BERNSTEIN AS-i Safety at Work Program

700 0001 000 . 02.2011 . We reserve the right to make changes
Switch technology –
Economy meets safety
Sensor technology –
Compact intelligence
Enclosure technology –
Function and design
www.bernstein.eu
Contact
International Headquarters
BERNSTEIN AG
Tieloser Weg 6
D-32457 Porta Westfalica
Tel. + 49 571 793-0
Fax + 49 571 793-555
[email protected]
www.bernstein.eu
Denmark
BERNSTEIN A/S
Tel. + 45 7020 0522
Fax + 45 7020 0177
[email protected]
France
BERNSTEIN S.A.R.L.
Tel. +33 1 64 66 32 50
Fax +33 1 64 66 10 02
[email protected]
United Kingdom
BERNSTEIN Ltd.
Tel. +44 1922 744999
Fax +44 1922 457555
[email protected]
Netherlands
BERNSTEIN BV
Tel. +31 314 366088
Fax +31 314 361256
[email protected]
Austria
BERNSTEIN GmbH
Tel. +43 2256 62070-0
Fax +43 2256 62618
[email protected]
Italy
BERNSTEIN S.r.l.
Tel. +39 035 4549037
Fax +39 035 4549647
[email protected]
Switzerland
BERNSTEIN (Schweiz) AG
Tel. +41 44 775 71-71
Fax +41 44 775 71-72
[email protected]
China
BERNSTEIN Safe Solutions
(Taicang) Co., Ltd.
Tel. +86 512 81608180
Fax +86 512 81608181
[email protected]
BERNSTEIN
AS-i Safety at Work Program
What is AS-i?
CSMS
2
MAK’s
SHS3
SLK
ENK (VTU)
AS-Interface is the innovative solution for sensor
and actuator wiring, regardless of whether standard
or safety-relevant applications are concerned.
Only one yellow, two-wire ribbon cable with reverse
polarity protected profiling is laid to transmit the
energy and data to up to 248 inputs and 248 outputs.
Modern systems must nowadays be inexpensive,
flexible, service-friendly and able to detect faults.
All these properties are incorporated in the
AS-Interface right from the start.
Suitable slaves can be plugged in any position
according to the “plug & play” principle. The contact
between the device connection and the cable is made
by the so-called piercing technology.
The simplicity and safety in installation, operation
and maintenance as well as the long-term potential
for reducing costs speak for themselves.
Here, the contacts pierce the insulation through to
the wire. The given geometry of the BUS adapter and
the cable cross-section prevent installation errors.
SK
SKT
Ti2
I88
ENK
The AS-Interface cannot and is not intended to replace
the existing and proven bus systems. AS-Interface is
a standalone solution or an extension of the existing
system.
Linking to ProfiSafe, Profinet, Profibus, Ethernet, CAN,
Ethercat, DeviceNet, Interbus and Powerlink is possible
without any problems by gateways. AS-Interface and
every sensor/actuator connected to it then behave as
slaves of the master bus system.
The high integration capability into other networks
simplifies the modular set-up of automation networks.
SRM
Emergency
stopping
Owing to the many providers of components of
this non-proprietary system, almost every type of
sensor and actuator is available with AS-i interface.
This enables AS-i systems to be established in all
conceivable branches, from automation technology
and process technology, ship building and commercial
vehicles to building technology.
AS-Interface is standardised in accordance with
EN 50295 and IEC 62026-2.
In addition to the advantages already mentioned,
safety systems up to PL e/SIL 3 can also be implemented
with AS-i as described on the following pages.
3
Safety at Work, the Safety Bus
Safety functions up to PL e according to EN 13849
and SIL 3 according to 62061 can be implemented
with AS-Interface Safety at Work.
The safety-relevant data is transmitted on a two-wire
ribbon cable and therefore minimises the wiring effort.
This along with the simplicity in planning, installation
and maintenance is one of the main reasons why AS-i
Safety at Work is the most frequently used safety bus.
For a Safety at Work system you only require the
safety-oriented slaves, a master and a safety monitor.
The latter dynamically monitors the safe users and
switches off the safety path in the event of an error
or at the prompting of a safety function.
With ASIMON the safety application is created
quickly and easily on the PC by drag & drop
The safety application is created with the Windows
program “ASIMON” and then loaded into the safety
monitor. Changes and extensions to the safety application can be made by a software adaptation combined with the piercing connection technology in a
few seconds, even in a safety application program.
There are two possible system structures for setting
up an AS-i Safety at Work system. (see page 6/7).
4
5
System Structure 1:
Safety Gateway in Stainless Steel
System Structure 2:
Safety Basis Monitor
For large and medium safety applications
For the smallest safety applications
The standard master safety monitor combinations
with the AS-i power supply unit are used for large
and medium safety applications.
The Safety Basis Monitor is used for the smallest safety applications with only a few safety-relevant users. This device not
only unites master and monitor in one housing with a width
of just 22.5 mm but also needs only one standard 24 Volt
power supply unit for applications with a current consumption of less than 0.5 Ampere. It also has safe outputs and safe
and standard inputs on board.
Up to 62 safety-relevant users (31 per circuit,
two circuits contained in the safety monitor) such
as emergency stop, door and hood monitors, holds,
light grids, two-hand operation and, of course, also
safe outputs can be integrated into such systems
and linked with ASIMON.
Because of the consistent design on compact machines, it
is also of economic interest to implement the smallest safety
applications with AS-i Safety at Work with this safety monitor.
An AS-Interface Safety at Work system also reduces the number of I/Os on a controller in addition to reducing the wiring
effort and completes a large part of the documentation automatically and incidentally with ASIMON.
Status information or, in the case of a Profisafe
interface, the safety-relevant information of the
safety slaves can be transmitted directly to a
suitable controller with the gateway of the master.
General features
l2 safety relay outputs
2 safety non-expendable semiconductors
AS-i Safety only previously paid off when used in systems
with a greater safety requirement.
l4 EDM input
lField bus interface
l1/2 AS-I circuits
lDiagnostic and adjustments facilities via display
lRobust stainless steel enclosure
l16 enable circuits
l256 devices in the ASIMON program
General features
Comparison of Safety Tech nology System Costs
Conventional wiring was often the less expensive
solution in the past in small function blocks with one
emergency stop and one door hold for example.
6
l4 safety inputs or optionally
8 standard inputs + 8 standard outputs
lSignal outputs
Costs
Safety
Big
20 safety signals
Average
8 safety signals
Costs
Safety
Small
2 safety signals
Equipment
costs
Conventionally
AS-i Safety
50 %
57 %
62 %
85 %
Equipment
costs
Conventionally
AS-i Safety
74 %
77 %
Installation of
the machine
Conventionally
AS-i Safety
25 %
7%
19 %
5%
Installation of
the machine
Conventionally
AS-i Safety
13 %
9%
lIP20 plastic enclosure
Conventionally
AS-i Safety
13 %
3%
l8 enable circuits
Conventionally
AS-i Safety
100 %
89 %
l128 devices in the ASIMON program
Installation
of the control
cabinet
Conventionally
AS-i Safety
25 %
4%
19 %
2%
Installation
of the control
cabinet
Result
Conventionally
AS-i Safety
100 %
62 %
100 %
98 %
Result
lChip card for easy unit exchange
lAS-i Power24 capacity
l2 safety non-expendable semiconductors
l1 AS-i circuit
lDiagnostic facilities via LEDs
lChip card for easy unit exchange
Conclusion: AS-i Safety already pays off in small machines!
lAS-i Power24 capacity
7
System Benefits
General Information about
BERNSTEIN AS-i Products
The use of the AS-i Bus considerably reduces the
planning and documentation effort because only
minimum circuit digrams have to be drawn.
In addition to the drastic reduction in the installation
time in comparison with standard wiring, numerous
components such as safety relays, terminal boxes
and thus their processing as well as integrated screw
connections and terminals and PLC I/Os plus an enormous quantity of cables are saved. This leads in turn
to a reduction in the amount of space required in the
control cabinet, cable ducts and machines.
lThe safety switches Ti2, I88 Bi2 and ENK
can be fitted with all actuators for the
respective product series on request
General
technical data
lThe mechanical switches are always
equipped with 2 positive break contacts p as a slow action element
lVoltage range: 26,6 … 31,6 V
lJump switch systems are available
on request
lMetal switches of the ENM2, GC and SN2 series and D switches can be equipped
with AS-Interface on request
The systems can be commissioned fast thanks
to the simple and reliable connection technology.
If changes have to be made sooner or later, this is
no problem as long as the maximum number of
slaves has not been reached.
lPlug assignment
- Pin 1
- Pin 2
- Pin 3
- Pin 4
Without Aux Including Aux
AS-i +AS-i +
FreiAux –
AS-i –AS-i –
FreiAux +
lAS-i address: Preset address 0
Just connect the necessary slave to the cable and
transfer it to the configuration by laptop or directly
on the master. Finished.
This also enables prevention of unwanted machine
failures. If this does happen, the excellent diagnostic
properties show the error directly on the monitor.
Since it is only a two-wire cable, the AS-i system can
be adapted optimally to a modular machine. This can
be done by connecting two wires to a complete system
or by separate sub-systems which are networked by
a master bus system (e. g. Profibus).
These properties of the AS-i ultimately lead to substantial advantages for the machine user. The commissioning and maintenance costs as well as machine
downtimes are considerably reduced. And if the system
needs to be extended or modified after a time, the
existing system can be disassembled quickly.
System data can also be read out of the slaves or
changed by connecting with a master bus system.
This enables remote maintenance to the smallest
element of an automation safety system.
lAS interface specification: Profile S-0.B
- IO-Code: 0 x 0
- ID-Code: 0 x B
- ID-Code 1: 0 x F
- ID-Code 2: 0 x E
Direct Connection Technology
The direct connection allows the switch
to be connected directly to the two-pole
AS-Interface cable. This saves the coupling
module and the M12 connection cable.
The direct connection technology is recognisable by a “D” at the end of the article
designation. Switches of the type 1 and 2,
such as Ti2, I88, SK, SKT etc. are available
with the direct connection technology.
Safety figures
PL according to EN 13498/SIL
according to 62061 up to
Cat
B10d
Ti2
c*
1
6 Mio
I88, Bi2, ENK
c*
1
20 Mio
SKT, SK, ENK, VTU
c*
1
2 Mio
SLK
c*
1
2 Mio
SHS3
c*
1
2 Mio
SRM
c*
1
0,2 Mio
MAK 42, MAK 52
e
4
20 Mio
Emergency stopping
e
4
0,1 Mio
CSMS
e/3
4
Safety Basis Monitor
e/3
4
Safety monitor
e/3
4
*By fault exclusion according to EN 13849-1 and EN 13849-2, PL d
can be achieved. By using 2 safety switches and mutual monitoring,
Cat 4, PL e can be achieved.
8
9
Application Example
Application Example
E.C.H. Will, Hamburg
Walterwerke, Kiel
E.C.H. Will is a leading provider of machines for paper
producing and processing companies and small format
cutters, format cutting systems and processing lines
for manufacturing school excercise books.
Use of CSMS to monitor safety doors of a format
cutting machine.
The machines run at a very high process speed.
The doors need to be opened frequently for maintenance or to clear paper jams.
A non-contact system is the ideal solution because
wear is not a problem. Before our CSMS systems were
used, various products were installed, none of which
supplied reliable switching signals in the long term.
10
“There were frequent error messages on the bus,”
the site technical manager says. “Standstills are
downtimes and are to be avoided at all cost.”
Walterwerke in Kiel manufactures waffle baking
machines. Walterwerke used the AS-i ENK because
of its robust housing among other things.
The compact design which has the system disappear
invisibly behind the door profiles is just one of the
advantages which convinced the customer, in addition
to the reliable application for all safety doors.
This switch is used with a special axis lever actuator
for safety prompting of a flap in the hot temperature
ranges.
Our switch has been installed in the plants as a
conventional system. In the course of changing over
to the new Machinery Directive, the AS-i Bus has been
introduced and the Bernstein switch inserted again in
the appropriate configuration. They are very pleased
with the technical solution.
The baking trays which enter the oven at high speed
have to be monitored for correct position. There is
also a flap above the entrance to protect the operator
from reaching into the high temperature oven. The
AS-i Safety at Work switch stops the system if the flap
is opened.
11
AS-i Slaves
AS-i Slaves
Contactless safety sensors
Safety Hinge Switch
Transponder technology
CSMS
Contactless Safety
Monitoring Switch
6073200060 AS-i CSMS-M-ST
6073200061 AS-i CSMS-S
6073200062 AS-i CSMS-SET
Spacer
(CSMS Accessories)
6073900070
CSMS Spacer 5 mm
lSafety slave
lDynamically coded signal transmission
lTamperproof operation
lSwitching status and function reserve indicator
lAS-i status display
lCan be conspicuously mounted
lSuitable for harsh environments
lM12 connector
lNon-contact operation gives superior life expectancy
lSwitching distance 15 mm
lSwitching distance 15 mm
lFor installing the CSMS on metal bases
6073200071 AS-i CSMS-R-M-ST
6073200072 AS-i CSMS-R-S
6073200011 AS-i SHS3 SA R
6073200013 AS-i SHS3 SR R
lSafety slave
lCoded actuator
lSwitching status indicator
lAS-i status display
lSuitable for concealed installation
lSuitable for harsh environments
lNon-contact operation gives superior life expectancy
lM12 connector
SLK
MAK 52
6073200068 AS-i MAK 52
6402052307 TK-52-CD/2
MAK 42
6073200067 AS-i MAK 42
6402042053 TK-42-CD/2
lSafety slave
lCoded actuator (magnetic)
lSwitching status indicator
lAS-i status display
lSuitable for concealed installation
lSuitable for harsh environments
lNon-contact operation gives superior life expectancy
SRM
AS-i SRM-LU-175
AS-i SRM-LU-300
AS-i SRM-QF-175
AS-i SRM-QF-300
lSafety slave
lRope-pull switch in metal housing
lAS-i status display
lTensioned length up to 75 meters (version 300)
(37,5 meters version 175)
lQuick-Fix quick action clamping head QF available
Safety switch with separate actuator
SK
6073205050 AS-i SK F30 M
6073205028 AS-i SK M
6073205039 AS-i SK M D
SKT
6073200006 AS-i SKT
6073200029 AS-i SKT D
ENK VTU
6073504025 AS-i ENK VTU
6073504038 AS-i ENK VTU D
12
lSafety slave
lInterlock switch for safety doors and protective hoods
lSpring force (closed-circuit current) type F
and magnetic force (working current) type M
lStatus display for the actuating and interlock position
lThe status LEDs could alternatively
be switched by the control system
lAS-i status display
lFeed-in of the interlock by external
power supply system
Safety rope-pull switch
6073200009
6073200010
6073200007
6073200008
lSafety slave
lCoded actuator (magnetic)
lSwitching status indicator
lAS-i status display
lSuitable for concealed installation
lSuitable for harsh environments
lNon-contact operation gives superior life expectancy
lSafety slave
lHinge Switch
lAS-i status display
lSwitching point freely adjustable
by user over a range of 270°
lFine adjustment +/- 1,5°
lFreely and repeatedly adjustable switching point
Safety interlock (without actuator)
6073200058 AS-i SLK-F-R1-A0-0
6073200057 AS-i SLK-M-R0-A0-0
Magnetic technology (at the beginning of 2011)
CSMS Reed
SHS3
lSafety slave
lSafety switch with separate actuator
lAS-i status display
lPlastic housing
lVariable actuator with
two actuator openings
lSafety slave
lSafety switch with separate actuator
lSlim and short switch design
lAS-i status display
lPlastic housing
lRotary head in 90° steps
l2 actuating entries
lSafety slave
lSafety switch with separate actuator
lEspecially robust switch design
lAS-i status display
lPlastic housing
lRotary head in 90° steps
13
AS-i Slaves
AS-i Slaves
Position safety switches
Emergency stop switches and control elements (in the portfolio from the beginning of 2011)
Ti2
6073403020
6073403035
6073402019
6073402034
6073401018
6073401033
AS-i Ti2 Hw
AS-i Ti2 Hw D
AS-i Ti2 Riw
AS-i Ti2 Riw D
AS-i Ti2 w
AS-i Ti2 w D
lSafety slave
lSmallest switch with integrated
AS Safety at Work interface
lAS-i status display
lActuator of the standard program available
lPlastic housing
lFixing measures according to DIN EN 50047
Emergency stop buttons, illuminated pushbuttons and indicator lamps are available in the new, elegant housing. The housing is specially designed for
40 mm profile rails and features a special assembly concept. It can also be used outside the profile rails of course. Start, enable and request buttons can
also be connected decentrally to the AS-i system with the control elements. The status of the process can be displayed by the illuminated pushbuttons.
With these AS-i solutions, the necessary functions can be placed exactly where they are needed.
Emergency stop
6073100074
AS-i EMERGENCY
STOPPING BUTTON
I88
6073303017
6073303032
6073302016
6073302031
6073301015
6073301030
AS-i I88 Hw
AS-i I88 Hw D
AS-i I88 RiwK
AS-i I88 RiwK D
AS-i I88 w
AS-i I88 w D
lSafety slave
lSwitch design according to
industry standard DIN EN 50047
lAS-i status display
lActuator of the standard program available
lPlastic housing
Press button / Signal lamp
Control element
Bi2
6073201052 AS-i Bi2 w
6073201051 AS-i Bi2 w D
lEmergency stopping button with
integrated safety AS-i slave
lWith 30 mm emergency stopping button
lReset via right hand rotation
l2 coloured status display of emergency stopping button
lM12 connector
lSafety slave
lSide-positionned M12 connection
lAS-i status display
lActuator of the standard program available
lPlastic housing
6073100075
AS-i CONTROL ELEMENT
lIlluminated push button with AS-i interface slave
l2 x 22 mm illuminated push button
lM12 connector
l2 coloured status display per button
(programmable via AS-i)
E/A module
ENK
6073501023
6073501036
6073502024
6073502037
6073504025
6073504038
14
AS-i ENK iw
AS-i ENK iw D
AS-i ENK Riw
AS-i ENK Riw D
AS-i ENK VTU
AS-i ENK VTU D
lSafety slave
lAS-i status display
lActuator of the standard program available
lEspecially robust switch design
lFixing measures according to DIN EN 50041
Turning-on box
6073100027
AS-i TURNING-ON-BOX 4 IN
lAS-i Slave
l4 digital input PNP
lStatus display of inputs via LED
lAS-i status display
lVia ASI cable connectable
lConnectors M12
15
Master / Safety Monitor / Power Supply Unit
Safety basis monitor (in the portfolio from the beginning of 2011)
Software package
This safety monitor is intended for the smallest AS-i safety systems. With this safety monitor, the smallest safety applications can be implemented with AS-i,
something which was previously unthinkable for cost reasons. The programming of the safety application is done quickly and simply with the Windows program
ASIMON as is usual in AS-i Safety at Work.
In this package is included:
lASIMON for programming the safety monitor
lAS-i Control Tool for addressing, diagnostic and
testing of the AS-i bus syste
lSerial cable for connecting the master and monitor
at the computer
6073800021
AS-i PROG SW + KBL
Basis monitor
6073100073
AS-i BASIS MONITOR
lIntegrated master
lA special power supply unit AS-i is
not necessary (up to 0,5 ampere)
lIntegrated safety outputs
lIntegrated safety inputs
lIntegrated standard inputs
lOnly 22,5 mm installation width
Hand-held programming device
Safety monitor
lAddressing / Programming up to 62 slaves max.
lDisplay of all existing slaves in the bus system
lReading and writing of slave datas
lLCD Display
lRechargeable battery integrated
lCharging device is included in delivery
6073100005
AS-i HND PRG
6073100004
AS-i SMON B+W
lSafety monitor for 2 AS-i circuits
l16 enable circuits
l2 x two channel relay enable circuits in the device
l2x EDM and 2 x start input in the device
lDisplay for addresses and exact fault location
lConfiguration storable on chip card
85
96
120
Master
6073100001
AS-i MST PROFIBUS
lAS interface master with profibus slave
l2 AS-i master integrated
lDouble address recognition
lEarth fault monitor integrated
lDisplay for ASI slaves addresses and
exact fault location
lLEDs for status display
lSimple use with only 4 integrated buttons
lGateways for Profisafe, Profinet, Ethernet, Powerlink,
EtherCat, -CanOpen, DeviceNet, Modbus, Master for
all Allen-Bradley ControlLogix available
Accessories see side 18/19
55
76
7
75
120
1
External
power
supply system
6073100003
AS-i NT 4A B+W
l90 V AC up to 265 V AC multi voltage
power supply unit
l4 A primarily clocked power supply unit
lLED operating mode display
lAS-i data decoupling
lSELV
126
Power supply
70
2
3
4
129
5
16
17
Accessories
Connecting module 3
lFor connecting AS-i devices on AS-i profile cable
with M12 connecting line
lCodification of the M12 connector turnable
over a range of 90°
Connecting module 4
6073900047
AS-i CABLE BRIDGE
lBranch for AS-i profile cable
lThe connection under the cables is
effected when opening the cover
Connecting cable 5
lFor connecting AS-i devices on AS-i profile
cable with an integrated, 2 meters long ready-made
connecting line and M12 straight connecting box
lConnecting cable for the connection of the
ASi Slave and the connecting module
lDouble-sided ready-made straight M12
connecting units (connector/socket)
31
43,9
L
48,5
L
Ø14,5
6073900048
AS-i CONNECTING C.M12 1M G/G
L
Ø14,5
M12 x1
6073900043
AS-i KOP. M. 0.3 RK U. M12 G
48,5
Ø14,5
M12 x1
31
Ø14,5
6073900042
AS-i CONNECTING MODULE
M12 SCREW
Cable bridge 2
Connecting module
Connecting cable
6073900049
AS-i CONNECTING C.M12 1M G/W
lConnecting cable for the connection of the
ASi Slave and the connecting module
lDouble-sided ready-made M12 connecting units,
straight connector/angled socket
38,5
31,25
L
Ø12,6
lConnecting module for connecting AS-i devices
on AS-i profile cable with an integrated, 2 meters
long ready-made connecting line and M12 angled
connecting box
27,5
20
6073900044
AS-i KOP. M. 0.3 RK U. M12 W
Ø14,5
Ø14,5
M12 x1
31
M12 x1
Ø14,5
Yellow cable EPDM
Connecting module + double 1
lFor connecting AS-i devices on AS-i profile cable
with an integrated, 2 meters long ready-made
connecting line and M12 straight connecting box
6073900040
AS-i KABEL EPDM YELLOW
lYellow AS-i profile cable EPDM
2 mm
6073900045
AS-i KOP.2F M.0.5RK U. M12 G
4 mm
6,5 mm
10 mm
Connecting module + double
Black cable EPDM
lFor connecting AS-i devices on AS-i profile cable
with an integrated, 2 meters long ready-made
connecting line and M12 angled connecting box
6073900041
AS-i KABEL EPDM BLACK
lBlack AS-i profile cable EPDM
2 mm
6073900046
AS-i KOP.2F M.0.5RK U. M12 W
4 mm
6,5 mm
10 mm
18
19