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MLC 530 SPG
Safety Light Curtains
EN 2018/07 - 50132717
We reserve the right to
make technical changes
S A F E I M P L E M E N T A T I O N A N D O P E R A T I O N
O r i g i n a l o p e r a t i n g i n s t r u c t i o n s
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© 2018
Leuze electronic GmbH & Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: +49 7021 573-0
Fax: +49 7021 573-199
http://www.leuze.com
info@leuze.com
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Table of contents
Table of contents
1 About this document ............................................................................................5
1.1 Used symbols and signal words .............................................................................................5
1.2 Checklists................................................................................................................................ 6
2 Safety .....................................................................................................................7
2.1 Intended use and foreseeable misuse.................................................................................... 7
2.1.1 Intended use........................................................................................................................ 7
2.1.2 Foreseeable misuse ............................................................................................................8
2.2 Necessary competencies........................................................................................................ 8
2.3 Responsibility for safety.......................................................................................................... 9
2.4 Disclaimer ............................................................................................................................... 9
3 Device description ..............................................................................................10
3.1 Overview of Smart Process Gating (SPG)............................................................................ 10
3.2 Device overview of the MLC family....................................................................................... 10
3.3 Connection technology .........................................................................................................12
3.4 Display elements .................................................................................................................. 12
3.4.1 Operating indicators on the MLC500 transmitter.............................................................. 12
3.4.2 Operating indicators on the MLC530SPG receiver ......................................................... 13
3.4.3 Alignment display ..............................................................................................................15
4 Functions.............................................................................................................16
4.1 Start/restart interlock RES ....................................................................................................16
4.2 Transmission channel changeover ....................................................................................... 17
4.3 Operating range selection..................................................................................................... 17
4.4 Signal output......................................................................................................................... 17
4.5 Blanking ................................................................................................................................ 18
4.5.1 Fixed blanking ...................................................................................................................18
4.6 Smart Process Gating........................................................................................................... 20
4.6.1 SPG prerequisites .............................................................................................................22
4.6.2 Examples of signal generation for SPG mode ..................................................................24
4.6.3 Operating mode1 (qualified stop) .....................................................................................24
4.6.4 Operating mode5.............................................................................................................. 26
4.6.5 Operating mode 6 (partial gating)...................................................................................... 27
4.6.6 SPG termination by the control .........................................................................................29
4.6.7 SPG timeout extension...................................................................................................... 29
4.6.8 Gating sequence reset ......................................................................................................30
4.6.9 SPG restart........................................................................................................................ 31
4.6.10 Override............................................................................................................................. 32
4.7 Error reset............................................................................................................................. 32
5 Applications ........................................................................................................33
5.1 Access guarding with SPG ...................................................................................................33
5.1.1 Blanking............................................................................................................................. 34
6 Mounting..............................................................................................................35
6.1 Arrangement of transmitter and receiver ..............................................................................35
6.1.1 Calculation of safety distanceS ........................................................................................35
6.1.2 Calculation of safety distance if protective fields act orthogonally to the approach direction...36
6.1.3 Calculation of safety distanceS for parallel approach to the protective field .................... 41
6.1.4 Minimum distance to reflective surfaces ...........................................................................42
6.1.5 Resolution and safety distance during fixed blanking .......................................................43
6.1.6 Preventing mutual interference between adjacent devices ...............................................44
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Table of contents
6.2 Mounting the safety sensor................................................................................................... 45
6.2.1 Suitable mounting locations ..............................................................................................46
6.2.2 Definition of directions of movement .................................................................................47
6.2.3 Fastening via BT-NC60 sliding blocks............................................................................... 47
6.2.4 Fastening via BT-2HF swivel mount.................................................................................. 48
6.2.5 Fastening via BT-2SB10 swiveling mounting brackets .....................................................48
6.2.6 One-sided mounting on the machine table........................................................................ 49
7 Electrical connection..........................................................................................50
7.1 Pin assignment transmitter and receiver .............................................................................. 51
7.1.1 MLC500 transmitter..........................................................................................................51
7.1.2 MLC530SPG receiver .....................................................................................................53
7.2 Operating mode1 (SPG with qualified stop function)........................................................... 53
7.3 Operating mode5 ................................................................................................................. 55
7.4 Operating mode 6 (partial gating) ......................................................................................... 57
8 Starting up the device ........................................................................................59
8.1 Switching on ......................................................................................................................... 59
8.2 Aligning the sensor ...............................................................................................................59
8.3 Acknowledgement button ..................................................................................................... 60
8.3.1 Unlocking start/restart interlock .........................................................................................60
8.3.2 SPG restart and override................................................................................................... 61
8.4 Teaching of fixed blanking areas .......................................................................................... 62
9 Testing .................................................................................................................63
9.1 Before the initial start-up and following modifications........................................................... 63
9.1.1
9.2 Regularly by qualified persons.............................................................................................. 65
9.3 Periodically by the operator ..................................................................................................65
9.3.1 Checklist – periodically by the operator............................................................................. 66
Checklist for integrator – to be performed prior to the initial start-up and following modifications .... 63
10 Maintenance ........................................................................................................67
11 Troubleshooting..................................................................................................68
11.1 What to do in case of failure? ...............................................................................................68
11.2 Operating indicators of the LEDs.......................................................................................... 68
11.3 Error messages 7-segment display ......................................................................................69
12 Disposal ...............................................................................................................74
13 Service and support ...........................................................................................75
14 Technical data .....................................................................................................76
14.1 General specifications .......................................................................................................... 76
14.2 Dimensions and weights....................................................................................................... 78
14.3 Dimensioned drawings: Accessories .................................................................................... 80
15 Order guide and accessories.............................................................................83
16 EC Declaration of Conformity ............................................................................89
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1 About this document
1.1 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating possible property damage
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for danger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures for
danger avoidance are not followed.
About this document
DANGER Signal word for life-threatening danger
Indicates dangers with which serious or fatal injury is imminent if the measures
for danger avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.
Tab.1.3: Terms and abbreviations
AOPD Active Optoelectronic Protective Device
(Active Optoelectronic Protective Device)
Blanking Deactivation of the protective function of individual beams or beam areas with
monitoring for interruption
CS Switching signal from a control
(Controller Signal)
FG Function group
(Function Group)
LED LED, display element in transmitter and receiver
MLC Brief description of the safety sensor, consisting of transmitter and receiver
MTTF
d
Mean time to dangerous failure
(Mean Time To dangerous Failure)
OSSD Safety-related switching output
(Output Signal Switching Device)
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About this document
PFH
d
Probability of a dangerous failure per hour
(Probability of dangerous Failure per Hour)
PFI (Protection Field Interrupted)
PL Performance Level
P-mode Protective mode
Reduced resolution Reduction of the detection capability of the protective field without monitoring
for tolerating small objects in the protective field
RES Start/restart interlock
(Start/REStart interlock)
Scan Consecutive scans of the protective field from the first to the last beam
Safety sensor System consisting of transmitter and receiver
SIL Safety Integrity Level
SPG Smart Process Gating
TH Timer halt signal
State ON: device intact, OSSD switched on
OFF: device intact, OSSD switched off
Locking: device, connection or control / operation faulty, OSSD switched off
(lock-out)
1.2 Checklists
The checklists (see chapter 9 "Testing") serve as a reference for the machine manufacturer or supplier.
They replace neither testing of the complete machine or system prior to initial commissioning nor their periodic testing by a qualified person (see chapter 2.2 "Necessary competencies"). The checklists contain minimum testing requirements. Depending on the application, other tests may be necessary.
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2 Safety
For mounting, operating and testing, this document as well as all applicable national and international standards, regulations, rules and directives must be observed. Relevant and supplied documents must be observed, printed out and handed to affected persons.
Ä Before working with the safety sensor, completely read and observe the documents applicable to your
task.
In particular, the following national and international legal regulations apply for the commissioning, technical inspections and work with safety sensors:
• Machinery directive 2006/42/EC
• Low voltage directive 2014/35/EU
• EMC directive 2014/30/EU
• Use of work equipment directive 89/655/EEC supplemented by directive 95/63EC
• OSHA 1910 Subpart O
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and employment protection act
• Product Safety Law (ProdSG and 9. ProdSV)
Safety
NOTICE
For safety-related information you may also contact local authorities (e.g., industrial inspectorate, employer's liability insurance association, labor inspectorate, occupational safety and
health authority).
2.1 Intended use and foreseeable misuse
WARNING
A running machine may result in serious injury!
Ä Make certain that the safety sensor is correctly connected and that the protective function of
the protective device is ensured.
Ä Make certain that, during all conversions, maintenance work and inspections, the system is
securely shut down and protected against being restarted.
2.1.1
Intended use
• The safety sensor may only be used after it has been selected in accordance with the respectively applicable instructions and relevant standards, rules and regulations regarding labor protection and safety
at work, and after it has been installed on the machine, connected, commissioned, and checked by a
competent person (see chapter 2.2 "Necessary competencies"). The devices are designed for indoor
use only.
• When selecting the safety sensor it must be ensured that its safety-related capability meets or exceeds
the required performance level PLr ascertained in the risk assessment (see chapter 14.1 "General
specifications").
• The safety sensor protects persons or body parts at points of operation, danger zones or access points
of machines and systems.
• With the “access guarding” function, the safety sensor detects persons only when they enter the danger
zone but cannot tell whether there are any persons inside the danger zone. For this reason, a start/
restart interlock or a suitable stepping behind protection in the safety chain is essential in this case.
• The construction of the safety sensor must not be altered. When manipulating the safety sensor, the
protective function is no longer guaranteed. Manipulating the safety sensor also voids all warranty
claims against the manufacturer of the safety sensor.
• The safety sensor must be inspected regularly by a competent person to ensure proper integration and
mounting (see chapter 2.2 "Necessary competencies").
• The safety sensor must be exchanged after a maximum of 20 years. Repairs or the exchange of wear
parts do not extend the mission time.
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Safety
2.1.2
Foreseeable misuse
Any use other than that defined under the “Approved purpose” or which goes beyond that use is considered improper use.
In principle, the safety sensor is not suitable as a protective device for use in the following cases:
• Danger posed by ejected objects or the spraying of hot or hazardous liquids from within the danger
zone
• Applications in explosive or easily flammable atmospheres
2.2 Necessary competencies
The safety sensor may only be configured, installed, connected, commissioned, serviced and tested in its
respective application by persons who are suitably qualified for the given task. General prerequisites for
suitably qualified persons:
• They have a suitable technical education.
• They are familiar with the relevant parts of the operating instructions for the safety sensor and the operating instructions for the machine.
Task-specific minimum requirements for suitably qualified persons:
Configuration
Specialist knowledge and experience in the selection and use of protective devices on machines as well as
the application of technical rules and the locally valid regulations on labor protection, safety at work and
safety technology.
Mounting
Specialist knowledge and experience needed for the safe and correct installation and alignment of the
safety sensor with regard to the respective machine.
Electrical installation
Specialist knowledge and experience needed for the safe and correct electrical connection as well as safe
integration of the safety sensor in the safety-related control system.
Operation and maintenance
Specialist knowledge and experience needed for the regular inspection and cleaning of the safety sensor –
following instruction by the person responsible.
Servicing
Specialist knowledge and experience in the mounting, electrical installation and the operation and maintenance of the safety sensor in accordance with the requirements listed above.
Commissioning and testing
• Experience and specialist knowledge in the rules and regulations of labor protection, safety at work and
safety technology that are necessary for being able to assess the safety of the machine and the use of
the safety sensor, including experience with and knowledge of the measuring equipment necessary for
performing this work.
• In addition, a task related to the subject matter is performed in a timely manner and knowledge is kept
up to date through continuous further training ‑ Competent person in terms of the German Betriebssicherheitsverordnung (Ordinance on Industrial Safety and Health) or other national legal regulations.
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2.3 Responsibility for safety
Manufacturer and operator must ensure that the machine and implemented safety sensor function properly
and that all affected persons are adequately informed and trained.
The type and content of all imparted information must not lead to unsafe actions by users.
The manufacturer of the machine is responsible for:
• Safe machine construction
• Safe implementation of the safety sensor, verified by the initial test performed by a competent person
(see chapter 2.2 "Necessary competencies")
• Imparting all relevant information to the operating company
• Adhering to all regulations and directives for the safe commissioning of the machine
The operator of the machine is responsible for:
• Instructing the operator
• Maintaining the safe operation of the machine
• Adhering to all regulations and directives for labor protection and safety at work
• Periodic testing by a competent person (see chapter 2.2 "Necessary competencies")
2.4 Disclaimer
The liability of Leuze electronic GmbH + Co. KG is to be excluded in the following cases:
• Safety sensor is not used as intended.
• Safety notices are not adhered to.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Proper function is not tested (see chapter 9 "Testing").
• Changes (e.g., constructional) are made to the safety sensor.
Safety
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3 Device description
The safety sensor consists of a transmitter and a receiver (see chapter 3.2 "Device overview of the MLC
family"). It is protected against overvoltage and overcurrent acc. to IEC60204-1 (protection class3). The
safety sensor is not dangerously influenced by ambient light (e.g., welding sparks, warning lights).
3.1 Overview of Smart Process Gating (SPG)
SPG is a timing-controlled control process for access guarding with bridging function. External muting sensors are not necessary here. Instead, two independent control signals are needed for activation of the
bridging function:
• A CS switching signal (“controller signal”) from a control (see chapter 4.6 "Smart Process Gating").
• A protective field interruption(PFI) which was created by the transport material; this interruption must
be detected by the receiver within 4s after the CS signal is applied.
The CS switching signal can be supplied by a standard PLC or by a safety PLC, whereby various safety
levels are reached (see following table).
Tab.3.1: Dependence of the safety level on the used control
Device description
Safety Integrity Level in accordance with ENIEC62061
Standard PLC SIL2 PLd
Safety PLC SIL3 PLe
3.2 Device overview of the MLC family
The series is characterized by four different receiver classes (Basic, Standard, Extended, SPG) with specific features and properties (see table below).
Tab.3.2: Device models in the series with specific features and functions
Device type Transmitter Receiver
Function
package
Model MLC 500
MLC 501
OSSDs (2x) ■ ■ ■ ■
AS-i ■ ■
Transmission
channel
changeover
■ ■ ■ ■ ■ ■
MLC 500/AMLC 502 MLC 510
Basic Standard Ex-
MLC 511
Performance level in accordance with
ENISO13849-1:2008
SPG
tended
MLC 510/AMLC 520 MLC 530 MLC 530
SPG
LED indicator ■ ■ ■ ■ ■ ■ ■ ■
7‑segment
display
Automatic
start/restart
RES ■ ■ ■
EDM ■
Linkage ■
Blanking ■ ■
Muting ■
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■ ■ ■
■ ■ ■
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Device type Transmitter Receiver
a
b
b
Device description
Function
package
Model MLC 500
MLC 501
MLC 500/AMLC 502 MLC 510
MLC 511
Basic Standard Ex-
tended
MLC 510/AMLC 520 MLC 530 MLC 530
SPG
SPG
SPG ■
Multi-scan ■ ■
Range reduc-
■ ■
tion
Test input ■
Protective field properties
The beam distance and the number of beams are dependent on the resolution and protective field height.
NOTICE
Depending on the resolution, the effective protective field height can be larger than the optically
active area of the safety sensor housed in yellow (see chapter 3.2 "Device overview of the MLC
family" and see chapter 14.1 "General specifications").
Device synchronization
The synchronization of receiver and transmitter for creating a functioning protective field is done optically,
i.e. without cables, via two specially coded synchronization beams. A cycle (i.e. a pass from the first to the
last beam) is called a scan. The length of a scan determines the length of the response time and affects the
calculation of the safety distance (see chapter 6.1.1 "Calculation of safety distanceS").
NOTICE
For the correct synchronization and function of the safety sensor, at least one of the two synchronization beams must be free during synchronization and operation.
During the SPG process, an interruption of up to 60s is possible (see chapter 4.6 "Smart
Process Gating").
a Optically active area, housed in yellow
b Synchronization beams
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Fig.3.1: Transmitter-receiver system
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Device description
1
2
QR code
A QR code as well as the corresponding web address are located on the safety sensor.
At the web address, you will find device information and error messages (see chapter 11.3 "Error messages 7-segment display") after scanning the QR code with a mobile end device or after entering the web
address.
When using mobile end devices, mobile service charges can accrue.
Fig.3.2: QR code with corresponding web address (URL) on the safety sensor
3.3 Connection technology
The transmitter and receiver feature an M12 connector as an interface to the machine control with the following number of pins:
Device model Device type Device plug
MLC 500 Transmitter 5-pin
MLC 530 SPG Extended receiver, Smart Process
3.4 Display elements
The display elements of the safety sensors simplify start-up and fault analysis.
3.4.1
Operating indicators on the MLC500 transmitter
Located in the connection cap on the transmitter are two LEDs which serve as function indicators:
8-pin
Gating
1 LED1, green/red
2 LED2, green
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Fig.3.3: Indicators on the MLC 500 transmitter
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Device description
1
4
5
6
2
7
3
Tab.3.3: Meaning of the LEDs on the transmitter
LED Color State Description
1 Green/red OFF Device switched off
Red Device error
Green Normal operation
2 Green Flashing For 10s after switch-on: reduced
range selected by the wiring (see
chapter 7.1 "Pin assignment transmitter and receiver").
OFF Transmission channel C1
ON Transmission channel C2
3.4.2
Operating indicators on the MLC530SPG receiver
Three LEDs and a 7-segment display for visualizing the operating state are located on the receiver:
1 LED1, red/green
2 LED2, yellow
3 LED3, blue
4 OSSD icon
5 RES icon
6 Blanking/SPG icon
7 7‑segment display
Fig.3.4: Indicators on the MLC 530 SPG receiver
Tab.3.4: Meaning of the LEDs on the receiver
LED Color State Description
1 Red/green OFF Device switched off
Red OSSD off
Red, flashing slowly (approx.1Hz) External error
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Red, flashing fast (approx.10Hz) Internal error
Green OSSD on
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Device description
LED Color State Description
2 Yellow OFF • RES activated and enabled
• or RES blocked and protective
field interrupted
ON, OSSD off RES activated and blocked but
ready to be unlocked - protective
field free
ON, OSSD on CS switching signal is applied
3 Blue OFF No special function (blanking,
SPG,…) active
ON Protective field parameter (blank-
ing) correctly taught
Slowly flashing • SPG active
• or override active
Short flashing Protective field interrupted and
RES blocked
• Teaching of protective field parameters
• or restart/override necessary
7‑segment display
In normal operation, the 7-segment display shows the number of the operating mode. In addition, it helps
during the detailed error diagnostics (see chapter 11 "Troubleshooting") and serves as an alignment aid
(see chapter 8.2 "Aligning the sensor").
Tab.3.5: Meaning of the 7-segment display
Display Description
After switching on
8 Self test
tnn Response time (t) of the receiver in milliseconds (nn)
In normal operation
1, 5 or 6 Selected operating mode
1, 5 or 6 flashing Weak signal
For alignment
Alignment display (see chapter 3.4.3 "Alignment display").
• Segment1: beam area in upper third of the protective field
• Segment2: beam area in middle third of the protective field
• Segment3: beam area in lower third of the protective field
For error diagnostics
F… Failure, internal device error
E… Error, external error
U… Usage info, application error
For error diagnostics, the error's respective letter is displayed first followed by the number code. The display is repeated cyclically. In the case of blocking errors, the voltage supply must be separated and the
cause of the error must be eliminated. Before switching on again, the steps taken before initial commissioning must be repeated (see chapter 9.1 "Before the initial start-up and following modifications").
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Device description
The 7-segment display switches to alignment mode when the device has not yet been aligned or when the
protective field has been interrupted (after 5s). In this case, a fixed beam area from the protective field is
assigned to every segment.
3.4.3
Alignment display
Approximately 5s after a protective-field interruption, the 7-segment display switches to alignment mode.
In this mode, one third of the total protective field (top, middle, bottom) is assigned to one of the three horizontal segments and the state of this sub-protective field displayed as follows:
Tab.3.6: Function of alignment display
Segment Description
On All beams in the beam area are uninterrupted.
Flashing At least one, but not all beams in the beam area are uninterrupted.
Switched off All beams in the beam area are interrupted.
When the protective field has been free for about 5s, the device switches back to the display of the operating mode.
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4 Functions
An overview of features and functions of the safety sensor can be found in chapter “Device description” (see chapter 3.2 "Device overview of the MLC family").
The different functions are grouped into several operating modes (see table below).
Depending on the function required, select the suitable operating mode via corresponding electrical wiring
(see chapter 7 "Electrical connection").
Tab.4.1: Overview of functions and function groups (FG) in the individual operating modes
Functions 1 5 6
Fixed blanking with 1-beam tolerance ■ ■ ■
MaxiScan ■ ■ ■
SPG ■ ■ ■
Qualified stop ■ ■
Start/restart interlock (RES) ■ ■ ■
Range reduction ■ ■ ■
Functions
Operating modes
Transmission channel changeover ■ ■ ■
Partial gating ■
Max. conveyor speed 0.2m/s 0.6m/s 0.2m/s
Automatic gating end 2s 1s 2 s
4.1 Start/restart interlock RES
After accessing the protective field, the start/restart interlock ensures that the safety sensor remains in the
OFF state after the protective field has been cleared. It prevents automatic release of the safety circuits
and automatic start-up of the system, e.g. if the protective field is again clear or if an interruption in the voltage supply is restored.
NOTICE
For access guarding, the start/restart interlock function is mandatory. The protective device may
only be operated without start/restart interlock in certain exceptional cases and under certain
conditions acc. to ENISO12100.
Using start/restart interlock
Ä Select the desired operating mode (see chapter 7 "Electrical connection").
The start/restart interlock function is automatically activated.
Switching the safety sensor back on after shutting down (OFF state):
Ä Press the reset button (press/release between 0.15s and 4s)
NOTICE
The reset button must be located outside the danger zone in a safe place and give the operator
a good view of the danger zone so that he/she can check whether anyone is located in it (according to EN62046) before pressing the reset button.
DANGER
Risk of death if start/restart is operated unintentionally!
Ä Ensure that the reset button for unlocking the start/restart interlock cannot be reached from
the danger zone.
Ä Before unlocking the start/restart interlock, make certain that no people are in the danger
zone.
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After the reset button has been actuated, the safety sensor switches to the ON state.
4.2 Transmission channel changeover
Transmission channels are used to prevent mutual interference of safety sensors which are located close
to each other.
NOTICE
To guarantee reliable operation, the infrared beams are modulated so they can be discerned
from the ambient light. Welding sparks or warning lights, e.g. from passing high-lift trucks,
thereby do not influence the protective field.
With the factory setting, the safety sensor works in all operating modes with transmission channelC1.
The transmission channel of the transmitter can be switched by changing the supply voltage polarity (see
chapter 7.1.1 "MLC500 transmitter").
Select transmission channelC2 on the receiver:
Ä Connect pins 1, 3, 4 and 8 of the receiver and switch it on.
ð The receiver is switched to transmission channelC2. Switch the receiver off and again disconnect the
connection between pins 1, 3, 4 and 8 before switching the receiver back on.
Re-select transmission channelC1 on the receiver:
Ä Repeat the procedure described above to again select transmission channel C1 on the receiver.
ð The receiver is switched to transmission channelC1 again.
Functions
NOTICE
Faulty function due to incorrect transmission channel!
Select the same transmission channel on the transmitter and corresponding receiver.
4.3 Operating range selection
In addition to selecting the suitable transmission channels (see chapter 4.2 "Transmission channel
changeover"), the operating range selection also serves to prevent mutual interference of adjacent safety
sensors. At reduced operating range the light power of the transmitter reduces, so that around half of the
nominal range is reached.
Ä Wire pin4 (see chapter 7.1 "Pin assignment transmitter and receiver").
ð The wiring of pin4 determines the transmitting power and thereby the range (without wiring pin4 the
reduced operating range is selected).
WARNING
Impairment of the protective function due to incorrect transmitting power!
The light power emitted from the transmitter is reduced through a single channel and without
safety-relevant monitoring.
Ä Do not use this configuration option for safety purposes.
Ä Note that the distance to reflective surfaces must always be selected so that no reflection
bypass can occur even at maximum transmitting power (see chapter 6.1.4 "Minimum distance to reflective surfaces").
4.4 Signal output
The signal output outputs 24 V on a valid gating sequence. Flashing occurs in the event of a faulty gating
sequence, e.g., if no protective field violation occurs after 4 s.
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4.5 Blanking
Blanking functions are used when objects must be located in the protective field for operational reasons.
Functions
NOTICE
If the “blanking” function is activated, suitable objects must be located within their respective
protective field areas. Otherwise the OSSDs switch to the OFF state even if the protective field
is free or they remain in the OFF state.
WARNING
Faulty application of blanking functions may result in serious injury!
Ä Only use the function when the objects introduced do not have glossy or reflective top and/
or bottom surfaces. Only matte surfaces are permitted.
Ä Make sure that objects take up the entire width of the protective field so that the protective
field cannot be accessed from the sides of the objects; otherwise the safety distance with reduced resolution must be calculated corresponding to the gap in the protective field.
Ä If necessary, properly mount mechanical locks which are fixed firmly to the object (see chap-
ter 14.1 "General specifications") to prevent the “formation of shadows”, for example from
tall objects or crooked installation.
Ä Monitor the position of the objects and the locks, if applicable, at all times by integrating
them electrically into the safety circuit.
Ä Blankings in the protective field and changes to the protective field resolution should only be
performed by qualified and instructed persons (see chapter 2.2 "Necessary competencies").
Ä Only give corresponding tools such as a key for the teach key switch to qualified personnel.
4.5.1
Fixed blanking
With the “Fixed blanking” function, the safety sensor offers the chance of stationarily blanking up to 10protective field areas consisting of any number of adjacent beams.
Prerequisites:
• At least one of the two synchronization beams may not be blanked.
• Taught blanking areas must have a minimum distance to each other which corresponds to the resolution of the safety sensor.
• No “shadows” may form in the protective field (see figures below).
Fixed blanking with beam tolerance
Fixed blanking with beam tolerance is used for access guarding, for example to blank a roller conveyor so
that it is resistant to interference.
In doing so, the receiver automatically applies a tolerance area of one beam on both sides of a taught fixed
object, thereby expanding the movement area of the object by +1beam. On the borders of the blanked object, the resolution is reduced correspondingly by 2beams.
Activation of the function
Select operating mode1, 5 or6 (see chapter 7 "Electrical connection").
Fig.4.1: Fixed blanking: mechanical locks prevent side access to the protective field
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Functions
Fig.4.2: Fixed blanking: prevention of formation of "shadows"
Teaching of fixed blanking areas
Teaching protective field areas with blanking is performed via a key switch in the following steps:
Ä Mount all objects to be blanked in the protective field in the locations at which they are to be blanked.
Ä Press the teach key switch and release it within 0.15s and 4s.
ð The teach event begins. LED3 flashes blue.
Ä Press the teach key switch again and release it within 0.15s and 4s.
ð The teach event ends. LED3 illuminates blue if at least one beam area is blanked. All objects have
been correctly taught.
NOTICE
After teaching a free protective field (teaching finished), thus determining a protective field without areas with fixed blanking, the blue LED switches off.
During teaching, the object size detected can vary by no more than one beam. Otherwise teaching is
ended with the U71 user message (see chapter 11.1 "What to do in case of failure?").
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4.6 Smart Process Gating
CS
PFI
SPG active
t1
t2
D
D
SPG is a timing-controlled control process for access guarding with bridging function. It is used only for material transport out of or into danger zones.
External muting sensors are replaced by two independent control signals to activate the bridging function:
• A CS switching signal (“controller signal”) from a control.
• A PFI interruption signal from the protective field which was created by the transport material; this signal must be detected by the receiver within 4s after the CS switching signal is applied.
Functions
CS Switching signal from the PLC
PFI Protective field interrupted
SPG
active
t1 t < 4s
t2 t = 1s or 2s
D < 200mm
Fig.4.3: SPG principle
Gating active
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Functions
A
B
C
D
E
F
G
H
I
Fig.4.8: SPG system limits
A MLC 530 SPG (receiver)
B Transmitter
C MLC 530 SPG controller
D PFI
E PLC
F CS switching signal
G System process
H OSSD
I Transport material
Dot-dashed MLC 530 SPG system limit
The CS switching signal can be supplied by a standard PLC or by a safety PLC, whereby various safety
levels can be reached (see following table).
Tab.4.2: Dependence of the safety level on the used control
Safety Integrity Level in accordance with ENIEC62061
Max. possible performance
level in accordance with
ENISO13849-1:2008
Standard PLC SIL2 PLd
Safety PLC SIL3 PLe
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Functions
4.6.1
SPG prerequisites
SPG is only suitable if the following are known to a control:
• When will an object penetrate the protective field?
• When will the object again leave the protective field?
• Does this information come from a source that cannot easily be tampered with?
This information is frequently available from a processing cell in exit applications: the control knows when
the processing time ends and when the drive of the transport system must be switched on. The protective
field of the access guarding can be interrupted shortly afterwards.
Prerequisites for PLC signal:
• The CS switching signal from a control must not arise directly from the actions of a person.
• It may not be a signal from a sensor, pushbutton or similar which directly and unchanged generates the
CS switching signal. Suitable signals are derived from extended switching signals or running orders, for
example.
• The protective field must be interrupted within 4s after activation of the CS switching signal. Otherwise,
the receiver switches to the protective mode, i.e., the OSSDs are switched off if the protective field is
interrupted (U53).
• The CS switching signal may not be generated until the transport material is less than 200mm from the
protective field in order to prevent the intrusion of persons into the danger zone during the activation
phase.
• The CS switching signal must be deactivated within 20s after the protective field is cleared (0V). Otherwise, the receiver switches to the interlock state (E75).
Furthermore, the following prerequisites apply for the application:
• The safety sensor must remain in sync in order to receive a valid protective field signal. For this reason,
the two synchronization beams may be interrupted for no more than 60s during the SPG process.
• The transport material may only move in accordance with the specified maximum speed (operating
mode1 / operating mode6 v
= 0.2m/s; operating mode 5v
max
= 0.6m/s) so that after exiting the pro-
max
tective field no gap larger than 200mm is formed in order to prevent the intrusion of persons during the
deactivation phase (if necessary, a hard guard is to be extended accordingly). If necessary, it is also
possible to deviate from these values according to a risk analysis or separate system standard. When
designing the system, compliance with the limit of 200mm is particularly important. This limit must also
be adhered to when starting up the system or in case of changed conveyor speeds.
NOTICE
Transmitter and receiver of the protective device must be mounted in such a way that they cannot be pushed or damaged by the transported goods.
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Functions
CS
PFI
SPG active
t1
t2
D
D
d e
CS Switching signal from the PLC
PFI Protective field interrupted
SPG
active
d Entry
e Exit
t1 <4s
t2 1s or 2s
D < 200mm
Gating active
Activate SPG
Ä Activate operating mode1, 5 or6 (see chapter 4.6.3 "Operating mode1 (qualified stop)", see chapter
4.6.4 "Operating mode5" or see chapter 4.6.5 "Operating mode 6 (partial gating)").
Ä Connect the timer stop input to 0V in operating mode5. Antivalent to CS in the other operating modes
(1 and 6).
ð The TH timer halt signal is then not used.
SPG is ended in the following cases:
• The entire protective field is clear for longer than 1s (operating mode5) or 2s (operating mode1 or 6).
• The signals from the protective field and CS are both inactive for longer than 0.1s.
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Functions
TH
CS
PFI
SPG
active
a
t1
t2
t4
t3
4.6.2
Examples of signal generation for SPG mode
Ideal conditions for SPG operation often present themselves in the area of conveyor lines, such as with
cross conveyors. In this situation, the exact order and precise position of the transported goods is usually
known. Using this knowledge, the CS switching signal and the prerequisites can be easily generated in the
PLC.
In the example provided, the CS switching signal is automatically generated from the process. In the area
of order picking stations, it must be ensured that the CS switching signal is never derived from a keypress
or used directly. In this case, generating the CS switching signal would depend on the actions of a person,
which could facilitate deliberate misuse.
4.6.3
Operating mode1 (qualified stop)
This operating mode is intended primarily for speeds<0.2m/s, such as they occur in, e.g., the automotive
sector. For this purpose, t2 is set to 2s. Furthermore, the qualified stop function can also be used to perform a normal stop without interruption of the protective field even after the CS switching signal was activated, see figure.
CS Switching signal from the PLC
TH Timer halt signal from the PLC
PFI Protective field interrupted
SPG
active
a Antivalent signal change between CS and TH
t1 <4s
t2 2s
t3 <20s
t4 <10min
Gating active
Fig.4.4: Operating mode1 (qualified stop)
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Functions
TH
CS
PFI
SPG
active
1
2 3
a
t1
NOTICE
To ensure the qualified stop function, a safe PLC is necessary in operating mode1. The TH
control signal must not be generated simply by inverting the CS switching signal.
The SPG sequence is initiated by the antivalent signal change between CS and TH within 0.5s.
If it is not possible for the protective field to be interrupted within 4s after initiation of the SPG sequence,
the possibility exists in operating mode1 and 6 to perform a qualified stop.
The function of the SPG stop as well as of a restart is initiated by the renewed edge change of the CS and
TH signals, see the following figure.
CS Switching signal from the PLC
TH Timer halt signal from the PLC
PFI Protective field interrupted
SPG
Gating active
active
a Antivalent signal change between CS and TH
t1 <4s
Fig.4.5: Operating mode1 (qualified stop) between 1 and 2
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Functions
CS
PFI
t1
SPG
active
t3
t2
t4
4.6.4
Operating mode5
NOTICE
In operating mode5, it is also possible to use non-safety-related PLCs; PLd is thereby reached.
In operating mode5, it is possible to realize higher conveyor speeds than are possible in operating mode1.
The transport material may only move with the specified maximum speed of 0.6m/s so that after exiting the
protective field no gap larger than 200mm is formed in order to prevent the intrusion of persons during the
deactivation phase (if necessary, a hard guard is to be extended accordingly). If necessary, it is also possible to deviate from these values according to a risk analysis or separate system standard.
CS Switching signal from the PLC
TH Timer halt signal from the PLC (optional)
PFI Protective field interrupted
SPG
active
t1 <4s
t2 1s
t3 <20s
t4 <10min
Fig.4.6: Operating mode5
Gating active
here, t2 is 1s; the protective field can thereby be cleared for up to 1s.
NOTICE
The timeout of 10min can optionally be extended by another control signal (TH timer halt signal)
by the PLC to up to 100h. If this signal is not used, the timer halt input must be wired to 0V.
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Functions
4.6.5
Operating mode 6 (partial gating)
Similar to operating mode 1, this operating mode is mainly intended for speeds <0.2m/s. For this purpose,
t2 is set to 2s. In addition to the functionality of operating mode1, it also includes partial gating. The top
four beams are excluded from gating (see figure).
This means unauthorized riding along on the transport material can be recognized, and so-called pendulum
flaps can be monitored.
With partial gating, the upper four beams are not bridged, even during gating. Interruptions always cause
the OSSDs to switch off.
NOTICE
To ensure the qualified stop function, a safe PLC is necessary in operating mode6. The TH
control signal must not be generated simply by inverting the CS switching signal.
NOTICE
The upper four axes must be free during operation in operating mode6. Interruptions cause the
OSSDs to switch off.
NOTICE
If operating mode 6 is to be used to monitor the pendulum flaps, the following additional safety
information must be observed:
Ä The pendulum flap / swing door must feature a solid design and require tools for disman-
tling.
Ä The safety door must be designed in accordance with ISO14120 and ISO13857. Side ac-
cess without triggering the pendulum flap must not be possible.
Ä The distances from transmitter to receiver must be designed so as to prevent a passageway
next to the transport material.
Ä The transport material may not actuate the pendulum flap (e.g., excessive load).
Ä The transmitter, receiver, pendulum flap/door must be protected against damage, e.g., to
prevent warping or slipping.
Ä The pendulum flap must not be made of transparent material; torsion must safely interrupt
the corresponding protective field area.
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Functions
TH
CS
PFI
SPG
active
a
t1
t2
t4
t3
The SPG sequence is initiated by the antivalent signal change between CS and TH within 0.5s.
If it is not possible for the protective field to be interrupted within 4s after initiation of the SPG sequence,
the possibility exists in operating mode6 to perform a qualified stop.
The function of the SPG stop as well as of a restart is initiated by the renewed edge change of the CS and
TH signals, see figure.
CS Switching signal from the PLC
TH Timer halt signal from the PLC
a Antivalent signal change between CS and TH
PFI Protective field interrupted
SPG
Gating active
active
t1 <4s
t2 <2s
t3 <20s
t4 <10min
Fig.4.7: Operating mode6 (qualified stop)
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Functions
CS
PFI
SPG
active
t < 0,1 s
4.6.6
SPG termination by the control
The initiated SPG sequence can be ended by removing the CS signal.
CS Switching signal from the PLC
PFI Protective field interrupted
SPG
active
Fig.4.8: SPG termination
Gating active
NOTICE
This can be used to minimize the gap that forms after ending the SPG.
4.6.7
If the resulting gap is bigger than 200mm and no other measures are possible (e.g., enclosing with a fence
or similar), the SPG interrupt by control must be used to shorten the gap.
SPG timeout extension
The standard SPG timeout time can be extended from 10min to up to 100h. In order to prevent easy manipulation, the bridging cycle is time-limited. If this time is exceeded (timeout), SPG ends and leads to the
shutdown of the OSSDs, even if an object is located in the protective field (E79).
The SPG timeout of 10min can optionally be extended by another control signal (THtimer halt signal) from
the PLC to up to 100h.
If a TH timer halt signal is used, it must swap with the CS switching signal within 0.5s after activation of
SPG, i.e., CS switches from 0V to +24V and TH from +24V to 0V. In the event of a faulty control, the receiver switches to the interlock state (E69).
NOTICE
If this signal is not used, the timer halt input must be wired to 0V.
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CS
TH
t1
t2 t3
PFI
SPG
active
max. 100 h
PLC
MLC
PLC External signals from the PLC
RES
PFI
t1
t4
CS
P-Mode
SPG
active
MLC Internal signals in the safety sensor
CS Switching signal from the PLC
TH Timer halt signal from the PLC
PFI Protective field interrupted
SPG
Gating active
active
t1 <4s
t2 =1s or 2s
t3 <20s
Functions
4.6.8
Fig.4.9: SPG timeout extension
Gating sequence reset
WARNING
Unauthorized reset may result in serious injury!
Ä A person with the necessary competence must observe the procedure exactly.
Ä Make certain that the danger zone can be viewed from the reset button and that the entire
process can be observed by the person with the necessary competence.
CS Switching signal from the PLC
RES Restart button
PFI Protective field interrupted
P-mode Protective mode
SPG
Gating active
active
t1 <4s
t4 <1h
Leuze electronic MLC 530 SPG 30
Fig.4.10: Gating sequence reset
Page 31
Functions
After the CS switching signal is applied for 4s, the device switches to protective mode (Protection Mode),
i.e., if light beams are now interrupted, the OSSDs switch off. If there is then no protective field violation,
the RES signal can be used to start a new gating sequence. This restart must occur within no more than
one hour, otherwise the device switches to an interlock state.
It may be necessary to reapply the CS switching signal before initiating a new gating sequence.
4.6.9
SPG restart
An SPG restart is necessary if:
• the protective field is interrupted, but at least one synchronization beam is not occupied.
• and CS is activated (operating mode5) or CS and TH are activated (operating mode1 or 6)
WARNING
Unauthorized restart may result in serious injury!
Ä A person with the necessary competence must observe the procedure exactly.
Ä Make certain that the danger zone can be viewed from the reset button and that the entire
process can be observed by the person with the necessary competence.
Ä Before and during the restart, ensure that there are no people in the danger zone.
Perform SPG restart
Ä If the safety sensor responds with an error message, perform an error reset first (see chapter 4.7 "Error
reset").
Ä Press and release the reset button within 0.15s to 4s.
The safety sensor switches on.
NOTICE
If, after the button is pressed for the second time, a valid SPG state is present (CS switching
signal is applied, protective field interrupted), the initiated SPG sequence is continued. The ML
signal output alternately delivers 0V and 24V until the OSSDs are switched on again.
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Functions
4.6.10
Override
An override is necessary if:
• the protective field is interrupted and both synchronization beams are interrupted
• and CS is activated (operating mode5) or CS and TH are activated (operating mode1 or 6)
WARNING
Unmonitored overrides may result in serious injury!
Ä A competent person must watch the event carefully.
Ä If necessary, the competent person must release the reset button immediately to stop the
dangerous movement.
Ä Make certain that the danger zone can be viewed from the reset button and that the entire
process can be observed by a responsible person.
Ä Before and during the override, ensure that there are no people in the danger zone.
Perform override
Ä If the safety sensor responds with an error message, perform an error reset (see chapter 4.7 "Error re-
set").
Ä Press and release the reset button within 0.15s to 4s.
Ä Press the reset button a second time and keep it pressed down.
ð The safety sensor switches on.
• Case1: valid SPG condition
If a valid SPG condition is found to exist, the OSSDs remain in the ON state, even if the reset button is
released. The system resumes its normal operation.
• Case2: invalid SPG condition
In these cases, the release of the OSSDs is maintained only for as long as the reset button is pressed.
NOTICE
Override not possible if there are problems with the application!
The causes of the invalid SPG condition are to be investigated and remedied by a person with
the necessary competence.
The system pauses during the override if the reset button is released or the maximum time for the override
(120s) is exceeded.
NOTICE
The duration of the override is limited to 120s.
If the button remains pressed down after 120s, the safety sensor assumes its interlock state after 150s.
Thereafter, the reset button must be pressed again and held down in order to continue the process. A stepby-step override is possible in this way.
NOTICE
If, after the button is pressed for the second time, a valid SPG state is present (CS switching
signal is applied, protective field interrupted), the initiated SPG sequence is continued. The ML
signal output alternately delivers 0V and 24V until the OSSDs are switched on again.
4.7 Error reset
If an internal or external error is detected by the receiver, it goes into the interlock state (see chapter 11.1
"What to do in case of failure?").
After trouble shooting acknowledge with the reset button or alternatively by switching the voltage supply on
and off.
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5 Applications
The safety sensor only creates square protective fields.
5.1 Access guarding with SPG
Typical application areas for the MLC 530 SPG for material infeed into or out of danger zones are in the automotive and intralogistics sectors.
Applications
Fig.5.1: Smart Process Gating (SPG) at automotive production lines
Fig.5.2: Smart Process Gating (SPG) at conveyor lines
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Applications
5.1.1
Blanking
During fixed blanking, beams are blanked at a fixed location (Fixed blanking).
NOTICE
Objects brought into the protective field must take up the entire field width so that it cannot be
accessed next to the object. Otherwise locks are to be provided to prevent access.
WARNING
Risk of injury due to inadmissible application of blanking!
Blanking is not permitted with danger zone guarding since the blanked areas would form accessible bridges to the danger zone.
Ä Do not use blanking for danger zone guarding.
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6 Mounting
Improper mounting may result in serious injury!
The protective function of the safety sensor is only ensured if appropriately and professionally
mounted for the respective, intended area of application.
Mounting
WARNING
Ä Only allow the safety sensor to be installed by qualified persons (see chapter 2.2 "Neces-
sary competencies").
Ä Maintain the necessary safety distances (see chapter 6.1.1 "Calculation of safety dis-
tanceS").
Ä Make sure that stepping behind, crawling under or stepping over the protective device is reli-
ably ruled out and reaching under, over or around is taken into account in the safety distance, if applicable with additional distanceCRO corresponding to ENISO13855.
Ä Take measures to prevent that the safety sensor can be used to gain access to the danger
zone, e.g. by stepping or climbing into it.
Ä Observe the relevant standards, regulations and these instructions.
Ä Clean the transmitter and receiver at regular intervals: environmental conditions (see chap-
ter 14 "Technical data"), care (see chapter 10 "Maintenance").
Ä After mounting, check the safety sensor for proper function.
6.1 Arrangement of transmitter and receiver
Optical protective devices can only perform their protective function if they are mounted with adequate
safety distance. When mounting, all delay times must be taken into account, such as the response times of
the safety sensor and control elements as well as the stopping time of the machine, among others.
The following standards specify calculation formulas:
• IEC61496-2, "Active optoelectronic protective devices": distance of the reflecting surfaces/deflecting
mirrors
• EN13855, "Safety of machines - The positioning of protective equipment in respect of approach
speeds of parts of the human body": mounting situation and safety distances
NOTICE
In accordance with ISO13855, with a vertical protective field, it is possible to pass under beams
over 300mm or pass over beams under 900mm. If the protective field is horizontal, climbing on
the safety sensor must be prevented through suitable installation or with covers and the like.
6.1.1
Calculation of safety distanceS
NOTICE
When using blanking, observe the necessary additional distances to the safety distance (see
chapter 6.1.5 "Resolution and safety distance during fixed blanking").
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Mounting
General formula for calculating the safety distanceS of an Optoelectronic Protective Device acc. to
ENISO13855
S [mm] = Safety distance
K [mm/s] = Approach speed
T [s] = Total time of the delay, sum from (ta+ti+tm)
t
[s] = Response time of the protective device
a
t
[s] = Response time of the safety relay
i
t
[s] = Stopping time of the machine
m
C [mm] = Additional distance to the safety distance
NOTICE
If longer stopping times are determined during regular inspections, an appropriate additional
time must be added to tm.
6.1.2
Calculation of safety distance if protective fields act orthogonally to the approach direction
With vertical protective fields, ENISO13855 differentiates between
• SRT: safety distance concerning access through the protective field
• SRO: safety distance concerning access over the protective field
The two values are distinguished by the way additional distanceC is determined:
• CRT: from a calculation formula or as a constant (see chapter 6.1.1 "Calculation of safety distanceS")
• CRO: from the following table “Reaching over the vertical protective field of electro-sensitive protective
equipment (excerpt from ENISO13855)”
The larger of the two values SRT and SRO is to be used.
Calculation of safety distanceSRT acc. to ENISO13855 when access occurs through the protective
field:
Calculation of safety distanceSRT for point of operation guarding
S
[mm] = Safety distance
RT
K [mm/s] = Approach speed for point of operation guarding with approach reaction and normal approach di-
rection to the protective field (resolution 14to40mm): 2000mm/s or 1600mm/s, when
SRT>500mm
T [s] = Total time of the delay, sum from (ta+ti+tm)
t
[s] = Response time of the protective device
a
t
[s] = Response time of the safety relay
i
t
[s] = Stopping time of the machine
m
C
[mm] = Additional distance for point of operation guarding with approach reaction with resolutions of
RT
14to40mm, d=resolution of protective device CRT=8×(d-14)mm
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Mounting
Calculation of safety distanceSRT for access guarding
S
[mm] = Safety distance
RT
K [mm/s] = Approach speed for access guarding with approach direction orthogonal to the protective field:
2000mm/s or1600mm/s, when SRT>500mm
T [s] = Total time of the delay, sum from (ta+ti+tm)
t
[s] = Response time of the protective device
a
t
[s] = Response time of the safety relay
i
t
[s] = Stopping time of the machine
m
C
[mm] = Additional distance for access guarding with approach reaction with resolutions of 14to40mm,
RT
d=resolution of protective device CRT=8×(d-14)mm. Additional distance for access guarding for resolutions>40mm: CRT=850mm (standard value for arm length)
Calculation example
Access to a robot with a stopping time of 250ms is to be safeguarded with a safety light curtain with 90mm
of resolution and 1500mm of protective field height whose response time is 6ms. The safety light curtain
directly switches the contactors whose response time is contained in the 250ms. An additional interface
therefore does not have to be taken into consideration.
Ä Calculate safety distanceSRT using the formula acc. to ENISO13855.
K [mm/s] = 1600
T [s] = (0.006+0.250)
C
[mm] = 850
RT
S
[mm] = 1600mm/s×0.256s+850mm
RT
S
[mm] = 1260
RT
This safety distance is not available in the application. This is why a new calculation is done with a safety
light curtain with 40mm of resolution (response time=14ms):
Ä Re-calculate safety distanceSRT using the formula acc. to ENISO13855.
K [mm/s] = 1600
T [s] = (0.014+0.250)
C
[mm] = 8×~(40-14)
RT
S
[mm] = 1600mm/s×0.264s+208mm
RT
S
[mm] = 631
RT
The safety light curtain with a 40mm resolution is thus suitable for this application.
NOTICE
For the calculation with K=2000mm/s, safety distanceSRT equals 736mm. The adoption of approach speed K=1600mm/s is therefore permitted.
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Mounting
a
3
C
RO
KxT
b
1
2
S
RO
Calculation of safety distanceSRo acc. to ENISO13855 when protective field is accessed from
above:
Calculation of safety distanceSRo for point of operation guarding
S
[mm] = Safety distance
RO
K [mm/s] = Approach speed for point of operation guarding with approach reaction and normal approach di-
rection to the protective field (resolution 14to40mm): 2000mm/s or 1600mm/s, when
SRO>500mm
T [s] = Total time of the delay, sum from (ta+ti+tm)
t
[s] = Response time of the protective device
a
t
[s] = Response time of the safety relay
i
t
[s] = Stopping time of the machine
m
C
[mm] = Additional distance in which a body part can move towards the protective device before the pro-
RO
tective device triggers: value (see the following table “Reaching over the vertical protective field
of electro-sensitive protective equipment (excerpt from ENISO13855)”).
1 Safety sensor
2 Danger zone
3 Floor
a Height of the point of operation
b Height of the upper beam of the safety sensor
Fig.6.1: Additional distance to the safety distance when reaching over and under
Tab.6.1: Reaching over the vertical protective field of electro-sensitive protective equipment(excerpt from
ENISO13855)
Heighta
of the
point of
operation
[mm]
Heightb of the upper edge of the protective field of the electro-sensitive protective
equipment
900 1000 1100 1200 1300 1400 1600 1800 2000 2200 2400 2600
Additional distanceCRO to the danger zone [mm]
2600 0 0 0 0 0 0 0 0 0 0 0 0
2500 400 400 350 300 300 300 300 300 250 150 100 0
2400 550 550 550 500 450 450 400 400 300 250 100 0
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Mounting
Heighta
of the
point of
operation
Heightb of the upper edge of the protective field of the electro-sensitive protective
equipment
900 1000 1100 1200 1300 1400 1600 1800 2000 2200 2400 2600
Additional distanceCRO to the danger zone [mm]
[mm]
2200 800 750 750 700 650 650 600 550 400 250 0 0
2000 950 950 850 850 800 750 700 550 400 0 0 0
1800 1100 1100 950 950 850 800 750 550 0 0 0 0
1600 1150 1150 1100 1000 900 850 750 450 0 0 0 0
1400 1200 1200 1100 1000 900 850 650 0 0 0 0 0
1200 1200 1200 1100 1000 850 800 0 0 0 0 0 0
1000 1200 1150 1050 950 750 700 0 0 0 0 0 0
800 1150 1050 950 800 500 450 0 0 0 0 0 0
600 1050 950 750 550 0 0 0 0 0 0 0 0
400 900 700 0 0 0 0 0 0 0 0 0 0
200 600 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
Depending on the specified values you can work with the above-mentioned table in three ways:
1. Given are:
• Heighta of the point of operation
• DistanceS of the point of operation from the safety sensor, and additional distanceC
RO
To be determined is the required heightb of the upper beam of the safety sensor and thereby its protective
field height.
Ä Look for the line with the specification of the point of operation height in the left column.
Ä In this line, look for the column with the next highest specification for additional distance CRO.
ð The required height of the upper beam of the safety sensor is up top in the column head.
2. Given are:
• Heighta of the point of operation
• Heightb of the upper beam of the safety sensor
To be determined is the required distance S of the safety sensor to the point of operation and thereby additional distance CRO.
Ä In the column head, look for the column with the next lowest entry for the height of the upper beam of
the safety sensor.
Ä Look for the line with the next highest specification of the point of operation heighta in this column.
ð In the intersection point of the line and the column, you will find additional distanceCRO.
3. Given are:
• DistanceS of the point of operation from the safety sensor, and additional distanceC
RO.
• Heightb of the upper beam of the safety sensor
To be determined is the permitted heighta of the point of operation.
Ä In the column head, look for the column with the next lowest entry for the height of the upper beam of
the safety sensor.
Ä Look for the next lowest value for real additional distance CRO in this column.
ð In this line, go to the left column: here you will find the permitted height of the point of operation.
Ä Now calculate safety distanceS using the general formula acc. to ENISO13855 (see chapter 6.1.1
"Calculation of safety distanceS").
ð The larger of the two values SRT and SRO is to be used.
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Mounting
Calculation example
The feeding-in area in a press with a stopping time of 130ms is to be safeguarded with a safety light curtain with 20mm of resolution and 600mm of protective field height. The response time of the safety light
curtain is 12ms; the press Safety PLC has a response time of 40ms.
The safety sensor can be reached over. The upper edge of the protective field is located at a height of
1400mm; the point of operation is located at a height of 1000mm
Additional distanceCRO to the point of operation is 700mm (see table “Reaching over the vertical protective
field of electro-sensitive protective equipment (excerpt from ENISO13855)”).
Ä Calculate safety distanceSRO using the formula acc. to ENISO13855.
K [mm/s] = 2000
T [s] = (0.012+0.040+0.130)
C
[mm] = 700
RO
S
[mm] = 2000mm/s×0.182s+700mm
RO
S
[mm] = 1064
RO
SRO is larger than 500mm; this is why the calculation may be repeated with approach speed 1600mm/s:
K [mm/s] = 1600
T [s] = (0.012+0.040+0.130)
C
[mm] = 700
RO
S
[mm] = 1600mm/s×0.182s+700mm
RO
S
[mm] = 992
RO
NOTICE
Depending on the machine construction, stepping behind protection, e.g. using a second horizontally arranged safety light curtain, is necessary. In most cases, it will be more appropriate to
choose a longer safety light curtain which makes the additional distanceCRO equal to 0.
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Mounting
6.1.3
Calculation of safety distanceS for parallel approach to the protective field
Calculation of safety distanceS for danger zone guarding
S [mm] = Safety distance
K [mm/s] = Approach speed for danger zone guarding with approach direction parallel to the protective field
(resolution up to 90mm): 1600mm/s
T [s] = Total time of the delay, sum from (ta+ti+tm)
t
[s] = Response time of the protective device
a
t
[s] = Response time of the safety relay
i
t
[s] = Stopping time of the machine
m
C [mm] = Additional distance for danger zone guarding with approach reaction H=height of the protec-
tive field, H
the protective device C=1200mm-0.4×H; H
=minimum installation height permitted, but no smaller than0, d=resolution of
min
=15×(d-50)
min
Calculation example
The danger zone in front of a machine with a stopping time of 140ms is to be safeguarded as close to the
floor height as possible using a horizontal safety light curtain as a replacement for a PS mat. Installation
heightH
can be=0 - additional distanceC to the safety distance is then 1200mm. The shortest possible
min
safety sensor is to be used; the first value to be selected is to be 1350mm.
The receiver with 40mm of resolution and 1350mm protective field height has a response time of 13ms,
an additional relay interface a response time of 10ms.
Ä Calculate safety distanceSRO using the formula acc. to ENISO13855.
K [mm/s] = 1600
T [s] = (0.140+0.013+0.010)
C [mm] = 1200
S [mm] = 1600mm/s×0.163s+1200mm
S [mm] = 1461
The safety distance of 1350mm is not sufficient; 1460mm are necessary.
This is why the calculation is repeated with a protective field height of 1500mm. The response time is now
14ms.
Ä Re-calculate safety distanceSRO using the formula acc. to ENISO13855.
K [mm/s] = 1600
T [s] = (0.140+0.014+0.010)
C [mm] = 1200
S [mm] = 1600mm/s×0.164s+1200mm
S [mm] = 1463
A suitable safety sensor has been found; its protective field height is 1500mm.
The following changes should now be taken into account in this example of the application conditions:
Small parts are occasionally thrown out of the machine; these can fall through the protective field. This
should not trigger the safety function. In addition, the installation height is increased to 300mm.
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MaxiScan
a
b
4°
4°
c
a
900 mm
200 mm
800 mm
300 mm
400 mm
600 mm
500 mm
700 mm
3 m
5 m 10 m
b
131 mm
15 m
20 m
25 m
1100 mm
1000 mm
K [mm/s] = 1600
T [s] = (0.140+0.100+0.010)
C [mm] = 1200-0.4×300
S [mm] = 1600mm/s×0.250s+1080mm
S [mm] = 1480
Mounting
6.1.4
Minimum distance to reflective surfaces
WARNING
Failure to maintain minimum distances to reflective surfaces may result in serious injury!
Reflective surfaces can indirectly deflect the transmitter beams to the receiver. In this case, interruption of the protective field is not detected.
Ä Determine the minimum distancea (see figure below).
Ä Make certain that all reflective surfaces are the necessary minimum distance away from the
protective field according to IEC61496-2 (see the following diagram “Minimum distance to
reflective surfaces as a function of the protective field width”).
Ä Check that reflective surfaces do not impair the detection capability of the safety sensor be-
fore start-up and at appropriate intervals.
a Required minimum distance to reflective surfaces [mm]
b Protective field width [m]
c Reflective surface
Fig.6.2: Minimum distance to reflective surfaces depending on protective field width
a Required minimum distance to reflective surfaces [mm]
b Protective field width [m]
Fig.6.3: Minimum distance to reflective surfaces as a function of the protective field width
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Mounting
Tab.6.2: Formula for calculating the minimum distance to reflective surfaces
Distance(b) transmitter-receiver Calculation of the minimum distance(a) to reflective sur-
faces
b≤3m a[mm]=131
b>3m a[mm]=tan(2.5°)×1000×b[m]=43.66×b[m]
6.1.5
Resolution and safety distance during fixed blanking
The calculation of the safety distance must always be based on the effective resolution. If the effective resolution deviates from the physical resolution, this must be documented near the protective device on the
supplied sign in a lasting, wipe-resistant manner.
Tab.6.3: Effective resolution and additional distance to the safety distance during fixed blanking with ±1beam size
tolerance for access guarding in accordance with ENISO13855 when approaching the protective field
orthogonally
Physical resolution Effective resolution on the ob-
ject edges
Additional distance to the
safety distance C=8×(d-14) or
850mm
14mm 34mm 160mm
20mm 45mm 850mm
30mm 80mm 850mm
40mm 83mm 850mm
90mm 283mm 850mm
WARNING
Faulty application of blanking functions may result in serious injury!
Ä Note that the additional distances to the safety distance may require additional measures be
taken for preventing stepping behind.
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Mounting
2
4
1
3
6.1.6
Preventing mutual interference between adjacent devices
If a receiver is located in the beam path of an adjacent transmitter, optical crosstalk, and thus erroneous
switching and failure of the protective function, may result.
Fig.6.4: Optical crosstalk between adjacent safety sensors (transmitter1 influences receiver2) due to incorrect
mounting
1 Transmitter1
2 Receiver1
3 Transmitter2
4 Receiver2
NOTICE
Possible impairment of the availability due to systems mounted close to each other!
The transmitter of one system can influence the receiver of the other system.
Ä Prevent optical crosstalk between adjacent devices.
Ä Mount adjacent devices with a shield between them or install a dividing wall to prevent mutual interfer-
ence.
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Ä Mount the adjacent devices opposite from one another to prevent mutual interference.
2
4
1
3
Fig.6.5: Opposite mounting
1 Receiver1
2 Transmitter1
3 Transmitter2
4 Receiver2
In addition to design characteristics, the safety sensor offers functions that can remedy this:
• Selectable transmission channels (see chapter 4.2 "Transmission channel changeover")
• Range reduction (Range reduction)
• Also: opposite mounting
Mounting
6.2 Mounting the safety sensor
Proceed as follows:
• Select the type of fastening, e.g. swivel mount or swiveling mounting bracket (see chapter 6.2.4 "Fastening via BT-2HF swivel mount"orsee chapter 6.2.5 "Fastening via BT-2SB10 swiveling mounting
brackets")
• Have a suitable tool at hand and mount the safety sensor in accordance with the notices regarding the
mounting locations (see chapter 6.2.1 "Suitable mounting locations").
• If possible, affix safety notice stickers on the mounted safety sensor or device column (included in delivery contents).
After mounting, you can electrically connect (see chapter 7 "Electrical connection"), start up, align (see
chapter 8 "Starting up the device"), and test (see chapter 9.1 "Before the initial start-up and following modifications") the safety sensor.
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Mounting
6.2.1
Suitable mounting locations
Area of application: Mounting
Tester: Technician who mounts the safety sensor
Tab.6.4: Checklist for mounting preparations
Check: Yes No
Do the protective field height and dimensions satisfy the requirements of EN13855?
Is the safety distance to the point of operation maintained (see chapter 6.1.1 "Calculation
of safety distanceS")?
Is the minimum distance to reflective surfaces maintained (see chapter 6.1.4 "Minimum
distance to reflective surfaces")?
Is it impossible for safety sensors that are mounted next to one another to mutually interfere with one another (see chapter 6.1.6 "Preventing mutual interference between adjacent
devices")?
Can the point of operation or the danger zone only be accessed through the protective
field?
Has bypassing the protective field by crawling under, reaching over, or jumping over been
prevented or has corresponding additional distanceCRO in accordance with ENISO13855
been observed?
Is stepping behind the protective device prevented or is mechanical protection available?
Do the transmitter and receiver connections point in the same direction?
Can the transmitter and receiver be fastened in such a way that they cannot be moved
and turned?
Is the safety sensor accessible for testing and replacing?
Is it impossible to actuate the reset button from within the danger zone?
Can the entire danger zone be seen from the installation site of the reset button?
Can reflection caused by the installation site be ruled out?
Also observe the additional SPG-specific information (see chapter 4.6 "Smart Process Gating").
NOTICE
If you answer one of the items on the checklist above with no, the mounting location must be
changed.
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Mounting
a) b) c) d)
6.2.2
Definition of directions of movement
The following terms for alignment movements of the safety sensor around one of its axes are used:
a Sliding: movement along the longitudinal axis
b Turning: movement around the longitudinal axis
c Tilting: lateral turning movement diagonal to the front screen
d Pitching: lateral turning movement in the direction of the front screen
Fig.6.6: Directions of movement during alignment of the safety sensor
6.2.3
Fastening via BT-NC60 sliding blocks
By default, transmitter and receiver are delivered with 2BT-NC60 sliding blocks each in the side slot. This
makes fastening the safety sensor to the machine or system to be safeguarded easy via four M6 screws.
Sliding in the direction of slot to set the height is possible, but turning, tilting and pitching is not.
Fig.6.7: Mounting via sliding blocks BT-NC60
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Mounting
6.2.4
Fastening via BT-2HF swivel mount
With the swivel mount (see chapter 15 "Order guide and accessories"), sold separately, the safety sensor
can be aligned as follows:
• Sliding through the vertical threaded holes in the wall plate of the swivel mount
• Turning by 360° around the longitudinal axis by fixing on the screw-on cone
• Pitching in the direction of the protective field with horizontal threaded holes in the wall mounting
• Tilting around main axis
The wall mounting through threaded holes makes it possible to lift the mounting bracket after the screws
have been loosened over the connection cap. Therefore, the mounting brackets do not need to be removed
from the wall when exchanging the device. Loosening the screws is sufficient.
For increased mechanical loads, mounting brackets are also available in a vibration-damped version
(BT-2HF-S) (see chapter 15 "Order guide and accessories").
6.2.5
Fig.6.8: Mounting via swivel mount BT-2HF
Fastening via BT-2SB10 swiveling mounting brackets
Fig.6.9: Mounting via swiveling mounting brackets BT-2SB10
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Mounting
For larger protective field heights > 900 mm, the use of the BT-2SB10 swiveling mounting brackets is recommended (see chapter 15 "Order guide and accessories"). For increased mechanical requirements, these
are also available as vibration-damped version (BT-2SB10-S). Depending on the installation situation, environmental conditions and protective field length (> 1200 mm), other mounting brackets may also be necessary.
6.2.6
One-sided mounting on the machine table
The safety sensor can be mounted directly on the machine table via an M5 screw on the blind hole in the
end cap. On the other end, a BT-2HF swivel mount can be used, for example, so that turning movements
for alignment are possible despite the fact that the sensor is mounted on one side. The full resolution of the
safety sensor is thus preserved on all points of the protective field down to the machine table.
Fig.6.10: Mounting directly on the machine table
WARNING
Impairment of the protective function due to reflections on the machine table!
Ä Make sure that reflections on the machine table are prevented reliably.
Ä After mounting and every day after that, check the detection capability of the safety sensor
in the entire protective field using a test rod (see chapter 9.3.1 "Checklist – periodically by
the operator").
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7 Electrical connection
WARNING
Faulty electrical connection or improper function selection may result in serious injury!
Ä Only allow qualified persons (see chapter 2.2 "Necessary competencies") to perform the
electrical connection.
Ä Make certain that the safety sensor is protected against overcurrent.
Ä For access guarding, activate the start/restart interlock and make certain that it cannot be
unlocked from within the danger zone.
Ä Select the functions so that the safety sensor can be used as intended (see chapter 2.1 "In-
tended use and foreseeable misuse").
Ä Select the safety-relevant functions for the safety sensor (see chapter 4 "Functions").
Ä Always loop both safety-related switching outputs OSSD1 and OSSD2 into the work circuit
of the machine.
Ä Signal outputs must not be used for switching safety-relevant signals.
NOTICE
SELV/PELV
Ä Acc. to EN60204-1, the external power supply must demonstrate the ability to bridge short-
term mains failures of up to 20ms. The power supply unit must ensure safe mains separation (SELV/PELV) and a current reserve of at least 2A.
Electrical connection
NOTICE
Laying cables!
Ä Lay all connection cables and signal lines within the electrical installation space or perma-
nently in cable ducts.
Ä Lay the cables and lines so that they are protected against external damages.
Ä For further information: see EN ISO 13849-2, Table D.4.
NOTICE
Device connection
Ä Use shielded cables for device connection.
NOTICE
Reset
Pin1 of the receiver is a clocked input and output. It is thus not possible to couple the reset signal with other devices. This can result in an erroneous, automatic reset trigger.
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7.1 Pin assignment transmitter and receiver
2
3
1
4
5
FE
VIN1
1
RNG
4
VIN2
3FE5
-A1
MLCx00T
n.c.
2
Electrical connection
7.1.1
MLC500 transmitter
MLC 500 transmitters are equipped with a 5-pin M12 connector.
Fig.7.1: Pin assignment and connection diagram transmitter
Tab.7.1: Pin assignment transmitter
Pin Core color (CB-M12-xx000E-5GF) Transmitter
1 Brown VIN1 - supply voltage
2 White n.c.
3 Blue VIN2 - supply voltage
4 Black RNG - range
5 Gray FE - functional earth, shield
FE FE - functional earth, shield
The polarity of the supply voltage selects the transmission channel of the transmitter:
• VIN1=+24V, VIN2=0V: transmission channelC1
• VIN1=0V, VIN2=+24V: transmission channelC2
The wiring of pin4 determines the transmitting power and thereby the range:
• Pin4=+24V: standard range
• Pin4=0V or open: reduced range
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Electrical connection
VIN1
1
RNG
4
VIN2
3FE5
-A1
MLCx00T
n.c.
2
+ 24V
FE
0V
+ 24V
FE
0V
1
WH
GY
BU
BN
BK
VIN1
1
RNG
4
VIN2
3FE5
-A1
MLCx00T
+ 24V
FE
0V
+ 24V
FE
0V
2
n.c.
2
WH
GY
BU
BN
BK
VIN2
3
RNG
4
VIN1
1FE5
-A1
MLCx00T
+ 24V
FE
0V
+ 24V
FE
0V
3
n.c.
2
WH
GY
BN
BU
BK
VIN2
3
RNG
4
VIN1
1FE5
-A1
MLCx00T
+ 24V
FE
0V
+ 24V
FE
0V
4
n.c.
2
WH
GY
BN
BU
BK
1 Transmission channel C1, reduced range
2 Transmission channel C1, standard range
3 Transmission channel C2, reduced range
4 Transmission channel C2, standard range
Fig.7.2: Connection examples transmitter
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Electrical connection
3
4
1
7
8
FE
2
6
5
OSSD2
5
OSSD1
8
VIN1
2
IN3
3
VIN2
7
FE
-A1
MLCx30R
IN4
4
IO1
1
IN8
6
7.1.2
MLC530SPG receiver
MLC 530 SPG receivers are equipped with a 8-pin M12 connector.
Fig.7.3: Pin assignment and connection diagram receiver
Tab.7.2: Pin assignment receiver
Pin Core color (CB-M12-xx000E-5GF) Receiver
1 White IO1 - control-input function selection, control-input
reset button, signal output
2 Brown VIN1 - supply voltage
3 Green IN3 - control input
4 Yellow IN4 - control input
5 Gray OSSD1 - safety-related switching output
6 Pink OSSD2 - safety-related switching output
7 Blue VIN2 - supply voltage
8 Red IN8 - control input
FE FE - functional earth, shield
7.2 Operating mode1 (SPG with qualified stop function)
The following functions can be selected via external wiring:
• Timing controlled SPG (see chapter 4.6 "Smart Process Gating")
• Qualified stop function (see chapter 4.6.3 "Operating mode1 (qualified stop)")
• SPG timeout extension to up to 100h (see chapter 4.6.7 "SPG timeout extension")
• Fixed blanking can be taught with position tolerance of ±1beam (see chapter 4.5.1 "Fixed blanking")
Permanent settings which cannot be changed by control signals:
• MaxiScan activated
• Start/restart interlock activated (see chapter 4.1 "Start/restart interlock RES")
NOTICE
Teach blanking by opening the bridge between pin1 and pin8 with a teach key switch and applying a voltage of +24V to pin1 and a voltage of 0V to pin8 (see table below).
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Tab.7.3: Pin assignment operating mode1
0V
PE
bn
-W1
bk
wh
-W2
bu
gn
ye
gy
pk
rd
bu
-W1
gy
bn
-W2
0V
PE
0V
+24V+24V
0V
RES
TH
CS
^ ^
^^
F-SPS
-A1
VIN1
1
n.c.
2
RNG
4
VIN2
3
5
FE
MLC500-T
-A2
MLC530R-SPG Operating Mode 1
IO1
1
VIN2
7
IN3
3
VIN1
2
FE
IN4
4
OSSD1
5
OSSD2
6
IN8
8
1
Electrical connection
Pin Color General
desc.
SPG SPG with
timeout extension
Teaching-in
blanking
SPG restart/
RES
1 White IO1/RES Pin8 (bridge) Pin8 (bridge) 24V (bridge open) 24V
2 Brown VIN1 0V 0V - -
3 Green IN3 CS CS - Antivalent to
Pin4 with
qualified stop
4 Yellow IN4 TH TH - -
5 Gray OSSD1 OSSD1 OSSD1 - -
6 Pink OSSD2 OSSD2 OSSD2 - -
7 Blue VIN2 24V 24V - -
8 Red IN8 Pin1 (bridge) Pin1 (bridge) 0V (bridge open) Pin1 (bridge)
FE - FE FE FE - -
1 Optional teach key switch
Fig.7.4: Operating mode 1: connection example with Smart Process Gating (SPG)
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1
5
4
2
3
1 MLC 500 transmitter
2 MLC 530 SPG receiver
3 Safety Programmable Logic Controller SPLC
4 Connection cable CB-M12-10000E-5GF
5 Connection cable CB-M12-10000E-8GF
Electrical connection
Fig.7.5: Operating mode 1: connection example with Smart Process Gating (SPG)
7.3 Operating mode5
The following functions can be selected via external wiring:
• Timing controlled SPG (see chapter 4.6 "Smart Process Gating")
• SPG timeout extension to up to 100h (see chapter 4.6.7 "SPG timeout extension")
• Fixed blanking can be taught with position tolerance of ±1beam (see chapter 4.5.1 "Fixed blanking")
Permanent settings which cannot be changed by control signals:
• MaxiScan activated.
• Start/restart interlock activated (see chapter 4.1 "Start/restart interlock RES")
NOTICE
Teach blanking by opening the bridge between pin1 and pin4 with a teach key switch and applying a voltage of +24V to pin1 and a voltage of 0V to pin4 (see table below).
Tab.7.4: Pin assignment operating mode5
Pin Color General
desc.
1 White IO1/RES Pin4 (bridge) Pin4 (bridge) 24V (bridge open) 24V
SPG SPG with
timeout extension
Teaching-in
blanking
SPG restart/
RES
2 Brown VIN1 24V 24V - -
3 Green IN3 CS CS - -
4 Yellow IN4 Pin1 (bridge) Pin1 (bridge) 0V (bridge open) Pin1 (bridge)
5 Gray OSSD1 OSSD1 OSSD1 - -
6 Pink OSSD2 OSSD2 OSSD2 - -
7 Blue VIN2 0V 0V - -
8 Red IN8 TH TH - -
FE - FE FE FE - -
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Electrical connection
+24V
0V
+24V
0V
0V
PE
0V
PE
-A1
VIN11n.c.2RNG
4
VIN2
3
5
FE
MLC500-T
-A2
MLC530R-SPG Operating Mode 5
IO1
1
VIN1
2
LS IN3
3
VIN2
7
FE
IN4
4
OSSD15OSSD2
6
TH IN8
8
RES
bn
-W1
bk
CS
TH
SPS
wh
-W2
bn
gn
ye
gy
pk
rd
bu
-W1
gy
bu
-W2
Safety relay
1
1 Optional teach key switch
Fig.7.6: Operating mode 5: circuit diagram example with Smart Process Gating (SPG)
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1
5
4
2
3
1 MLC 500 transmitter
2 MLC 530 SPG receiver
3 Control PLC
4 Connection cable CB-M12-10000E-5GF
5 Connection cable CB-M12-10000E-8GF
Electrical connection
Fig.7.7: Operating mode 5: connection example with Smart Process Gating (SPG)
7.4 Operating mode 6 (partial gating)
The following functions can be selected via external wiring:
• Timing controlled SPG (see chapter 4.6 "Smart Process Gating")
• Qualified stop function (see chapter 4.6.3 "Operating mode1 (qualified stop)")
• SPG timeout extension to up to 100h (see chapter 4.6.7 "SPG timeout extension")
• Fixed blanking can be taught with position tolerance of ±1beam (see chapter 4.5.1 "Fixed blanking")
Permanent settings which cannot be changed by control signals:
• MaxiScan activated
• Start/restart interlock activated (see chapter 4.1 "Start/restart interlock RES")
NOTICE
Teach blanking by opening the bridge between pin1 and pin3 with a teach key switch and applying a voltage of +24V to pin1 and a voltage of 0V to pin3 (see table below).
Tab.7.5: Pin assignment operating mode6
Pin Color General
desc.
SPG SPG with timeout ex-
tension
Teaching-in
blanking
SPG restart/
RE
1 White IO1 PIN3 (bridge) PIN3 (bridge) 24V (bridge
24V
open)
2 Brown VIN1 24V 24V - -
3 Green IN3 PIN1 (bridge) PIN1 (bridge) 0V (bridge
open)
4 Yellow IN4 CS CS - -
PIN1
(bridge)
5 Gray OSSD1 OSSD1 OSSD1 - -
6 Pink OSSD2 OSSD2 OSSD2 - -
7 Blue VIN2 0V 0V - -
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Electrical connection
-RES
OSSD2
F PLC
3
+24V
FE
5
-W2
0V
83
gy
6
0V
0V
ye-W1
electronic
IN3
IN8
CS
-A3
-W1
FE
4
-A1
0V
1
bl
n.c.
OSSD1
bk
PE
1
-W2 rd
5
-A2
VIN1
VIN1
MLC530-R SPG Operating Mode 6
MLC500-T
IN4
IO1
Leuze
+24V
Leuze
bl
VIN2
wh
SH
72
VIN2
2
SH
br gn
TH
gy
PE
4
pk
RNG
br
OSSD1
electronic
1
OSSD2
Pin Color General
desc.
SPG SPG with timeout ex-
tension
Teaching-in
blanking
8 Red IN8 TH TH - -
FE - FE FE FE - -
SPG restart/
RE
1 Optional teach key switch
Fig.7.8: Operating mode 6: circuit diagram example with Smart Process Gating (SPG)
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8 Starting up the device
WARNING
Improper use of the safety sensor may result in serious injury!
Ä Make certain that the entire device and the integration of the optoelectronic protective de-
vice were inspected by qualified and instructed persons (see chapter 2.2 "Necessary competencies").
Ä Make certain that a dangerous process can only be started while the safety sensor is
switched on.
Prerequisites:
• Safety sensor mounted (see chapter 6 "Mounting") and connected (see chapter 7 "Electrical connection") correctly
• Operating personnel were instructed in proper use
• Dangerous process is switched off, outputs of the safety sensor are disconnected, and the system is
protected against being switched back on
Ä After start-up, check the function of the safety sensor (see chapter 9.1 "Before the initial start-up and
following modifications").
Starting up the device
8.1 Switching on
Requirements for the supply voltage (power supply unit):
• Reliable mains separation is ensured.
• Current reserve of at least 2A is available.
• The RES function is activated - either in the safety sensor or in the downstream control.
Ä Switch on the safety sensor.
ð The safety sensor performs a self test and then displays the response time of the receiver.
Check operational readiness of sensor
Ä Check whether LED2 illuminates yellow constantly (see chapter 3.4.2 "Operating indicators on the
MLC530SPG receiver").
ð The safety sensor is ready to be unlocked.
8.2 Aligning the sensor
NOTICE
Faulty or incorrect alignment may result in an operating fault!
Ä The alignment performed during start-up should only be performed by qualified persons (see
chapter 2.2 "Necessary competencies").
Ä Observe the data sheets and mounting instructions of the individual components.
Prealignment
Fasten the transmitter and receiver in a vertical or horizontal position and at the same height so that
• the front screens are directed at each other.
• the transmitter and receiver connections point in the same direction.
• the transmitter and receiver are arranged parallel to each other, i.e. they are the same distance from
each other at the beginning and end of the device.
Alignment can be performed with a clear protective field by observing the LEDs and the 7-segment display
(see chapter 3.4 "Display elements").
Leuze electronic MLC 530 SPG 59
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Ä Loosen the screws on the mounting brackets or device columns.
NOTICE
Loosen the screws only enough so that the devices can just be moved.
Ä Turn the transmitter and receiver toward one another so that LED2 on the receiver just illuminates yel-
low and does not switch off (see chapter 3.4.2 "Operating indicators on the MLC530SPG receiver").
ð The receiver with activated alignment display shows flashing segments in the 7-segment display.
Ä Tighten the fastening screws on the mounting brackets or device columns.
NOTICE
Separate alignment aids such as the AC-ALM are also available as accessories.
8.3 Acknowledgement button
NOTICE
Starting up the device
8.3.1
Reset
Pin1 of the receiver is a clocked input and output. It is thus not possible to couple the reset signal with other devices. This can result in an erroneous, automatic reset trigger.
Unlocking start/restart interlock
With the acknowledgement button, the start/restart interlock can be unlocked or an SPG restart or override
triggered (see chapter 4.6 "Smart Process Gating"). In this way, the responsible person can restore the ON
state of the safety sensor following process interruptions (due to triggering of protective function, failure of
the voltage supply, SPG error) (see chapter 4.6.9 "SPG restart").
WARNING
Premature unlocking of the start/restart interlock may result in serious injury!
If the start/restart interlock is unlocked, the system can start up automatically.
Ä Before unlocking the start/restart interlock, make certain that no people are in the danger
zone.
The red LED of the receiver illuminates as long as the restart is locked (OSSD off). The yellow LED illuminates when the protective field is free and RES is activated (ready to be unlocked).
Ä Make certain that the active protective field is clear.
Ä Make certain that there are no people in the danger zone.
Ä Press and release the reset button within 0.15 to 4s. The receiver switches to the ON state.
If you keep the reset button pressed longer than 4s:
• Starting at 4s: the reset request is ignored.
• Starting at 30s: a +24V short circuit is assumed on the reset input and the receiver switches to the interlock state (see chapter 11.1 "What to do in case of failure?").
NOTICE
An individual acknowledgement unit must be provided for each MLC 530 receiver.
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Starting up the device
8.3.2
SPG restart and override
In the event of an error in the SPG sequence (e.g.: timeout, failure of the supply voltage, sequence error,
etc.), the SPG function can be triggered manually and the system started even with light axes of the safety
sensor interrupted. Interfering objects can thereby again be cleared. A CS switching signal must be
present. In operating modes 1 and 6, the antivalent TH signal is to be applied in addition to the CS switching signal.
WARNING
Premature unlocking of the start/restart interlock may result in serious injury!
If the start/restart interlock is unlocked, the system can start up automatically.
Ä Before unlocking the start/restart interlock, make certain that the cause of locking (e.g., se-
quence error) has been rectified.
Ä Before unlocking the start/restart interlock, make certain that no people are in the danger
zone.
Depending on whether or not the synchronization beams are occupied, an SPG restart (see chapter 4.6.9
"SPG restart") or override (see chapter 4.6.10 "Override") is to be performed.
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8.4 Teaching of fixed blanking areas
1
2
3
4
Objects for "fixed blanking" cannot change their position during the teach event. The object must have a
minimum size corresponding to the physical resolution of the AOPD. Teaching is done in the following
steps:
• Initiating by actuating and releasing the teach key switch
• Accepting by actuating and releasing the teach key switch after 60s or less.
A new teach event deletes the previously taught state. If the “Fixed blanking” function is to be deselected,
this can be done by teaching a free protective field.
Starting up the device
1 Initial situation
2 Bring objects into the protective field
3 Start teaching - activate and release key switch
4 End teaching - activate and release key switch
Fig.8.1: Teaching of fixed blanking areas
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9 Testing
NOTICE
Ä Safety sensors must be replaced at the end of their mission time (see chapter 14 "Technical
data").
Ä Always exchange entire safety sensors.
Ä Observe any nationally applicable regulations regarding the tests.
Ä Document all tests in a comprehensible manner and include the configuration of the safety
sensor along with the data for the safety- and minimum distances in the documentation.
9.1 Before the initial start-up and following modifications
WARNING
Unpredictable machine behavior during initial start-up may result in serious injury!
Ä Make certain that there are no people in the danger zone.
Ä Before they begin work, train the operators on their respective tasks. The training is the responsibility of
the operating company.
Ä Attach notes regarding daily testing in the respective national language of the operator on the machine
in a highly visible location, e.g. by printing out the corresponding chapter (see chapter 9.3 "Periodically
by the operator").
Ä Test the electrical function and installation according to this document.
Acc. to IEC/TS62046 and national regulations (e.g. EU directive2009/104/EC), tests are to be performed
by qualified persons (see chapter 2.2 "Necessary competencies") in the following situations:
• Prior to initial commissioning
• Following modifications to the machine
• After longer machine downtime
• Following retrofitting or new configuration of the machine
Ä As preparation, check the most important criteria for the safety sensor according to the following check-
list (see chapter 9.1.1 "Checklist for integrator – to be performed prior to the initial start-up and following
modifications"). Completing the checklist does not replace testing by a qualified person (see chapter
2.2 "Necessary competencies")!
ð Not until proper function of the safety sensor is ascertained may it be integrated in the control circuit of
the system.
Testing
9.1.1
Leuze electronic MLC 530 SPG 63
Checklist for integrator – to be performed prior to the initial start-up and following modifications
NOTICE
Completing the checklist does not replace testing by a qualified person (see chapter 2.2
"Necessary competencies")!
Ä If you answer one of the items on the following check list with no, the machine must no
longer be operated.
Ä IEC/TS62046 contains additional recommendations on testing protective devices
Page 64
Testing
Tab.9.1: Checklist for integrator – to be performed prior to the initial start-up and following modifications
Check: Yes No not ap-
plicable
Is the safety sensor operated acc. to the specific environmental conditions that are to be maintained (see chapter 14 "Technical data")?
Is the safety sensor correctly aligned and are all fastening screws and
connectors secure?
Are safety sensor, connection cables, connectors, protection caps and
command devices undamaged and without any sign of manipulation?
Does the safety sensor satisfy the required safety level (PL, SIL, category)?
Are both safety-related switching outputs (OSSDs) integrated in the
downstream machine control acc. to the required safety category?
Are switching elements that are controlled by the safety sensor monitored according to the required safety level (PL, SIL, category) (e.g.,
contactors through EDM)?
Are all points of operation near the safety sensor accessible only
through the protective field of the safety sensor?
Are the necessary additional protective devices in the immediate surroundings (e.g., safety guard) properly mounted and secured against
tampering?
If it is possible to be present undetected between the safety sensor and
point of operation: is an assigned start/restart interlock functional?
Is the command device for unlocking the start/restart interlock mounted
in such a way that it cannot be reached from within the danger zone
and so that the complete danger zone can be seen from the installation
location?
Has the maximum stopping time of the machine been measured and
documented?
Is the required safety distance maintained?
Does interruption with a test object intended for this purpose cause the
dangerous movement(s) to stop?
Is the safety sensor effective during the entire dangerous movement(s)?
Is the safety sensor effective in all relevant operating modes of the machine?
Is start-up of dangerous movements reliably prevented if an active light
beam or the protective field is interrupted with a test object intended for
this purpose?
Was the sensor detection capacity successfully tested (see chapter
9.3.1 "Checklist – periodically by the operator")?
Were distances to reflective surfaces taken into account during configuration and no reflection bypasses subsequently detected?
Are notices for regular testing of the safety sensor legible to the operator and are they located in a highly visible location?
Are changes to the safety function (e.g.: blanking, protective field
switchover) not easy to achieve through tampering?
Are settings that could result in an unsafe state possible only by means
of key, password or tool?
Are there incentives that pose stimulus for tampering?
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Check: Yes No not ap-
Were the operators instructed prior to starting work?
Does switching signal CS >200mm no longer apply before the protective field?
Does switching signal CS >200mm no longer apply after the protective field has been cleared?
Are the top or bottom beam uninterrupted?
Are CS signals (or TH, if applicable) being generated by the control?
Is the CS switching signal difficult to manipulate?
Does the pendulum flap (see chapter 4.6.5 "operating mode6") prevent access?
9.2 Regularly by qualified persons
The reliable interaction of safety sensor and machine must be regularly tested by qualified persons (see
chapter 2.2 "Necessary competencies") in order to detect changes to the machine or impermissible tampering with the safety sensor.
Acc. to IEC/TS 62046 and national regulations (e.g., EU directive 2009/104/EC), tests of elements which
are subject to wear must be performed by qualified persons (see chapter 2.2 "Necessary competencies") at
regular intervals. Testing intervals may be regulated by nationally applicable regulations (recommendation
acc. to IEC/TS62046: 6months).
Ä Only allow testing to be performed by qualified persons (see chapter 2.2 "Necessary competencies").
Ä Observe the nationally applicable regulations and the time periods specified therein.
Ä As preparation, observe the checklist (see chapter 9.1 "Before the initial start-up and following modifi-
cations").
Testing
plicable
9.3 Periodically by the operator
The function of the safety sensor must be checked depending on the given risk according to the following
checklist so that damages or prohibited tampering can be detected.
Depending on the risk assessment, the test cycle must be defined by the integrator or operating company
(e.g., daily, on shift changes, ...) or is specified by national regulations or regulations of the employer's liability insurance association and may be dependent on the machine type.
Due to complex machines and processes, it may be necessary under certain circumstances to check some
points at longer time intervals. Observe the classification in “Test at least” and “Test when possible”.
NOTICE
For larger distances between transmitter and receiver and when using deflecting mirrors, a second person may be necessary.
WARNING
Unpredictable machine behavior during the test may result in serious injury!
Ä Make certain that there are no people in the danger zone.
Ä Before they begin work, train the operators on their respective tasks and provide suitable
test objects and an appropriate test instruction.
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Testing
9.3.1
Checklist – periodically by the operator
NOTICE
Ä If you answer one of the items on the following check list with no, the machine must no
longer be operated.
Tab.9.2: Checklist – regular function test by trained operators/persons
Test at least: Yes No
Are safety sensor and connectors securely mounted and free of obvious signs of damage,
changes or tampering?
Were no obvious changes made to access or entry possibilities?
Test the effectiveness of the safety sensor:
• The LED1 on the safety sensor must illuminate green (see chapter 3.4.2 "Operating
indicators on the MLC530SPG receiver").
• Interrupt an active beam or the protective field (see figure) with a suitable, opaque test
object:
Checking the protective field function with test rod (only for safety light curtains with a res-
olution of 14…40mm). For light curtains with different resolution ranges, this check is to
be performed separately for each resolution range in an analogous way.
• Does the OSSD LED on the receiver illuminate constantly red while the protective field
is interrupted?
When possible, test during running operation: Yes No
Protective device with approach function: during machine operation, the protective field is
interrupted with the test object – are the obviously dangerous machine parts stopped without noticeable delay?
Protective device with presence detection: the protective field is interrupted with the test
object – does this prevent operation of the obviously dangerous machine parts?
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10 Maintenance
NOTICE
Faulty operation if transmitter and receiver are soiled!
The surfaces of the front screen of transmitters, receivers and, where applicable, deflecting mirror must not be scratched or roughened at the positions where beams enter and exit.
Ä Do not use chemical cleaners.
Prerequisites for cleaning:
• The system is safely shut down and protected against restart.
Ä Clean the safety sensor periodically depending on the degree of contamination.
NOTICE
Prevent electrostatic charging of the front screens!
Ä To clean the front screens of transmitter and receiver, use only damp cloths.
Maintenance
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11 Troubleshooting
11.1 What to do in case of failure?
After switching the safety sensor on, the display elements (see chapter 3.4 "Display elements") assist in
checking the correct functionality and in faultfinding.
In case of failure, you can determine the fault from the LED displays or read a message from the 7-segment display. With the error message you can determine the cause of the error and initiate measures to
rectify it.
NOTICE
If the safety sensor responds with an error display, you will often be able to eliminate the
cause yourself!
Ä Switch off the machine and leave it switched off.
Ä Analyze and eliminate the cause of the fault using the following table.
Ä If you are unable to rectify the fault, contact the Leuze electronic branch responsible for you
or call the Leuze electronic customer service (see chapter 13 "Service and support").
11.2 Operating indicators of the LEDs
Troubleshooting
Tab.11.1: LED indicators at the transmitter - causes and measures
LED State Cause Measure
LED1 OFF Transmitter without supply
voltage
Red Device failed Replace the device.
Check the power supply unit and the electrical connection. Exchange the power
supply unit, if applicable.
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Tab.11.2: LED indicators at the receiver - causes and measures
LED State Cause Measure
LED1 OFF Device failed Replace the device.
Troubleshooting
Red
(7-segment display
during start-up: “C1”
or “C2” according to
the number of green
LEDS on the transmitter)
Red
(7-segment display
during start-up: “C1”.
LEDs on transmitter:
both green)
Red
(7-segment display
during start-up: “C2”.
LED1 on transmitter:
green)
Red, flashing slowly,
approx.1Hz
(7-segment display
“Exy”)
Red, flashing fast,
approx.10Hz
(7-segment display
“Fxy”)
Alignment incorrect or protective field interrupted
Remove all objects from the protective
field. Align the transmitter and receiver to
each other or place blanked objects correctly concerning size and position.
Receiver is set on C1,
transmitter on C2
Set the transmitter and receiver on the
same transmission channel and align both
correctly.
Receiver is set on C2,
transmitter on C1
Set the transmitter and receiver on the
same transmission channel and align both
correctly.
External error Check the connection of the cables and
the control signals.
Internal error If restart fails, exchange the device.
LED2 Yellow OSSD off Start/restart interlock is
locked and protective field is
free - ready for unlocking
LED3 Blue, quickly flashing Teach-in error or SPG condi-
tion violated
Blue, very quickly
flashing
Teaching of blankings still
active
11.3 Error messages 7-segment display
Tab.11.3: Messages of the 7-segment display (F:internal device error, E:external error, U:usage info during appli-
cation errors)
Error Cause/description Measures Sensor behavior
F[No. 0-255] Internal error In the event of an unsuccessful
OFF Very high overvoltage (±40V) Supply the device with the correct
Flashing Weak signal display Check the alignment or clean the
E01 Cross connection between
OSSD1 and OSSD2
If there are no people in the danger zone,
operate the reset button.
Re-teach the blanking areas or check the
SPG prerequisites.
Press the teach button again.
restart, contact customer service.
voltage.
front screens.
Check the wiring between OSSD1
and OSSD2.
OSSD switches off
E02 Overload on OSSD1 Check the wiring or exchange the
OSSD switches off
connected component (reducing
the load).
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Troubleshooting
Error Cause/description Measures Sensor behavior
E03 Overload on OSSD2 Check the wiring or exchange the
connected component (reducing
the load).
E04 High-impedance short circuit to
VCC OSSD1
E05 High-impedance short circuit to
VCC OSSD2
E06 Short circuit against GND at
OSSD1
E07 Short circuit against +24V at
OSSD1
E08 Short circuit against GND at
OSSD2
E09 Short circuit against +24V at
OSSD2
Check the wiring. Exchange the
cable, if applicable.
Check the wiring. Exchange the
cable, if applicable.
Check the wiring. Exchange the
cable, if applicable.
Check the wiring. Exchange the
cable, if applicable.
Check the wiring. Exchange the
cable, if applicable.
Check the wiring. Exchange the
cable, if applicable.
E10, E11 OSSD error, source unknown Check the wiring. Exchange the
cable and the receiver if necessary.
E14 Undervoltage (<+15V) Supply the device with the correct
voltage.
E15 Overvoltage (>+32V) Supply the device with the correct
voltage.
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
OSSD switches off
E16 Overvoltage (>+40V) Supply the device with the correct
voltage.
E18 Ambient temperature too high Ensure correct environmental con-
ditions
E19 Ambient temperature too low Ensure correct environmental con-
ditions
E22 Interference detected on plug
Check the wiring. OSSD switches off
pin3. Signal output: output signal is not equal to the signal input read-back value: it
switches simultaneously with
the other signal line.
E23 Interference detected on plug
Check the wiring. OSSD switches off
pin4. Signal output: output signal is not equal to the signal input read-back value: it
switches simultaneously with
the other signal line.
E24 Interference detected on plug
Check the wiring. OSSD switches off
pin8. Signal output: output signal is not equal to the signal input read-back value: it
switches simultaneously with
the other signal line.
Locking
OSSD switches off
OSSD switches off
E39 Actuation duration (2.5min)
exceeded for reset button or
cable short circuited
Leuze electronic MLC 530 SPG 70
Press the reset button. If the
restart is unsuccessful, check the
wiring of the reset button.
OSSD switches off
Page 71
Troubleshooting
Error Cause/description Measures Sensor behavior
E41 Invalid change of operating
mode due to reversal of the
supply voltage polarity during
Check the wiring and programming
of the device which controls this
signal.
Locking
operation
E60 Fault in the beam configuration Repeat the teach event. OSSD switches off
E61 Response time exceeded Reboot. If the problem occurs
OSSD switches off
again, swap out the device.
E62 Blanking areas overlap (teach
Repeat the teach event. OSSD switches off
error)
E64 After initiating the gating se-
Press the RES button OSSD switches off.
quence, the protective field
was interrupted too late (after
4s)
E65 Timeout 1h, elapsed during P-
Press the RES button OSSD switches off.
mode (no protective field violation after applying the CS signal), CS is still high after expiration of this time
E66 CS signal dropped out before
Check CS signal sequence OSSD switches off.
protective field was cleared
again during override
E67 TH signal dropped out before
Check TH signal sequence OSSD switches off.
protective field was cleared
again during override (operating mode1 or 6)
E68 Override timeout of 120s ex-
ceeded. Interlock state assumed after 150s. (>150s)
E69 Simultaneity violation of TH
and CS (>0.5s) (operating
mode1 or 6)
E70 If the protective field is inter-
rupted, CS is no longer active
or sync beams were interrupted for longer than 1min.
E71 Protective field violation before
gating sequence reset
E72 Signal error: CS/TH antiva-
lence violated at the end of the
sequence (operating mode1
or 6)
E73 Signal error: CS/TH antiva-
lence violated on qualified stop
(operating mode1 or 6)
Check wiring or acknowledgment
unit
The OSSD
switches off after
120s, interlock af-
ter 150s; the re-
ceiver must be de-
energized after
about 3min
Check CS/TH signal sequence OSSD switches off.
Check CS signal sequence or rec-
OSSD switches off.
tify interruption of the sync beams
Press the RES button OSSD switches off.
Check CS/TH signal sequence OSSD switches off.
Check CS/TH signal sequence OSSD switches off.
E74 Restart interlock locked
Unlocking restart interlock OSSD switches off.
(OSSD off) before SPG start
(CS is high)
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Troubleshooting
Error Cause/description Measures Sensor behavior
E75 CS applied for longer than 20s
Check CS signal sequence OSSD switches off.
after the end of the SPG sequence
E76 CS was ended before 4s
Check CS signal sequence OSSD switches off.
elapsed (operating mode5)
E77 No protective field violation af-
Check CS signal sequence OSSD switches off.
ter activation of the CS signal
and elapsing of the timeout
(1h) after changing to protective mode and deactivation of
the CS signal
E78 Signal error: CS/TH antiva-
Check CS signal sequence OSSD switches off.
lence violated during initiation/
restart with possible gating
timeout extension (operating
mode1 or 6)
E79 SPG timeout exceeded Timeout or use TH signal OSSD switches off.
E80…E86 Invalid operating mode due to
setting error, general operating
mode change
E87 Operating mode changed Check the wiring. Restart the sen-
E.g. reset button pressed during
start-up, check the circuit diagram
and the wiring and restart.
Locking
Locking
sor.
E90 Error in cascade Please contact customer service if
you are unable to restart the device
E92, E93 Error in the saved transmission
Perform channel switching again. Automatic reset
channel
U53 The protective field was not in-
terrupted within 4s after acti-
Press the RES button and start a
new sequence
vation of the control signal CS
(MLC in P-mode)
U54 Timeout of 1h elapsed during
P-mode (no protective field violation after applying the CS
Check the further processing of
the OSSD signals and the design
of the system.
signal) and CS has switched
back to low before this 1h
elapsed
U61 Teach-in not finished or not fin-
ished correctly
Repeat the teach event. Fixed
blanking: interrupt beams uniquely
or release them.
U62 Simultaneity error of the sig-
nals from the teach button (key
Exchange the teach button (key
switch).
switch). Time difference >4s
U63 2.5min teach timeout ex-
ceeded
Maintain the correct time sequence during teaching.
Locking
Protective mode
OSSD switches off.
OSSD remains off.
OSSD remains off.
OSSD remains off.
U69 Response time after teach-in
Use a device with fewer beams. OSSD remains off.
of floating blanking too long
(>99ms)
U71 Teach data not plausible Repeat the teach event. OSSD remains off.
U74 The reset input has switched
at the same time as a signal
line (cross connection to RES
Eliminate the cross connection between the signal lines and press
the reset button again.
OSSD remains off.
Restart interlock
not reset.
input).
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Troubleshooting
Error Cause/description Measures Sensor behavior
U75 Teach data inconsistent Repeat the teach event. OSSD remains off.
U76 Teaching error Repeat the teach event. Check
whether LED1 on the transmitter
illuminates green.
U80 CS signal already active on
No acknowledgment, display only OSSD remains off.
device startup
U82 Unexpected signals upon
pressing the acknowledgment
button (min. 1 free synchronization beam):
No acknowledgment, display only
Before successful acknowledgment, set CS or TH according to
operating mode.
• Operating mode1 or 6: CS
is not active or TH is active
• Operating mode5: CS is
not active
U83 Unexpected signals upon
pressing the acknowledgment
button (no free synchronization
beam):
No acknowledgment, display only
Before successful acknowledgment, set CS or TH according to
operating mode.
• Operating mode1 or 6: CS
is not active or TH is active
• Operating mode5: CS is
not active
U84 Protective field free for too
long
Check CS signal sequence, reduce gap in transport material
OSSD remains off.
OSSD remains off.
OSSD remains off.
OSSD switches off.
U85 CS signal drop without protec-
tive field violation
U86 One of the top four beams was
interrupted in operating
mode6
Check CS signal sequence OSSD remains on.
Remove object from protective
OSSD switches off.
field and restart the receiver
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12 Disposal
Ä For disposal observe the applicable national regulations regarding electronic components.
Disposal
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13 Service and support
24-hour on-call service at:
+49 7021 573-0
Service hotline:
+49 7021 573-123
E-mail:
service.protect@leuze.de
Return address for repairs:
Servicecenter
Leuze electronic GmbH + Co. KG
InderBraike1
D-73277Owen/Germany
Service and support
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14 Technical data
14.1 General specifications
Tab.14.1: Protective field data
Technical data
Physical resolution [mm]
Operating range [m] Protective field height [mm]
min. max. min. max.
14 0 6 150 3000
20 0 15 150 3000
30 0 10 150 3000
40 0 20 150 3000
90 0 20 450 3000
Tab.14.2: Safety-relevant technical data
Type in accordance with ENIEC61496 Type4
SIL in accordance with ENIEC61508 SIL3
SILCL in accordance with ENIEC62061 SILCL3
Performance Level (PL) in accordance with ENISO13849-1:2015 PLe
Category in acc. with ENISO13849-1:2015 Cat. 4
Average probability of a failure to danger per hour (PFHd) 7.73x10-91/h
Mission time (TM) 20 years
Tab.14.3: General system data
Connection technology M12, 5-pin (transmitter)
M12, 8-pin (receiver)
Supply voltage Uv, transmitter and receiver +24V, ± 20%, compensation necessary at 20ms
voltage dip, min.250mA (+OSSD load)
Residual ripple of the supply voltage ± 5% within the limits of U
v
Current consumption - transmitter 50mA
Current consumption receiver 150mA (without load)
Common value for ext. fuse in the supply line for
2A semi time-lag
transmitter and receiver
Synchronization Optical between transmitter and receiver
Protection class III
Degree of protection IP 65
Ambient temperature, operation -30…+55°C
Ambient temperature, storage -30…70°C
Ambient temperature, MLC xxx/V operation 0…55°C
Relative humidity (non-condensing) 0…95%
Vibration resistance 50m/s2 acceleration, 10-55 Hz in acc. with
ENIEC60068-2-6; 0.35mm amplitude
Shock resistance 100m/s2 acceleration, 16ms acc. to
ENIEC60068-2-6
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Technical data
Profile cross section 29mmx35.4mm
Dimensions see chapter 14.2 "Dimensions and weights"
Weight see chapter 14.2 "Dimensions and weights"
Tab.14.4: System data - transmitter
Light source LED; exempt group in acc. with EN62471:2008
Wavelength 940 nm
Pulse duration 800 ns
Pulse pause 1.9µs (min.)
Mean power <50µW
Input current pin4 (range) Against +24V: 10mA
Against 0V: 10mA
Tab.14.5: System data receiver, indication signals and control signals
Pin Signal Type Electrical data
1 RES/STATE Input:
Output:
Reaction time:
3, 4, 8 Depending on the oper-
Input: Against 0V: 4mA
ating mode
Tab.14.6: Technical data of the electronic safety-related switching outputs (OSSDs) on the receiver
Safety-related PNP transistor outputs (short-
Minimum Typical Maximum
Against +24V: 10mA
Against 0V: 80mA
100ms
Against +24V: 4mA
circuit monitored, cross-circuit monitored)
Switching voltage high active (Uv-1.5V) 18V 22.5V 27 V
Switching voltage low 0V +2.5V
Switching current 300mA 380mA
Residual current <2µA 200µA
In the event of a
failure (if the 0V
cable is interrupted), each of
the outputs behaves as a
120kΩ resistor
to Uv. A downstream safety
PLC must not detect this as a logical “1”.
Load capacity 0.3µF
Load inductivity 2H
Leuze electronic MLC 530 SPG 77
Page 78
Technical data
B
M12
A
R
R
C
2
9
3
5
,
4
H
PFN
Safety-related PNP transistor outputs (short-
Minimum Typical Maximum
circuit monitored, cross-circuit monitored)
Permissible wire resistance for load <200Ω
Note the additional restrictions
due to cable
length and load
current.
Permissible wire cross section 0.25mm
Permissible cable length between receiver and
2
100m
load
Test pulse width 60μs 340μs
Test pulse distance (5ms) 60 ms
OSSD restart delay time after beam interruption 100ms
NOTICE
The safety-related transistor outputs perform the spark extinction. With transistor outputs, it is
therefore neither necessary nor permitted to use the spark extinction circuits recommended by
contactor or valve manufacturers (RC elements, varistors or recovery diodes), since these considerably extend the decay times of inductive switching elements.
Tab.14.7: Patents
US patents US 6,418,546 B
14.2 Dimensions and weights
Dimensions and weights are dependent on
• the resolution
• the length
Fig.14.1: Dimensions of transmitter and receiver
Effective protective field heightH
goes beyond the dimensions of the optics area to the outer borders of
PFE
the circles labeled with R.
Leuze electronic MLC 530 SPG 78
Page 79
Calculation of the effective protective field height
Technical data
H
PFE
H
PFN
A mm Total height
B mm Additional dimensions for calculation of the effective protective field height (see table below)
C mm Value for calculating the effective protective field height (see tables below)
Tab.14.8: Additional dimensions for calculating the effective protective field height
mm Effective protective field height
mm Rated protective field height, this corresponds to the length of the yellow housing part (see tables
below)
R=resolution B C
30mm 19mm 9mm
40mm 25mm 15mm
90mm 50mm 40mm
Tab.14.9: Dimensions (nominal protective field heights) and weights
Device type Transmitter and receiver
Dimensions [mm] Weight [kg]
Type H
PFN
A
MLC…-150 150 216 0.30
MLC…-225 225 291 0.37
MLC…-300 300 366 0.45
MLC…-450 450 516 0.60
MLC…-600 600 666 0.75
MLC…-750 750 816 0.90
MLC…-900 900 966 1.05
MLC…-1050 1050 1116 1.20
MLC…-1200 1200 1266 1.35
MLC…-1350 1350 1416 1.50
MLC…-1500 1500 1566 1.65
MLC…-1650 1650 1716 1.80
MLC…-1800 1800 1866 1.95
MLC…-1950 1950 2016 2.10
MLC…-2100 2100 2166 2.25
MLC…-2250 2250 2316 2.40
MLC…-2400 2400 2466 2.55
MLC…-2550 2550 2616 2.70
MLC…-2700 2700 2766 2.85
MLC…-2850 2850 2916 3.00
MLC…-3000 3000 3066 3.15
Leuze electronic MLC 530 SPG 79
Page 80
Devices with different resolution ranges
59,5
301
39
16
29
12
R10
R3.1
4
R6
R3.1
R10
30
12
R3.1
18.4
31.7
In addition to device model, models with different resolution ranges are also available.
Integrated in the protective field here is a 300-mm-long area with 14 mm resolution.
Tab.14.10: Dimensions and weight (models with different resolution ranges)
Device type Transmitter and receiver
Dimensions [mm] Weight [kg]
Technical data
Type H
PFN
MLC…-14300/301800 2100 2166 2.25
MLC…-14300/901800 2100 2166 2.25
MLC…-14300/902250 2550 2316 2.4
Fig.14.2: Position of resolution limits; the change in resolution takes place at the marked position.
14.3 Dimensioned drawings: Accessories
A
Leuze electronic MLC 530 SPG 80
Fig.14.3: BT-L mounting bracket
Page 81
73
61
6.2
6.2
R3.1
R10
R10
22
10
R3.1
10.8
4
25
12.1
Fig.14.4: BT-Z parallel bracket
20
8,2
34
9
,
1
2
3
,
7
5
4
1
,
2
2
8
,
3
Ø 6,2
8
3
7
5
7
18Ø
28
Ø
4
2
,
3
1
2
,
7
5
9
,
1
Ø 6,2
8,2
20
34
8
2
9
,
4
5
3
7
5
7
18Ø
28
Ø
Technical data
Fig.14.5: Swivel mount BT-2HF
Leuze electronic MLC 530 SPG 81
Page 82
Technical data
20
8
5
0
20,5
39
6
0
Ø 5,3 (2x)
Ø 5,3 (2x)
3
4
Fig.14.6: Swiveling mounting bracket BT-2SB10
Leuze electronic MLC 530 SPG 82
Page 83
15 Order guide and accessories
Nomenclature
Part designation:
MLCxyy-za-hhhhei-ooo
Part designation for devices with different resolution ranges
MLC5yyzahhh/ahhhh-ooo
Tab.15.1: Part number code
MLC Safety sensor
x Series: 3 for MLC300
x Series: 5 for MLC500
yy Function classes:
00: Transmitter
01: Transmitter
02: Transmitter with test input
10: Basic receiver - automatic restart
11: Basic receiver - automatic restart
20: Standard receiver - EDM/RES selectable
30: Extended receiver - blanking/muting
Order guide and accessories
z Device type:
T: transmitter
R: receiver
a Resolution:
14: 14mm
20: 20mm
30: 30mm
40: 40mm
90: 90mm
hhhh Protective field height:
150…3000: from 150mm to 3000mm
e Host/Guest (optional):
H: Host
MG: Middle Guest
G: Guest
i Interface (optional):
/A: AS-i
ooo Option:
EX2: explosion protection (zones 2 + 22)
/V: high Vibration-proof
SPG: Smart Process Gating
Leuze electronic MLC 530 SPG 83
Page 84
Tab.15.2: Part descriptions, examples
Order guide and accessories
Examples for part desig-
Properties
nation
MLC500T14-600 Type4 transmitter, PLe, SIL3, resolution 14mm, protective field height
600mm
MLC500T30-900 Type4 transmitter, PLe, SIL3, resolution 30mm, protective field height
900mm
MLC530R90-1500-SPG Type4 Extended receiver, Smart Process Gating, PLe, SIL3, resolution
90mm, protective field height 1500mm
MLC530R14300/901800SPG
Extended receiver, Smart Process Gating. Type4, PLe, SIL3, resolution
14mm, protective field height 300mm and resolution 90mm, protective field
height 1800mm
Scope of delivery
• Transmitter including 2sliding blocks, 1instruction sheet
• Receiver including 2sliding blocks, 1self-adhesive notice sign “Important notices and notices for the
machine operator”, 1set of connecting and operating instructions (PDF file on CD-ROM)
Tab.15.3: Part numbers of MLC 500 transmitter depending on resolution and protective field height
Protective field height
hhhh [mm]
30mm
MLC500T30-hhhh
40mm
MLC500T40-hhhh
90mm
MLC500T90-hhhh
150 68000301 68000401 -
225 68000302 68000402 -
300 68000303 68000403 -
450 68000304 68000404 68000904
600 68000306 68000406 68000906
750 68000307 68000407 68000907
900 68000309 68000409 68000909
1050 68000310 68000410 68000910
1200 68000312 68000412 68000912
1350 68000313 68000413 68000913
1500 68000315 68000415 68000915
1650 68000316 68000416 68000916
1800 68000318 68000418 68000918
1950 68000319 68000419 68000919
2100 68000321 68000421 68000921
2250 68000322 68000422 68000922
2400 68000324 68000424 68000924
2550 68000325 68000425 68000925
2700 68000327 68000427 68000927
2850 68000328 68000428 68000928
3000 68000330 68000430 68000930
Leuze electronic MLC 530 SPG 84
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Order guide and accessories
Tab.15.4: Example part numbers for transmitters with different resolution ranges
Part no. Designation Resolution 1 Resolution 2 Protective field
length 2
68096002 ML-
14 30 1800
C500T14300/30180
0
68096005 ML-
14 90 1800
C500T14300/90180
0
68096003 ML-
14 90 2250
C500T14300/90225
0
Tab.15.5: Part numbers of MLC 530 SPG receiver depending on resolution and protective field height
Protective field height
hhhh [mm]
30mm
MLC530R30-hhhh-SPG
40mm
MLC530R40-hhhh-SPG
90mm
MLC530R90-hhhh-SPG
150 68009301 68009401 -
225 68009302 68009402 -
300 68009303 68009403 -
450 68009304 68009404 68009904
600 68009306 68009406 68009906
750 68009307 68009407 68009907
900 68009309 68009409 68009909
1050 68009310 68009410 68009910
1200 68009312 68009412 68009912
1350 68009313 68009413 68009913
1500 68009315 68009415 68009915
1650 68009316 68009416 68009916
1800 68009318 68009418 68009918
1950 68009319 68009419 68009919
2100 68009321 68009421 68009921
2250 68009322 68009422 68009922
2400 68009324 68009424 68009924
2550 68009325 68009425 68009925
2700 68009327 68009427 68009927
2850 68009328 68009428 68009928
3000 68009330 68009430 68009930
Leuze electronic MLC 530 SPG 85
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Order guide and accessories
Tab.15.6: Example part numbers for receivers with different resolution ranges
Part no. Designation Resolution 1 Resolution 2 Protective field
length 2
68096000 ML-
14 30 1800
C530R14300/3018
00-SPG
68096004 ML-
14 90 1800
C530R14300/9018
00-SPG
68096001 ML-
14 90 2250
C530R14300/9022
50S-SPG
Tab.15.7: Accessories
Part no. Article Description
Connection cables for MLC 500 transmitter, shielded
50133860 KD S-M12-5A-P1-050 Connection cable, 5-pin, 5m long
50133861 KD S-M12-5A-P1-100 Connection cable, 5-pin, 10m long
678057 CB-M12-15000E-5GF Connection cable, 5-pin, 15m long
678058 CB-M12-25000E-5GF Connection cable, 5-pin, 25m long
Connection cables for MLC 530 SPG receiver, shielded
50135128 KD S-M12-8A-P1-050 Connection cable, 8-pin, 5m long
50135129 KD S-M12-8A-P1-100 Connection cable, 8-pin, 10m long
50135130 KD S-M12-8A-P1-150 Connection cable, 8-pin, 15m long
50135131 KD S-M12-8A-P1-250 Connection cable, 8-pin, 25m long
User-configurable connectors for MLC 500 transmitter
429175 CB-M12-5GF Cable socket, 5-pin, metal housing, shield on
housing
User-configurable connectors for MLC 530 SPG receiver
429178 CB-M12-8GF Cable socket, 8-pin, metal housing, shield on
housing
Sensor connection modules
520160 AC-SCM8U Sensor connection module for control and display
units and operational controls with 4 M12x5 sockets and one M12x8 plug
520162 AC-SCM8U-BT-L Sensor connection module for control and display
units and operational controls incl. retaining plate
and mounting devices
Display and confirmation units
426363 AC-ABF-SL1 Display and confirmation unit
426290 AC-ABF10 Display and confirmation unit
426296 AC-ABF70 Display and confirmation unit, 2x connection cable
M12
Leuze electronic MLC 530 SPG 86
Page 87
Order guide and accessories
Part no. Article Description
Mounting technology
429056 BT-2L L mounting bracket, 2x
429057 BT-2Z Z mounting bracket, 2x
429393 BT-2HF 360° swivel mount, 2x incl. 1MLC cylinder
429394 BT-2HF-S 360° swivel mount, vibration-damped, 2x incl.
1MLCcylinder
424422 BT-2SB10 Swiveling mounting bracket for groove mounting,
±8°, 2x
424423 BT-2SB10-S Swiveling mounting bracket for groove mounting,
±8°, vibration damped, 2x
425740 BT-10NC60 Sliding block with M6 thread, 10x
425741 BT-10NC64 Sliding block with M6 and M4 thread, 10x
425742 BT-10NC65 Sliding block with M6 and M5 thread, 10x
Device columns
549855 UDC-900-S2 Device column, U-shaped, profile height 900mm
549856 UDC-1000-S2 Device column, U-shaped, profile height 1000mm
549852 UDC-1300-S2 Device column, U-shaped, profile height 1300mm
549853 UDC-1600-S2 Device column, U-shaped, profile height 1600mm
549854 UDC-1900-S2 Device column, U-shaped, profile height 1900mm
549857 UDC-2500-S2 Device column, U-shaped, profile height 2500mm
Deflecting mirror columns
549780 UMC-1000-S2 Continuous deflecting mirror column 1000mm
549781 UMC-1300-S2 Continuous deflecting mirror column 1300mm
549782 UMC-1600-S2 Continuous deflecting mirror column 1600mm
549783 UMC-1900-S2 Continuous deflecting mirror column 1900mm
Deflecting mirror
529601 UM60-150 Deflecting mirror, mirror length 210mm
529603 UM60-300 Deflecting mirror, mirror length 360mm
529604 UM60-450 Deflecting mirror, mirror length 510mm
529606 UM60-600 Deflecting mirror, mirror length 660mm
529607 UM60-750 Deflecting mirror, mirror length 810mm
529609 UM60-900 Deflecting mirror, mirror length 960mm
529610 UM60-1050 Deflecting mirror, mirror length 1110mm
529612 UM60-1200 Deflecting mirror, mirror length 1260mm
529613 UM60-1350 Deflecting mirror, mirror length 1410mm
529615 UM60-1500 Deflecting mirror, mirror length 1560mm
529616 UM60-1650 Deflecting mirror, mirror length 1710mm
529618 UM60-1800 Deflecting mirror, mirror length 1860mm
430105 BT-2UM60 Mounting bracket for UM60, 2x
Leuze electronic MLC 530 SPG 87
Page 88
Order guide and accessories
Part no. Article Description
Protective screens
347070 MLC-PS150 Protective screen, length 148mm
347071 MLC-PS225 Protective screen, length 223mm
347072 MLC-PS300 Protective screen, length 298mm
347073 MLC-PS450 Protective screen, length 448mm
347074 MLC-PS600 Protective screen, length 598mm
347075 MLC-PS750 Protective screen, length 748mm
347076 MLC-PS900 Protective screen, length 898mm
347077 MLC-PS1050 Protective screen, length 1048mm
347078 MLC-PS1200 Protective screen, length 1198mm
347079 MLC-PS1350 Protective screen, length 1348mm
347080 MLC-PS1500 Protective screen, length 1498mm
347081 MLC-PS1650 Protective screen, length 1648mm
347082 MLC-PS1800 Protective screen, length 1798mm
429038 MLC-2PSF Mounting device for MLC protective screen, 2x
429039 MLC-3PSF Mounting device for MLC protective screen, 3x
Muting indicators
548000 MS851 Muting indicator with incandescent lamp
660600 MS70/2 Muting double indicator with incandescent lamp
660611 MS70/LED-M12-2000-4GM LED muting indicator with connection cable 2m
Alignment aids
560020 LA-78U External laser alignment aid
520004 LA-78UDC External laser alignment aid for fastening in De-
vice Column
520101 AC-ALM-M Alignment aid
Test rods
349945 AC-TR14/30 Test rod 14/30mm
349939 AC-TR20/40 Test rod 20/40mm
Leuze electronic MLC 530 SPG 88
Page 89
16 EC Declaration of Conformity
EC Declaration of Conformity
Leuze electronic MLC 530 SPG 89
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