schmersal FWS 2106 Manual de usuario
FWS 2106
FWS 2506
Operating instructions
Fail-safe standstill monitor
EN 1
EN Operating instructions...................... pages 1 to 6
Translation of the original operating instructions
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1 About this document
1.1 Function
This operating instructions manual provides all the information you
need for the mounting, set-up and commissioning for the safe operation
and disassembly of the safety-monitoring module. The operating
instructions must be available in a legible condition and a complete
version in the vicinity of the device.
1.2
All operations described in this operating instructions manual must
be carried out by trained specialist personnel, authorised by the plant
operator only.
Please make sure that you have read and understood these operat-
ing instructions and that you know all applicable legislations regarding
occupational safety and accident prevention prior to installation and
putting the component into operation.
The machine builder must carefully select the harmonised standards
selection, mounting and integration of the components.
1.3 Explanation of the symbols used
Information, hint, note:
This symbol is used for identifying useful additional information.
Caution: Failure to comply with this warning notice could
lead to failures or malfunctions.
Warning: Failure to comply with this warning notice could
lead to physical injury and/or damage to the machine.
1.4 Appropriate use
The products described in these operating instructions are developed to
execute safety-related functions as part of an entire plant or machine. It
is the responsibility of the manufacturer of a machine or plant to ensure
the proper functionality of the entire machinery or plant.
The safety-monitoring module must be exclusively used in accordance
with the versions listed below or for the applications authorised by the
manufacturer. Detailed information regarding the range of applications
can be found in the chapter "Product description".
1.5 General safety instructions
The user must observe the safety instructions in this operating
as all prevailing safety regulations and accident prevention rules.
Further technical information can be found in the Schmersal
catalogues or in the online catalogue on the Internet:
www.schmersal.net.
The information contained in this operating instructions manual is
The entire concept of the control system, in which the
safety component is integrated, must be validated to
EN ISO 13849-2.
There are no residual risks, provided that the safety instructions as well
as the instructions regarding mounting, commissioning, operation and
maintenance are observed.
1.6 Warning about misuse
In case of inadequate or improper use or manipulations of
the safety-monitoring module, personal hazards or damages
to machinery or plant components cannot be excluded.
The relevant requirements of the standard EN 1088 must
be observed.
Content
1 About this document
1.1 Function..............................................1
1.2 ..................1
1.3 Explanation of the symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Appropriateuse........................................1
1.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.6 Warningaboutmisuse...................................1
1.7 Exclusionofliability.....................................2
2 Product description
2.1 Orderingcode .........................................2
2.2 Specialversions........................................2
2.3 Destinationanduse.....................................2
2.4 Technicaldata.........................................2
2.5 .....................................3
3 Mounting
3.1 General mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 Dimensions ...........................................3
4 Electrical connection
4.1 General information for electrical connection. . . . . . . . . . . . . . . . . .3
5 Operating principle and settings
6 Set-up and maintenance
6.1 Functionaltesting.......................................3
6.2 Maintenance ..........................................3
7 Disassembly and disposal
7.1 Disassembly...........................................3
7.2 Disposal..............................................3
8 Appendix
8.1 Wiringexamples .......................................4
8.2 ..........................5
8.3 Declarationofconformity.................................6
x.000 / KAS / 08.2010 / BZ-Nr. 50109-24V900 / Teile-Nr. 1181714 / Ausgabe D
2
Operating instructions
Fail-safe standstill monitor
FWS 2106
FWS 2506
EN
1.7 Exclusion of liability
We shall accept no liability for damages and malfunctions resulting from
defective mounting or failure to comply with this operating instructions
manual. The manufacturer shall accept no liability for damages resulting
from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary
forbidden; the manufacturer shall accept no liability for damages
resulting from such invasive work, arbitrary repairs, conversions
2 Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
FWS 2106
➀
No. Option Description
➀
Standstill frequencies of the inputs X2/X4:
A 1 Hz/2 Hz
C 1 Hz/1 Hz
FWS 2506
➀
No. Option Description
➀
Standstill frequencies of the inputs X2/X4:
A 1 Hz/2 Hz
C 1 Hz/1 Hz
Only if the information described in this operating instructions
manual are realised correctly, the safety function and therefore
the compliance with the Machinery Directive is maintained.
2.2 Special versions
For special versions, which are not listed in the order code below 2.1,
to the standard version.
2.3 Destination and use
The fail-safe standstill monitors are designed for control cabinet
mounting. Standstill monitors serve for the fail-safe detection of the
machine standstill and control of solenoid interlocks. For the standstill
detection, the signals of two proximity switches are evaluated. The
fail-safe standstill monitors meet the requirements of PL d or control
category 3 to EN ISO 13849-1.
all relevant components is required.
The additional standstill signal can be derived from an already available
standstill signal of the machine, e.g. evaluation of a tachogenerator by
a PLC or the standstill output of a frequency converter.
It is recommended to install the proximity switches on a disc cam
so that at least one proximity switch is always actuated. This can be
realised by a minimum 1:1 division of the disc cam. When the proximity
switches are correctly installed, the following exemplary signal
sequence should be obtained by the utilisation of the switching
hysteresis of the proximity switches during the rotation of the disc cam.
Proximity switch 1:
Proximity switch 2:
The adjustment of the proximity switches is facilitated, when the cam
Design
The fail-safe standstill monitor has a dual-channel structure. It includes
two safety relays with monitored positive guided contacts, which are
controlled by two microprocessors, which are independent from one
another. The series-wired NO contacts of the relays build the enabling
paths
so that in case of a wire breakage only one proximity switch is dead
2.4 Technical data
Standards: IEC/EN 60204-1, BG-GS-ET-20
yes
Standstill frequency: Version A: X1/X2: 1 Hz / 2 Hz
Version C: X1/X2: 1 Hz / 1 Hz
other versions: upon request
e: 24 … 230 VAC/DC
Rated operating current Ie: max. 0.4 A
i: 250 V
Internal electronic fuse: no
Power consumption: < 5 W
Input monitoring:
Cross-wire detection: no
Wire breakage detection: yes
Earth leakage detection: no
Hysteresis: 10% of the standstill frequency
Max. input frequency: FWS 2106: 4000 Hz
Min. impulse duration:
Outputs:
Stop category 0: FWS 2106: 1
FWS 2506: 4
Stop category 1: 0
Number of safety contacts: FWS 2106: 1
FWS 2506: 4
Number of auxiliary contacts: FWS 2106: 0
FWS 2506: 1
Number of signalling outputs: 2
Max. switching capacity of the
safety contacts:
6 A
Max. fuse rating: 4 A gG D-fuse
Required short-circuit current: 1000 A
EN 60947-5-1:
AC-15: 230 V / 3 A;
DC-13: 24 V / 2 A
Mechanical life: FWS 2106:
> 50 million operations
FWS 2506:
20 million operations
LED indication: Wiring diagram
Ambient conditions:
Ambient operating temperature: 0°C…+55°C
Storage and transport
temperature:
-25°C…+70°C
Protection class: Enclosure: IP 40,
Terminals: IP 20,
Wiring compartment: IP 54
Degree of pollution: 2
Fixing: Snaps onto standard DIN rails
to DIN EN 60715
Connection type: Screw terminals
Min. cable section: 0.2 mm²
Max. cable section: 2.5 mm², solid strand
or multi-strand lead
Tightening torque: 0.6 Nm
Weight: FWS 2106: 275 g
FWS 2506: 300 g
100 x 45 x 121 mm
3
FWS 2106
FWS 2506
Operating instructions
Fail-safe standstill monitor
EN
2.5
Standards: EN ISO 13849-1; IEC 61508
PL: up to d
Control category: up to 3
PFH value: 1.0 x 10-7 / h; applicable for
applications with up to max.
50,000 switching cycles / year
and max. 80 % contact load.
Diverging applications upon
request.
SIL: up to 2
Service life: 20 years
3 Mounting
3.1 General mounting instructions
Mounting: snaps onto standard DIN rails to EN 60715.
3.2 Dimensions
Device dimensions (H x W x D
4 Electrical connection
4.1 General information for electrical connection
The electrical connection may only be carried out by
authorised personnel in a de-energised condition.
Wiring examples: see appendix
5 Operating principle and settings
Operating principle after the operating voltage is switched on
After the operating voltage has been applied, the internal functions and
the condition of the safety relays will be tested by the fail-safe standstill
monitor during the initialization phase. After this check, the inputs of the
fail-safe standstill monitor will be evaluated.
The cyclic frequency of the connected proximity switches is compared
to a programmed limit frequency. To check the proximity switches,
a second comparison between the signal of the safety contact and
the detected frequency is executed. If the value drops below the
programmed frequency and the contact of the contactor indicates a
and the enabling paths are closed. If one of the standstill conditions no
relays are disabled. When the motor is started through the contactor,
the function of the proximity switches is tested. Five seconds after the
contactor start-up, the programmed limit frequency must be exceeded
at the cyclic inputs. If not, the fail-safe standstill monitor signals an
error. Error messages cause the safety relays to be disabled.
When two proximity switches are connected
If the programmed upper or lower limit frequency is exceeded, the
frequencies of both proximity switches are compared. A divergence of
over 30% will be considered faulty and signalled. The yellow LED is
Inputs
or bridge to X2
X6: connection for reset button
X8: connection for an additional standstill signal
"high": standstill
"low": motor runs
Outputs
Additional transistor outputs Y1/Y2
Y1: "Enabling signal"; the enabling paths are closed
Y2: "Fault"; if the fail-safe standstill monitor detects a fault,
Y2 is enabled.
Reset input
A high signal at X6 deletes all detected faults of the fail-safe standstill
monitor and causes the safety relays to be switched off.
Note
The additional outputs Y1 and Y2 must not be integrated in the safety
be laid so that in case of a wire breakage only one proximity switch
category 2, an individual fault must not lead to a loss of safety.
6 Set-up and maintenance
6.1 Functional testing
The safety function of the safety-monitoring module must be tested.
The following conditions must be previously checked and met:
2. Fitting and integrity of the power cable
6.2 Maintenance
In the case of correct installation and adequate use, the safety-
monitoring module features maintenance-free functionality.
A regular visual inspection and functional test, including the following
steps, is recommended:
Damaged or defective components must be replaced.
7 Disassembly and disposal
7.1 Disassembly
The safety monitoring module must be disassembled in the
de-energised condition only.
7.2 Disposal
The safety monitoring module must be disposed of in an appropriate
manner in accordance with the national prescriptions and legislations.
4
Operating instructions
Fail-safe standstill monitor
FWS 2106
FWS 2506
EN
8 Appendix
8.1 Wiring examples
The application examples shown are suggestions. They however do not
release the user from carefully checking whether the switchgear and its
set-up are suitable for the individual application.
The entire system can achieve PL d or control category 3 to
EN ISO 13849-1, if the fault exclusion "rupture or loosening of the
actuator, error in the solenoid interlock" can be substantiated and
documented. If this is impossible, a second switch must be installed on
the safety guard as a replacement for the NO contact of the AZM 161 in
order to achieve PL d or control category 3.
FWS 2106
AES 2335 FWS 2106
13
14
L1
L1
A1
A1
100mA
K1
K3
K3
A2
max.
Y1 Y2
X1 X2 X3 X4
X5 X6 X7 X8
K4
K4
3
K2
24...230V AC/DC
GND
N
N
M
R
E
S
0
A2
GND
24...230V AC/DC
H7
A2
A2 X3 X4 X5 X6 X7 X8 14 24 34
332313Y2Y1X2X1S22S21
100mA
max.
S14S13A1
A1
K2
P2
P1 K1
PE PE
GND GND
24...230V AC/DC
24...230V AC/DC
A1 A2
1413 21 22 41 42 51 52 71 72 63 64
AZM 161-12/12
FWS 2506
AES 2335 FWS 2506
13
14
L1
L1
A1
A1
100mA
K1
K3
K3
A2
max.
Y1 Y2
X1 X2 X3 X4
X5 X6 X7 X8
K4
K4
3
K2
24...230V AC/DC
GND
N
N
M
R
E
S
0
A2
GND
24...230V AC/DC
H7
A2
A2 X3 X4 X5 X6 X7 X8 14 24 34
332313Y2Y1X2X1S22S21
100mA
max.
S14S13A1
A1
K2
P2
P1 K1
PE PE
GND GND
24...230V AC/DC
24...230V AC/DC
23 33 43 51
24 34 44 52
A1 A2
1413 21 22 41 42 51 52 71 72 63 64
AZM 161-12/12
The wiring diagram is shown with guard doors closed and in a de-
be provided with suitable interference suppression circuitry.
Avoid laying proximity switch connection cables in areas where strong
interference signals are present (e.g. frequency converters or cable
may be necessary.
Requirements of the used proximity switches
NO contact, p-type, output voltage: 20 ... 30 VDC,
e.g. Schmersal IFL ..-..-10 P
5
FWS 2106
FWS 2506
Operating instructions
Fail-safe standstill monitor
EN
Legend
A
Positive break
R
Proximity switches
JReset button
I0
On/off switch
H
Start button
E
X
Additional standstill signal
A Solenoid interlock
B Safety switch
8.2 Integral System Diagnostics (ISD)
The LED indication of the safety-monitoring modules shows the
different switching conditions and errors. The switching conditions
are explained in the following tables.
Tables switching condition indication
Diagnostic LED System condition
The LED is green. Enabling paths closed
When two proximity switches are
connected, only one switch has exceeded
the lower limit frequency, the enabling
paths are open
The motor is running, the limit frequency
has been exceeded. The enabling paths
are open
In case of error messages, the LED lights orange intermittently.
Table error indications
Indication (orange)
LED
Error Cause
1 impulse Frequency sensor 1
too low,
Error input X2
Defective lead
Defective proximity
switch
2 impulses Frequency sensor 2
too low,
Error input X4
Defective lead
Defective proximity
switch
3 impulses Fault voltage X2/X4 One or both proximity
switches supply no
output voltage: defec-
tive proximity switch or
disconnected cable
4 impulses Interference at
inputs, no safe
evaluation
Too high capacitive or
inductive interference at
the inputs or the supply
voltage lead
5 impulses One or both relays did
not close within the
monitoring time
Too low operating
e;
Defective relay
6 impulses Relay not disabled
upon the actuation
of the switch
May be due to contact
welding
7 impulses Malfunction of inter-
nal data lines
Interruption of the inter-
nal data transfer due to
a high capacitive or in-
ductive interference on
the internal data lines
8 impulses Additional standstill
signal
The condition of the
additional standstill
signal does not corres-
pond with the detected
frequencies, e.g. the
additional standstill sig-
nal signals a standstill,
whereas the proximity
switches signal that
the limit frequency is
exceeded.
Deleting the error message
The error message is deleted, when the error cause is eliminated and
the FWS can check all functions.
6
Operating instructions
Fail-safe standstill monitor
FWS 2106
FWS 2506
EN
FWS 2106 B-EN
K. A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Möddinghofe 30, D - 42279 Wuppertal
Postfach 24 02 63, D - 42232 Wuppertal
E-Mail: [email protected]
Internet: http://www.schmersal.com
Note
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.
8.3 Declaration of conformity
EC Declaration of conformity
Translation of the original declaration of conformity
valid as of December 29, 2009
K.A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Germany
Internet: www.schmersal.com
We hereby certify that the hereafter described safety components both in its basic design and
construction conform to the applicable European Directives.
Place and date of issue: Wuppertal, October 7, 2009
Authorised signature
Heinz Schmersal
Managing Director
Name of the safety component / type: FWS 2106
FWS 2506
Description of the safety component: Safety-monitoring module /
Fail-safe standstill monitor
Harmonised EC-Directives: 2006/42/EC EC-Machinery Directive
2004/108/EC EMC-Directive
Person authorized for the compilation
of the technical documentation:
Möddinghofe 30
42279 Wuppertal
quality assurance system, referred to
in Appendix X, 2006/42/EC:
TÜV Rheinland Industrie Service GmbH
Alboinstrasse 56
12103 Berlin
ID n°: 0035
Appendix
Este manual sirve para los siguientes modelos
1
Tabla de contenidos
Otros manuales de Monitor de schmersal
