller will
Risk Assessment: a systematic means of quantifying initiate a “machine stop” command and/or prevent the
the relative level of danger different types of machine restarting of the machine until the fault has been cor-
hazards present to the machine operator and/or main- rected. The “stop” command may be immediate or time-
tenance personnel. This assessment is usually done in delayed depending upon the model safety controller
selected.
196
Safety Enable: (See “Authorized Output.”) Stop Categories:
“0” Requires immediate removal of power from the
Safety Interlock Switch: a switch designed expressly controlled devices.
to safely monitor the position of a machine barrier “1” Allows for a time delay up to 30 seconds for
guard. Such switches typically feature positive-break removal of power. This is commonly used with
contacts and are designed to be more tamper-resistant drive systems where immediate removal of power
than conventional position/presence-sensing switches. may result in a longer stop time.
Safety Output: (See “Authorized Output.”) Tamper-Resistant: a term applied to safety interlock
switches referring to their relative ability to be defeated
Safety Relay: an electromechanical relay designed or bypassed using simple, readily available means such
with positive-guided contacts. as a screwdriver, paper clip, piece of tape or wire, etc.
Switches and sensors designed expressly for use as
Self-Checking: the performing of periodic self-diagnos- machine guard safety interlocks are designed to be
tics on the safety control circuit to ensure that critical more “tamper-resistant” than conventional switches/sen-
individual components are functioning properly. sors (e.g. proximity switches, reed switches, convention-
al limit switches).
Self-Monitoring: see “Self-Checking”.
Time-delayed Authorized Outputs: a safety con-
Single-Channel Safety System: a safety control sys- troller’s authorized outputs whose activation is delayed
tem characterized by one safety interlock switch whose (up to 30 seconds) to satisfy Stop Category 1 require-
normally-closed contact is the sole input to a safety ments.
controller or a motor contactor. Such systems are
unable to detect a short circuit failure in the intercon- Trailing-edge Reset: (See “Manually-monitored
nection wiring and are only recommended for address- Reset.”)
ing Safety Categories B, 1 and 2 (see “Risk
Assessment”). Two-Hand Control: a machine control system which
requires “simultaneous” use of both of the operator’s
Solenoid-Latching Safety Interlock Switch: a two- hands to initiate a machine cycle.
piece safety interlock (actuating key and switch mecha-
nism) whose design prevents the removal of the actuat- UL (Underwriters Laboratories): an independent test-
ing key until released by an integral latching solenoid. ing and standards-making organization.
Solenoid latching is typically controlled by a time-delay, UL tests products for compliance to rele-
motion detector, position sensor or other control com- vant electrical and safety
ponents. standards/requirements.
197
MACHINE SAFETY STANDARDS
European Machinery Directive & CE Marking observing existing European Standards and relevant
national standards/specifications. Draft standards
The European safety requirements for man and (prEN) published by the European Union are also
machine are established in the European Machinery accepted and used as a basis for evaluating products
Directive (EMD). According to the EMD, machinery for compliance to the Directives. It is important to note
must be designed and built to meet the Directive’s that such draft standards may change before being
requirements as defined by existing and emerging finalized and adopted as EN standards.
European standards. These “European Norms”, pre-
pared by representatives of the European Economic SELECTED EUROPEAN STANDARDS
Community (EEC) member states and produced by the
European standards committees CEN and CENELEC, Type “A” Standards:
provide a harmonized baseline for the design and con-
struction of safe machinery. EN292, Safety Machinery – Basic Concepts, General
Principles of Design, Parts 1 & 2.
As of January 1, 1997, machinery sold into or within the
EEC must comply with the requirements of the Type “B1” Standards:
European Machinery Directive. Equipment which com-
plies may be affixed with the CE mark (for “Conformité EN294 Safety of Machinery – Safety Distances to
Europeene”). The CE mark on a machine signifies that Prevent Danger Zones from Being Reached by Upper
it conforms to the essential health and safety require- Limbs.
ments defined by the relevant European Norms.
EN349 Safety of Machinery – Minimum Gaps to Avoid
EUROPEAN STANDARDS Crushing of Parts of the Human Body.
These “Norms” form a hierarchical structure which
include: EN954-1 Safety of Machinery – Safety-Related Parts of
Control Systems – Part 1. General Principles of Design.
Type A Standards: Fundamental Safety Standards
which contain basic concepts, principles of design, and EN999 Safety of Machinery – The Positioning of
general aspects applicable to all machinery. Protective Equipment in Respect of Approach Speeds
of the Human Body.
Type B Standards: Group Safety Standards, each of
which focuses on a specific subject applicable to a EN1050 Safety of Machinery – Principles of Risk
range of machinery types. “B1 Standards” cover a spe- Assessment.
cific safety aspect defined in the Fundamental
Standards. “B2 Standards” cover the requirements of prEN811 Safety of Machinery – Safety Distances to
specific safety related devices such as two-hand con- Prevent Danger Zones from Being Reached by Lower
trols, interlocking devices, movable guards, etc. Limbs.
Type C Standards: Specific Machine Safety Selected Type “B2” Standards:

Standards, each of which define protective measures
required for hazardous areas of a specific machine or EN418 Safety of Machinery – Emergency Stop
group of machines. Devices, Functional Aspects – Principles for Design.
Type A and Type B Standards are intended to assist in EN547 Safety of Machinery – Two –Hand Control
the machinery design process, and eliminate the need Devices, Functional Aspects – Principles for Design.
to repeat these general requirements in the machine-
specific (Type C) Standards. EN1088 Safety of Machinery – Interlocking Devices
Associated with Guards – Principles for Design &
Many product standards are still in the planning stage Selection.
and the number of Type C Standards is continuously
increasing. Some are still in draft form (designated as prEN953 Safety of Machinery – General Requirements
“prEN” standards). Others exist as finished (“EN”) stan- for the Design and Construction of Guards.
dards.
prEN1760-1 Safety of Machinery – Pressure Sensitive
Where no machine-specific standard exists, the require- Safety Devices – Mats
ments of the Machinery Directive can be satisfied by & Floors.
198
prEN1760-2 Safety of Machinery – Pressure Sensitive ANSI B11.1
Safety Devices – Edges & Bars. Machine Tools - Mechanical Power Presses - Safety
Requirements for Construction, Care, and Use of
prEN61496 Safety of Machinery – Electrosensitive
Protective Equipment. ANSI B11.2
Hydraulic Power Presses - Safety Requirements for
Type “C” Standards: Construction, Care, and Use of
prEN415 Packaging Machines ANSI B11.3

Power Press Brakes - Safety Requirements for
prEN692 Mechanical Presses Construction, Care, and Use of
prEN693 Hydraulic Presses ANSI B11.4

Shears - Safety Requirements for Construction, Care,
prEN746 Thermoprocessing Machines and Use of
prEN931 Footwear Manufacturing Machines ANSI B11.5

Machine Tools - Iron Workers - Safety Requirements for
prEN1114-1. Rubber & Plastics Machines Construction, Care, and Use of
prEN1762 Food Processing Machines ANSI B11.6

Lathes - Safety Requirements for Construction, Care,
Domestic Standards: and Use of
Concern for worker safety is not limited to the European ANSI B11.7
community. Domestically machinery builders, machine Cold Headers & Cold Formers - Safety Requirements
users, and industrial safety professionals have each for Construction, Care, and Use of
recognized the importance of providing safe work-
places. ANSI B11.8
Drilling, Milling , and Boring Machines - Safety
Several standards-making organizations have devel- Requirements for Construction, Care, and Use of
oped, and continue to develop, more stringent machine
safety guidelines and standards. These include: ANSI B11.9
Grinding Machines - Safety Requirements for
Occupational Health and Safety Administration (OSHA) Construction, Care, and Use of
American National Standards Institute (ANSI) ANSI B11.10

Metal Sawing Machines - Safety Requirements for
Robotics Industry of America (RIA) Construction, Care, and Use of
Instrument Society of America (ISA) ANSI B11.11

National Fire Prevention Association (NFPA) Gear Cutting Machines - Safety Requirements for
Construction, Care, and Use of
Underwriters Laboratories, Inc. (UL)
ANSI B11.13
A number of selected domestic standards are listed Machine Tools - Single- and Multiple- Spindle Automatic
below. Bar and Chucking Machines -Safety Requirements for
Construction, Care, and Use of
OSHA 29 CFR 1910.212
General Requirements for (Guarding of) All Machines ANSI B11.14
Coil Slitting Machines/Systems — Safety Requirements
OSHA 29 CFR 1910.217 for Construction, Care, and Use of
(Guarding of) Mechanical Power Presses
ANSI B11.15
ISA S84.01 Pipe, Tube, and Shape Bending Machines - Safety
Safety Instrumented Systems Requirements for Construction, Care, and Use of
199
Sources for Standards:
ANSI B11.16
Metal Powder Compacting Presses - Safety EN & IEC Standards are available from:
Requirements for Construction, Care, and Use of
Global Engineering Documents
ANSI B11.17 15 Inverness Way East
Horizontal Extrusion Presses-Safety Requirements for Englewood, CO 80112
Construction, Care, and Use of Telephone: (800) 854-7179
ANSI B11.18 and

Machinery and Machine Systems for the Processing of
Coiled Strip, Sheet, and Plate - Safety Requirements American National Standards Institute (ANSI)
for 11 West 42nd Street
New York, NY 10036
ANSI B11.19 Telephone: (212) 642-4900
Performance Criteria for the Design, Construction,
Care, and Operation of Safeguarding when Referenced ANSI & NFPA Standards are available from:
by Other B11 Machine Tool Safety Standards
American National Standards Institute (ANSI)
ANSI B11.20 11 West 42nd Street
Machine Tools - Manufacturing Systems/Cells - Safety New York, NY 10036
Requirements for Construction, Care, and Use of Telephone: (212) 642-4900
ANSI B183 OSHA Regulations are available from:

Roll Forming and Roll Bending Machines - Safety
Requirements for Construction, Care, and Use of Superintendent of Documents
Government Printing Office
ANSI/RIA 15.06 Washington, DC 20402-9371
Safety Requirements for Industrial Robots and Robot Telephone: (202) 783-3238
Systems
NFPA 79
Electrical Standard for Industrial Machinery 1994
Edition
DECLARATIONS OF CONFORMITY
Each SCHMERSAL safety product has been
certified to conform to all relevant Standards and
Directives. Copies of the Declaration of Conformity
for any product in this catalog are available upon
request.
200
3 contacts,
for dual-
The inside story
channel
reliability
with
signalling
on the world’s
3 conduit
leading safety
entry points
for easy
installation interlock
Electrically-
insulated contacts
for added safety (no
switch…
potential for crossover) High-strength, corrosion-
resistant housing (IP67)
Difficult-to-defeat
multiple-cam Internationally
actuating mechanism accepted
(CE, UL, CSA, BG)
Integral, non-removable 4 actuator key

actuating head resists bypass entry points,
by preventing access to for ease of
operating plunger mounting
The AZ16. A well-designed

movable machine-guard system
deserves a well-designed interlock
switch. It should deliver every possible
feature to protect employees from injury
… be easy to install … and incorporate
the most advanced defeat-resistant safety Rugged, unbreakable
features. Clearly the AZ16 satisfies these stainless steel actuator
requirements, making it the leading choice key (Individually-coded
among safety-minded engineers worldwide. keys available)
The AZ16 enables you to effectively address a

wide variety of machine-guard interlocking
needs without compromising required operator
access or productivity. And its rugged, tamper-
resistant design ensures safe, reliable long-term
performance.
SCHMERSAL offers more than 250 safety interlocks,
cable-pull switches, and matched safety controllers, with
which you can easily satisfy your applications. All are CE-
compliant and meet ANSI and OSHA requirements. For
more details request our free catalog-handbook today.
REQUEST CATALOG GK-1

Machine Guard Safety Circuits
Need Regular Check-Ups.
Safety Controllers
are just what the doctor ordered.
Regardless of what type of man-machine safety system component failures are just some of the detectable
tem you’re using, the potential for electrical or mechani- faults. Schmersal also offers units that help pinpoint fault
cal failure is always present. That’s why many designers location through defined flashing LED patterns to mini-
equip their systems with safety controllers. These tire- mize equipment downtime.
less monitors detect faults that can compromise safety Why risk life, limb and liability when there are afford-
system operation. In so doing, they insure that the safe- able safety controllers with which to meet ANSI and
ty system will perform reliably when called upon to do OSHA “control reliability” requirements? Schmersal
so. FaultFinder safety controllers … the best preventive
Welded/stuck contacts, open/ short circuits, open/mis- medicine when system faults occur.
aligned guards, insufficient operating voltage and sys-
100 Grasslands Road, Elmsford, NY 10523 • Telephone 914-769-5006 • Fax 914-769-4169

web: www.schmersalusa.com • email: info@schmersalusa.com
PRINTED IN U.S.A. Price: $15.00
GK-2 15M-00

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GK-2 CATALOG-HANDBOOK

FOR MONITORING &

Microprocessor-based FaultFinder Series AES Safety Electromechanically-based FaultFinder Series

What are Safety Controllers?

What are their functions?

When should they be used?

COPYRIGHT © 2000 SCHMERSAL LLC

MACHINE GUARDING SOLENOID-LATCHING

Series AES Safety Controller

Quick Fault Locator … minimizes

Alphanumeric Product Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Achieving Control Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety Controller Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Product Section Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

• AES / AZR Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

• AES Series “Integral System Diagnostic” Charts . . . . . . . . . . . . . . . . . . . . . . 186

• AES / AZR Dimensional Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

• Selected Machine Safeguarding Terminology . . . . . . . . . . . . . . . . . . . . . . . . . 193

• Machine Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Copyright © 2000 by SCHMERSAL All Rights Reserved.

AES 1102 . . . . . . . . . . . . . . . . . . . . . . . . . 16 FWS 1106 . . . . . . . . . . . . . . . . . . . . . . . . . 76

AES 1112 . . . . . . . . . . . . . . . . . . . . . . . . . 18 FWS 2316 . . . . . . . . . . . . . . . . . . . . . . . . . 78

AES 1135, 1136, 1145 & 1146 . . . . . . . . . 20 FWS 3505-2204 . . . . . . . . . . . . . . . . . . . . . 80

AES 1165 & 1166 . . . . . . . . . . . . . . . . . . . 22 SRB-LV . . . . . . . . . . . . . . . . . . . . . . . . . . 154

AES 1235 & 1236 . . . . . . . . . . . . . . . . . . . 24 SRB-MSK . . . . . . . . . . . . . . . . . . . . . . . . 158

AES 2135 & 2136 . . . . . . . . . . . . . . . . . . . 26 SRB-NA-R-C.14 . . . . . . . . . . . . . . . . . . . . . 82

AES 2165 & 2166 . . . . . . . . . . . . . . . . . . . 28 SRB-NA-R-C.15 & SRB-NA-R-C.15/1 . . . . . 86

AES 2335 & 2336 . . . . . . . . . . . . . . . . . . . 30 SRB-NA-R-C.16 & SRB-NA-R-C.16/1 . . . . . 90

AES 3335 & 3336 . . . . . . . . . . . . . . . . . . . 32 SRB-NA-R-C.17 . . . . . . . . . . . . . . . . . . . . . 94

AES 3335AC . . . . . . . . . . . . . . . . . . . . . . . 34 SRB-NA-R-C.18 . . . . . . . . . . . . . . . . . . . . . 98

AES 3365 & 3366 . . . . . . . . . . . . . . . . . . . 36 SRB-NA-R-C.19 . . . . . . . . . . . . . . . . . . . . 102

AES 3535 & 3536 . . . . . . . . . . . . . . . . . . . 38 SRB-NA-R-C.20 . . . . . . . . . . . . . . . . . . . . 106

AES 3565 & 3566 . . . . . . . . . . . . . . . . . . . 40 SRB-NA-R-C.21 . . . . . . . . . . . . . . . . . . . . 110

AES 6112 . . . . . . . . . . . . . . . . . . . . . . . . . 42 SRB-NA-R-C.27 . . . . . . . . . . . . . . . . . . . . 114

AES 7112 . . . . . . . . . . . . . . . . . . . . . . . . . 44 SRB-NA-R-C.33 . . . . . . . . . . . . . . . . . . . . 118

ASL 2103 . . . . . . . . . . . . . . . . . . . . . . . . . . 70 SRB-NA-R-C.34 . . . . . . . . . . . . . . . . . . . . 122

AZR 11 RT2 . . . . . . . . . . . . . . . . . . . . . . . . 46 SRB-NA-R-C.35 . . . . . . . . . . . . . . . . . . . . 126

AZR 31 R2 . . . . . . . . . . . . . . . . . . . . . . . . . 52 SRB-NA-R-C.36 . . . . . . . . . . . . . . . . . . . . 130

AZR 31 S1 . . . . . . . . . . . . . . . . . . . . . . . . . 56 SRB-NA-R-C.38 . . . . . . . . . . . . . . . . . . . . 134

AZR 31 T0 . . . . . . . . . . . . . . . . . . . . . . . . . 58 SRB-C.44 . . . . . . . . . . . . . . . . . . . . . . . . . 138

AZR 31 T2 . . . . . . . . . . . . . . . . . . . . . . . . . 60 SRB-C.46 . . . . . . . . . . . . . . . . . . . . . . . . . 142

AZR 62 A2 . . . . . . . . . . . . . . . . . . . . . . . . 66 SRB-C.47 . . . . . . . . . . . . . . . . . . . . . . . . . 146

AZR 63 V2 . . . . . . . . . . . . . . . . . . . . . . . . . 68 SRB-NA-R-C.EW . . . . . . . . . . . . . . . . . . . 150

AZS 2305 . . . . . . . . . . . . . . . . . . . . . . . . . . 72 SRB-ZB-Mo . . . . . . . . . . . . . . . . . . . . . . . 162

FWS 1105 . . . . . . . . . . . . . . . . . . . . . . . . . 74 SRB-ZHK . . . . . . . . . . . . . . . . . . . . . . . . . 166

K.A. SCHMERSAL GmbH & Co. was founded as a

THE SCHMERSAL SYSTEM: CHANGING MAN-MACHINE

It is helpful to break down the definition of Control . Redundancy

Assuming the components are selected with

We can improve the safety system reliability by

with positive-break contacts. This will general- POSITIVE-BREAK POSITIVE-BREAK

This black box provides safety system fault

complex hard-wired circuit utilizing 3 positive- BOX

guided relays and over 40 wiring points, it is MCR

Figure 7 shows a typical example of a control

S13 S14 S21 S22 14 24

SERIES SRB/AZR SAFETY CONTROLLERS SERIES AES MICROPROCESSOR-BASED

FOUR BASIC SAFETY CONTROLLER CHARACTERISTICS

Index Chart below. This will direct you to the appropriate