Leuze electronic MLC 520 EX, MLC 502, MLC 510, MLC 511, MLC 510/A Original Operating Instructions
...
MLC 520 EX
Safety Light Curtains
EN 2014/12 - 50127400
We reserve the right to
make technical changes
SAFE IMPLEMENTATION AND OPERATION
Original operating instructions
© 2014
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.de
Leuze electronic MLC 520 EX 2
1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Approved purpose and foreseeable improper operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Notices for the safe use of sensors in potentially explosive areas . . . . . . . . . . . . . . . . . . . 9
3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Device overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Operating indicators on the MLC 520 receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.2 Alignment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Start/restart interlock RES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 EDM contactor monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Transmission channel changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Range reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Point of operation guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Access guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Danger zone guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Arrangement of transmitter and receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.1 Calculation of safety distance S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.2 Calculation of safety distance SRT or SRO if protective fields act orthogonally
to the approach direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.3 Calculation of safety distance S for parallel approach to the protective field . . . . . . . . . . 24
6.1.4 Minimum distance to reflective surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.5 Preventing mutual interference between adjacent devices . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Mounting the safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.1 Suitable mounting locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.2 Definition of directions of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.3 Fastening via BT-NC60 sliding blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.4 Fastening with BT-R swivel mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.5 One-sided mounting on the machine table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Mounting accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.1 Deflecting mirror for multiple-side guarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.1 Pin assignment transmitter and receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.1 MLC 500 transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.2 MLC 520 receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Circuit diagram examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Leuze electronic MLC 520 EX 3
7.2.1 MLC 520 circuit diagram example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8 Starting up the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 Aligning the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.3 Aligning of deflecting mirrors with the laser alignment aid. . . . . . . . . . . . . . . . . . . . . . . . . 38
8.4 Unlocking start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1 Before the initial start-up and following modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1.1 Checklist for integrator – to be performed prior to the initial start-up and
following modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.2 To be performed periodically by competent persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3 Periodically by the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.3.1 Checklist – periodically by the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1 What to do in case of error? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.2 Operating displays of the LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.3 Error messages 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12 Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
14 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
14.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
14.2 Dimensions, weight, response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
14.3 Dimensional drawings: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
15 Ordering information and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
16 EU Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Leuze electronic MLC 520 EX 4
1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Symbol indicating dangers to persons
NOTICE 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 injury
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.
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.
About this document
Table 1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbols for action steps
Text passages with this symbol instruct you to perform actions.
Table 1.3: Terms and abbreviations
AOPD
Active Optoelectronic Protective Device
EDM Contactor monitoring
(External Device Monitoring)
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
OSSD Safety-related switching output
Output Signal Switching Device)
(
PFH
d
Probability of dangerous Failure per Hour
PL
Performance Level
RES
Start/REStart interlock
Scan Consecutive scans of the protective field from the first to the last beam
Leuze electronic MLC 520 EX 5
Safety sensor System consisting of transmitter and receiver
About this document
SIL
State ON: device intact, OSSD switched on
1.2 Checklists
The checklists (see chapter 9) serve as a reference for the machine manufacturer or supplier. They
replace neither testing of the complete machine or system prior to the initial start-up nor their periodic
testing by a competent person. The checklists contain minimum testing requirements. Depending on the
application, other tests may be necessary.
Safety Integrity Level
OFF: device intact, OSSD switched off
Locking: device, connection or control / operation faulty, OSSD switched off
(lock-out)
Leuze electronic MLC 520 EX 6
2 Safety
Before using the safety sensor, a risk assessment must be performed according to valid standards (e.g.
EN ISO 12100, EN ISO 13849-1, IEC 61508, EN IEC 62061). The result of the risk assessment determines the required safety level of the safety sensor . 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.
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 start-up, technical
inspections and work with safety sensors:
• Machinery directive 2006/42/EC
• Low voltage directive 2006/95/EC
• EMC directive 2004/108/EC
• Use of work equipment directive 89/655/EEC supplemented by directive 95/63 EC
• OSHA 1910 Subpart O
• Safety regulations
• Accident-prevention regulations and safety rules
• Industrial safety regulation and employment protection act
• Product safety law (ProdSG)
Safety
For safety-related information you may also contact the local authorities (e.g., industrial inspec-
torate, employer's liability insurance association, labor inspectorate, occupational safety and
health authority).
2.1 Approved purpose and foreseeable improper operation
WARNING
A running machine may result in serious injury!
Make certain that the safety sensor is correctly connected and that the protective function of the pro-
tective device is ensured.
Make certain that, during all conversions, maintenance work and inspections, the system is securely
shut down and protected against being restarted.
Leuze electronic MLC 520 EX 7
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
• When selecting the safety sensor it must be ensured that its safety-related capability meets or
exceeds the required performance level PL
• The safety sensor protects persons or body parts at points of operation, danger zones or access
points of machines and plants.
• 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 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).
• The safety sensor must be exchanged after a maximum of 20 years. Repairs or the exchange of
parts subject to wear and tear do not extend the service life.
competent person (see chapter 2.2).
ascertained in the risk assessment .
r
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
• 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 Competent persons
Prerequisites for competent persons:
• They have a suitable technical education.
• They know the rules and regulations for labor protection, safety at work and safety technology and
can assess the safety of the machine.
• They know the instructions for the safety sensor and the machine.
• They have been instructed by the responsible person on the mounting and operation of the machine
and of the safety sensor.
2.3 Responsibility for safety
Manufacturer and operating company 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.
not suitable as a protective device for use in the following cases:
1
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
• imparting all relevant information to the operating company
• adhering to all regulations and directives for the safe starting-up of the machine
1. They perform a task related to the subject matter shortly thereafter and keep their knowledge up to date through continuous
further training.
Leuze electronic MLC 520 EX 8
The company operating 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
• regular testing by competent persons
2.4 Disclaimer
Leuze electronic GmbH + Co. KG is not liable 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).
• changes (e.g., constructional) are made to the safety sensor.
2.5 Notices for the safe use of sensors in potentially explosive areas
These notices apply for devices with the following classification:
Safety
Table 2.1: Classification of the devices
Device group Device category Equipment protection
level
II 3G Gc 2 (gas)
II 3D Dc 22 (dust)
WARNING
Safe use of sensors in potentially explosive areas!
Check whether the classification of the devices corresponds to the requirements of the application.
Safe operation is only possible if the devices are used properly and for their intended purpose.
Electrical devices may endanger the health of humans and (where applicable) animals and may threaten the safety of goods if used under unfavorable conditions or incorrectly in potentially explosive areas.
Observe the applicable national regulations, especially ATEX directive 94/4/EC and/or EN 60079-14,
for the configuration, commissioning, operation and recurring testing of explosion-proof systems.
Zone
Leuze electronic MLC 520 EX 9
3 Device description
The safety sensors from the MLC 500 series are active opto-electronic protective devices. They satisfy the
following standards:
Type in accordance with EN IEC 61496 4
Category in accordance with EN ISO 13849 4
Performance Level (PL) in accordance with EN ISO 13849-1 e
Device description
MLC 500
Safety Integrity Level (SIL) in accordance with IEC 61508 and SILCL in
accordance with EN IEC 62061
The safety sensors of the MLC 520 EX2 series satisfy the ATEX requirements in accordance with
EN 60079-0, EN 60079-15, EN 60079-28 for category 3G as well as EN 60079-0 and EN 60079-31 for
category 3D.
The safety sensor consists of a transmitter and a receiver (see figure 3.1). It is protected against overvoltage and overcurrent acc. to IEC 60204-1 (safety class 3). Its infrared beams are not influenced by
ambient light (e.g. welding sparks, warning lights).
3.1 Device overview
The series is characterized by three different receiver classes (Basic, Standard, Extended) with certain
features and properties (see table 3.1).
Table 3.1: Device models in the series with specific features and functions
OSSDs (2x)
AS-i
Transmitter Receiver
Basic Standard Extended
MLC 500
MLC 501
MLC 500/A MLC 502 MLC 510
MLC 511
3
MLC 510/A MLC 520 MLC 530
Transmission channel changeover
LED indicators
7-segment display
Automatic start/
restart
RES
EDM
Linkage
Blanking
Muting
Scan mode
Range reduction
Test input
Leuze electronic MLC 520 EX 10
Device description
a
b
b
Protective field properties
The beam distance and the number of beams are dependent on the resolution and protective field height.
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 figure 3.1 and see figure 14.1).
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).
For the correct synchronization and function of the safety sensor, at least one of the two synchro-
nization beams must be free during synchronization and operation.
a Optically active area, housed in yellow
b Synchronization beams
Figure 3.1: Transmitter-receiver system
QR code
A QR code as well as the corresponding web address are located on the safety sensor (see figure 3.2).
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.
Figure 3.2: QR code with corresponding web address (URL) on the safety sensor
Leuze electronic MLC 520 EX 11
3.2 Connection technology
1
3
4
2
5
The transmitter and receiver feature an M12 connector as an interface to the machine control with the
following number of pins:
Device models Device type Device plug
MLC 500 Transmitter 5-pin
MLC 520 Standard receiver 8-pin
3.3 Display elements
The display elements of the safety sensors simplify start-up and fault analysis.
3.3.1 Operating indicators on the MLC 520 receiver
Two LEDs and a 7-segment display for showing the operating state are located on the receiver:
Device description
1 LED1, red/green
2 LED2, yellow
3 OSSD icon
4 RES icon
5 7-segment display
Figure 3.3: Indicators on the MLC 520 receiver
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Table 3.2: Meaning of the LEDs
LED Color State Description
1 Red/green OFF Device switched off
Red OSSD off
Device description
Red slowly flashing
External fault
(approx. 1 Hz)
Red flashing fast
Internal fault
(approx. 10 Hz)
Green slowly flashing
OSSD on, weak signal
(approx. 1 Hz)
Green OSSD on
2 Yellow OFF
• RES deactivated
• or RES activated and enabled
• or RES blocked and protective field interrupted
ON RES activated and blocked but ready to be
unlocked - protective field free
7-segment display at the MLC 520 receiver
In normal operation, the 7-segment display shows the number of the selected transmission channel. In
addition, it helps during the detailed error diagnostics (see chapter 11) and serves as an alignment aid (see
chapter 8.2 "Aligning the sensor").
Table 3.3: Meaning of the 7-segment display
Display Description
After switching on
8 Self test
t n n Response time (t) of the receiver in milliseconds (n n)
In normal operation
C1 Transmission channel C1
C2 Transmission channel C2
For alignment
Alignment display (see table 3.4).
• Segment 1: beam area in upper third of the protective field
• Segment 2: beam area in middle third of the protective field
• Segment 3: 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. An AutoReset is carried out after 10 s for errors that do not cause locking,
with an unauthorized restart being impossible. In the case of blocking errors, the voltage supply must be
Leuze electronic MLC 520 EX 13
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).
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 5 s). In this case, a fixed beam area from the protective field is
assigned to every segment.
3.3.2 Alignment display
Approximately 5 s 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 hori-
zontal segments and the state of this sub-protective field displayed as follows:
In this mode, one third of the total protective field (Host, Middle Guest, Guest) is assigned to one of the
three horizontal segments and the state of this sub-protective field displayed as follows:
Table 3.4: Meaning of the alignment display
Segment Description
Switched on All beams in the beam area are free.
flashing At least one, but not all beams in the beam area are free.
Switched off All beams in the beam area are interrupted.
Device description
When the protective field has been free for about 5 s, the device switches back to the display of the operating mode.
Leuze electronic MLC 520 EX 14
4 Functions
An overview of features and functions of the safety sensor can be found in chapter Device description
(see chapter 3.1 "Device overview").
Overview of functions
• Start/restart interlock (RES)
•EDM
• Range reduction
• Transmission channel changeover
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.
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 EN ISO 12100.
Functions
WARNING
Deactivation of the start/restart interlock may result in serious injury!
Implement the start/restart interlock on the machine or in a downstream safety circuit.
Use start/restart interlock
Wire the MLC 520 receiver appropriately for the desired operating mode (see chapter 7 "Electrical con-
nection")
The start/restart interlock function is automatically activated.
Switching the safety sensor back on after shutting down (OFF state):
Press the reset button (press/release between 0.1 s and 4 s)
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 before
pressing the reset button.
DANGER
Risk of death if start/restart is operated unintentionally!
Ensure that the reset button for unlocking the start/restart interlock cannot be reached from the danger
zone.
Before unlocking the start/restart interlock, make certain that no people are in the danger zone.
After the reset button has been actuated, the safety sensor switches to the ON state.
4.2 EDM contactor monitoring
The contactor monitoring of the MLC 520 safety sensors can be activated through appropriate
wiring (see table 7.2)!
The "contactor monitoring" function monitors the contactors, relays or valves connected downstream of
the safety sensor. Prerequisite for this are switching elements with positive-guided feedback contacts
(normal closed contacts).
Leuze electronic MLC 520 EX 15
Implement the contactor monitoring function:
• through appropriate wiring of the MLC 520 safety sensors (see table 7.2).
• through the external contactor monitoring of the downstream safety relay, (e.g., MSI series from
Leuze electronic)
• or through contactor monitoring of the downstream safety PLC (optional, integrated via a safety bus)
If contactor monitoring is activated (see chapter 7 "Electrical connection"), it operates dynamically, i.e., in
addition to monitoring the closed feedback circuit every time before the OSSDs are switched on, it also
checks whether the release of the feedback circuit opened within 500 ms and, after the OSSDs are
switched off, whether it has closed again within 500 ms. If this is not the case, the OSSDs return to the
OFF state after being switched on briefly. An error message appears on the 7-segment display (E30, E31)
and the receiver switches to the fault interlock state from which it can only be returned to normal operation
by switching the supply voltage off and back on again.
4.3 Transmission channel changeover
Transmission channels are used to prevent mutual interference of safety sensors which are located close
to each other.
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, there-
by do not influence the protective field.
Functions
With the factory setting, the safety sensor works in all operating modes with transmission channel C1.
The transmission channel of the transmitter can be switched by changing the supply voltage polarity (see
chapter 7.1.1 "MLC 500 transmitter").
The transmission channel of the receiver can be switched by changing the supply voltage polarity (see
chapter 7.1.2 "MLC 520 receiver").
Faulty function due to incorrect transmission channel!
Select the same transmission channel on the transmitter and corresponding receiver.
4.4 Range reduction
In addition to selecting the suitable transmission channels (see chapter 4.3 "Transmission channel
changeover"), the range reduction also serves to prevent mutual interference of adjacent safety sensors.
Activating the function reduces the light power of the transmitter so that around half of the nominal range
is reached.
Reducing range:
Wire pin 4 (see chapter 7.1 "Pin assignment transmitter and receiver").
The wiring of pin 4 determines the transmitting power and thereby the range.
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-rele-
vant monitoring.
Do not use this configuration option for safety purposes.
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")
Leuze electronic MLC 520 EX 16
5 Applications
The safety sensor only creates square protective fields.
5.1 Point of operation guarding
Point of operation guarding for hand and finger protection is typically the most common application for this
safety sensor. In accordance with EN ISO 13855, resolutions from 14 to 40 mm make sense here. This
yields the necessary safety distance, among others (see chapter 6.1.1 "Calculation of safety distance S").
Applications
Figure 5.1: Point of operation guarding protects reaching into the danger zone, e.g. for cartoners or filling
systems
Figure 5.2: Point of operation guarding protects reaching into the danger zone, e.g. for a pick & place
robot application
5.2 Access guarding
Safety sensors with up to 90 mm resolution are used for access guarding into danger zones. They detect
people only upon entry into the danger zone, i.e., they do not detect parts of a person or whether a person
is present in the danger zone.
Leuze electronic MLC 520 EX 17
Figure 5.3: Access guarding on a transfer path
Applications
5.3 Danger zone guarding
Safety light curtains can be used in horizontal arrangement for danger zone guarding - either as standalone device for presence monitoring or as stepping behind protection for presence monitoring e.g. in
combination with a vertically-arranged safety sensor. Depending on the mounting height, resolutions of
40 or 90 mm are used (see chapter 15).
Figure 5.4: Danger zone guarding on a robot
Leuze electronic MLC 520 EX 18
6 Mounting
SKTC+=
WARNING
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.
Only allow competent persons to install the safety sensor.
Maintain the necessary safety distances (see chapter 6.1.1).
Make sure that stepping behind, crawling under or stepping over the protective device is reliably ruled
out and reaching under, over or around is taken into account in the safety distance, if applicable with
additional distance C
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.
Observe the relevant standards, regulations and these instructions.
Clean the transmitter and receiver at regular intervals: environmental conditions (see chapter 14), care
(see chapter 10).
After mounting, check the safety sensor for proper function.
corresponding to EN ISO 13855.
RO
Mounting
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:
• prEN IEC 61496-2, "Active Optoelectronic Protective Devices": distance of the reflecting surfaces/
deflecting mirrors
• EN 13855, "Safety of machines - The positioning of protective equipment in respect of approach
speeds of parts of the human body": mounting situation and safety distances
In accordance with ISO 13855, with a vertical protective field, it is possible to pass under beams
over 300 mm or pass over beams under 900 mm. 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 distance S
General formula for calculating the safety distance S of an optoelectronic protective device acc. to
EN ISO 13855:
S [mm] = Safety distance
K [mm/s] = Approach speed
T [s] = Total time of the delay, sum from (t
t
[s] = Response time of the protective device
a
t
[s] = Response time of the safety relay
i
[s] = Stopping time of the machine
t
m
C [mm] = Additional distance to the safety distance
+ ti + tm)
a
If longer stopping times are determined during regular inspections, an appropriate additional time
must be added to tm.
Leuze electronic MLC 520 EX 19
Mounting
S
RT
KT C
RT
+=
S
RT
KT C
RT
+=
S
RT
KT C
RT
+=
6.1.2 Calculation of safety distance SRT or SRO if protective fields act orthogonally to the approach direction
With vertical protective fields, EN ISO 13855 differentiates between
•S
: safety distance concerning access
RT
•SRO: safety distance concerning access
through the protective field
over the protective field
The two values are distinguished by the way additional distance C is determined:
•CRT: from a calculation formula or as a constant, see chapter 6.1.1 "Calculation of safety distance S"
•CRO: from a table (see table 6.1)
The larger of the two values S
and SRO is to be used.
RT
Calculation of safety distance S
acc. to EN ISO 13855 when access occurs through the protective field:
RT
Calculation of safety distance SRT 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 ap-
proach direction to the protective field (resolution 14 to 40 mm): 2000 mm/s or
1600 mm/s, when SRT > 500 mm
T [s] = Total time of the delay, sum from (ta + ti + tm)
[s] = Response time of the protective device
t
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 resolu-
RT
tions of 14 to 40 mm, d = resolution of protective device CRT = 8 (d - 14) mm
Calculation example
The feeding-in area in a press with a stopping time (including press Safety PLC) of 190 ms is to be safe-
guarded with a safety light curtain with 20 mm of resolution and 1200 mm of protective field height. The
safety light curtain has a response time of 22 ms.
Calculate safety distance S
using the formula acc. to EN ISO 13855.
RT
K [mm/s] = 2000
T [s] = (0.022 + 0.190)
[mm] = 8 (20 - 14)
C
RT
S
[mm] = 2000 mm/s 0.212 s + 48 mm
RT
S
[mm]= 472
RT
SRT is smaller than 500 mm; this is why the calculation may
Implement the stepping behind protection required here, e.g., through the use of an additional or
cascaded safety sensor for area protection.
Calculation of safety distance SRT for access guarding
S
[mm] = Safety distance
RT
K [mm/s] = Approach speed for access guarding with approach direction orthogonal to the protec-
tive field: 2000 mm/s or 1600 mm/s, if S
T [s] = Total time of the delay, sum from (ta + ti + tm)
t
[s] = Response time of the protective device
a
[s] = Response time of the safety relay
t
i
t
[s] = Stopping time of the machine
m
C
[mm] = Additional distance for access guarding with approach reaction with resolutions of
RT
14 to 40 mm, d = resolution of protective device CRT = 8 (d - 14) mm. Additional dis-
not be repeated with 1600 mm/s.
> 500 mm
RT
Leuze electronic MLC 520 EX 20
Mounting
S
RT
KT C
RT
+=
S
RT
KT C
RT
+=
S
RO
KT C
RO
+=
tance for access guarding for resolutions > 40 mm: CRT = 850 mm (standard value for
arm length)
Calculation example
Access to a robot with a stopping time of 250 ms is to be safeguarded with a safety light curtain with 90 mm
of resolution and 1500 mm of protective field height whose response time is 6 ms. The safety light curtain
directly switches the contactors whose response time is contained in the 250 ms. An additional interface
therefore does not have to be taken into consideration.
Calculate safety distance S
K [mm/s] = 1600
T [s] = (0.006 + 0.250)
C
[mm] = 850
RT
S
[mm] = 1600 mm/s 0.256 s + 850 mm
RT
S
[mm]= 1260
RT
using the formula acc. to EN ISO 13855.
RT
This safety distance is not available in the application. This is why a new calculation is done with a safety
light curtain with 40 mm of resolution (response time = 14 ms):
Re-calculate safety distance S
using the formula acc. to EN ISO 13855.
RT
K [mm/s] = 1600
T [s] = (0.014 + 0.250)
C
[mm] = 8 (40 - 14)
RT
[mm] = 1600 mm/s 0.264 s + 208 mm
S
RT
S
[mm]= 631
RT
The safety light curtain with a 40 mm resolution is thus suitable for this application.
For the calculation with K = 2000 mm/s, safety distance SRT equals 736 mm. The adoption of ap-
proach speed K = 1600 mm/s is therefore permitted.
Calculation of safety distance SRo acc. to EN ISO 13855 when protective field is accessed from above:
Calculation of safety distance S
S
[mm] = Safety distance
RO
K [mm/s] = Approach speed for point of operation guarding with approach reaction and normal ap-
T [s] = Total time of the delay, sum from (t
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
RO
for point of operation guarding
Ro
proach direction to the protective field (resolution 14 to 40 mm): 2000 mm/s or
1600 mm/s, when SRO > 500 mm
+ ti + tm)
a
the protective device triggers: value (see table 6.1)
Leuze electronic MLC 520 EX 21
1 Safety sensor
a
3
C
RO
KxT
b
1
2
S
RO
2 Danger zone
3Floor
a Height of the point of operation
b Height of the upper beam of the safety sensor
Figure 6.1: Additional distance to the safety distance when reaching over and under
Mounting
Table 6.1: Reaching over the vertical protective field of electro-sensitive protective
equipment(excerpt from EN ISO 13855)
Height a of
the point of
Height b of the upper edge of the protective field of the electro-sensitive protective equip-
ment
operation
[mm]
900 1000 1100 1200 1300 1400 1600 1800 2000 2200 2400 2600
Additional distance CRO to the danger zone [mm]
2600 000000000000
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
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 105095075055000000000
400 9007000000000000
200 60000000000000
0 000000000000
Leuze electronic MLC 520 EX 22
Mounting
S
RO
KT C
RO
+=
Depending on the specified values you can work with the above-mentioned table (see table 6.1) in three
ways:
1. Given are
• Height a of the point of operation
• Distance S of the point of operation from the safety sensor, and additional distance C
RO
To be determined is the required height b of the upper beam of the safety sensor and thereby its protective
field height.
Look for the line with the specification of the point of operation height in the left column.
In this line, look for the column with the next highest specification for additional distance C
The required height of the upper beam of the safety sensor is up top in the column head.
.
RO
2. Given are
• Height a of the point of operation
• Height b 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 C
.
RO
In the column head, look for the column with the next lowest entry for the height of the upper beam of
the safety sensor.
Look for the line with the next highest specification of the point of operation height a in this column.
In the intersection point of the line and the column, you will find additional distance C
RO.
3. Given are
• Distance S of the point of operation from the safety sensor, and additional distance C
RO
• Height b of the upper beam of the safety sensor
To be determined is the permitted height a of the point of operation.
In the column head, look for the column with the next lowest entry for the height of the upper beam of
the safety sensor.
Look for the next lowest value for real additional distance C
In this line, go to the left column: here you will find the permitted height of the point of operation.
in this column.
RO
Now calculate safety distance S using the general formula acc. to EN ISO 13855, see chapter 6.1.1
"Calculation of safety distance S".
The larger of the two values SRT or S
is to be used.
RO
Calculation example
The feeding-in area in a press with a stopping time of 130 ms is to be safeguarded with a safety light
curtain with 20 mm of resolution and 600 mm of protective field height. The response time of the safety
light curtain is 12 ms; the press Safety PLC has a response time of 40 ms.
The safety sensor can be reached over. The upper edge of the protective field is located at a height of
1400 mm; the point of operation is located at a height of 1000 mm
Additional distance C
to the point of operation is 700 mm (see table 6.1).
RO
Calculate safety distance SRO using the formula acc. to EN ISO 13855.
K [mm/s] = 2000
T [s] = (0.012 + 0.040 + 0.130)
C
[mm] = 700
RO
S
[mm] = 2000 mm/s 0.182 s + 700 mm
RO
S
[mm]= 1064
RO
SRO is larger than 500 mm; this is why the calculation may be repeated with approach speed 1600 mm/s:
Leuze electronic MLC 520 EX 23
K [mm/s] = 1600
S
RO
KT C
RO
+=
SKTC+=
SKTC+=
T [s] = (0.012 + 0.040 + 0.130)
C
[mm] = 700
RO
[mm] = 1600 mm/s 0.182 s + 700 mm
S
RO
S
[mm]= 992
RO
Depending on the machine construction, stepping behind protection, e.g. using a second hori-
zontally 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 distance C
6.1.3 Calculation of safety distance S for parallel approach to the protective field
Calculation of safety distance S for danger zone guarding
equal to 0.
RO
Mounting
S [mm] = Safety distance
K [mm/s] = Approach speed for danger zone guarding with approach direction parallel to the pro-
tective field (resolution up to 90 mm): 1600 mm/s
T [s] = Total time of the delay, sum from (t
t
[s] = Response time of the protective device
a
[s] = Response time of the safety relay
t
i
t
[s] = Stopping time of the machine
m
+ ti + tm)
a
C [mm] = Additional distance for danger zone guarding with approach reaction H = height of the
protective field, H
d = resolution of the protective device C = 1200 mm - 0.4 H; H
= minimum installation height permitted, but no smaller than 0,
min
= 15 (d - 50)
min
Calculation example
The danger zone in front of a machine with a stopping time of 140 ms 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
height H
can be = 0 - additional distance C to the safety distance is then 1200 mm. The shortest possible
min
safety sensor is to be used; the first value to be selected is to be 1350 mm.
The receiver with 40 mm of resolution and 1350 mm protective field height has a response time of 13 ms,
an additional MSI-SR4 relay interface a response time of 10 ms.
Calculate safety distance S
K [mm/s] = 1600
T [s] = (0.140 + 0.013 + 0.010)
C [mm] = 1200
S [mm] = 1600 mm/s 0.163 s + 1200 mm
S [mm]= 1461
using the formula acc. to EN ISO 13855.
RO
The safety distance of 1350 mm is not sufficient; 1460 mm are necessary.
This is why the calculation is repeated with a protective field height of 1500 mm. The response time is now
14 ms.
Re-calculate safety distance SRO using the formula acc. to EN ISO 13855.
Leuze electronic MLC 520 EX 24
K [mm/s] = 1600
SKTC+=
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
110 0 m m
1000 mm
T [s] = (0.140 + 0.014 + 0.010)
C [mm] = 1200
S [mm] = 1600 mm/s 0.164 s + 1200 mm
S [mm]= 1463
A suitable safety sensor has been found; its protective field height is 1500 mm.
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.
Determine the minimum distance a (see figure 6.2).
Make certain that all reflective surfaces are the necessary minimum distance away from the protective
field according to prEN IEC 61496-2 (see figure 6.3).
Check that reflective surfaces do not impair the detection capability of the safety sensor before start-
up and at appropriate intervals.
Mounting
a Required minimum distance to reflective surfaces [mm]
b Protective field width [m]
c Reflective surface
Figure 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]
Figure 6.3: Minimum distance to reflective surfaces as a function of the protective field width
Leuze electronic MLC 520 EX 25
Table 6.2: Formula for calculating the minimum distance to reflective surfaces
2
4
1
3
Mounting
Distance (b) transmit-
Calculation of the minimum distance (a) to reflective surfaces
ter-receiver
b 3 m a [mm] = 131
b > 3 m a [mm] = tan(2.5°) 1000 b [m] = 43.66 b [m]
6.1.5 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 (see figure 6.4).
1 Transmitter 1
2 Receiver 1
3 Transmitter 2
4 Receiver 2
Figure 6.4: Optical crosstalk between adjacent safety sensors (transmitter 1 influences receiver 2) due
to incorrect mounting
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.
Prevent optical crosstalk between adjacent devices.
Mount adjacent devices with a shield between them or install a dividing wall to prevent mutual interfer-
ence.
Mount the adjacent devices opposite from one another to prevent mutual interference.
Leuze electronic MLC 520 EX 26
1 Receiver 1
2
4
1
3
2 Transmitter 1
3 Transmitter 2
4 Receiver 2
Figure 6.5: Opposite mounting
Mounting
In addition to design characteristics, the safety sensor offers functions that can remedy this:
• Selectable transmission channels (see chapter 4.3)
• Range reduction (see chapter 4.4)
• Also: opposite mounting
6.2 Mounting the safety sensor
Proceed as follows:
• Select the type of fastening, e.g. sliding blocks (see chapter 6.2.3).
• 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).
• 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), start up, align (see chapter 8 "Starting up the
device"), and check (see chapter 9.1) the safety sensor.
6.2.1 Suitable mounting locations
Area of application: Mounting
Tester: technician who mounts the safety sensor
Table 6.3: Checklist for mounting preparations
Check: Yes No
Do the protective field height and dimensions satisfy the requirements of EN 13855?
Is the safety distance to the point of operation maintained (see chapter 6.1.1)?
Is the minimum distance to reflective surfaces maintained (see chapter 6.1.4)?
Is it impossible for safety sensors that are mounted next to one another to mutually interfere with one another (see chapter 6.1.5)?
Can the point of operation or the danger zone only be accessed through the protective
field?
Leuze electronic MLC 520 EX 27
Mounting
a) b) c) d)
Check: Yes No
Has bypassing the protective field by crawling under, reaching over, or jumping over
been prevented or has corresponding additional distance C
in accordance with
RO
EN ISO 13855 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?
If you answer one of the items on the check list (see table 6.3) with no, the mounting location
must be changed.
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
c Pitching: lateral turning movement in the direction of the front screen
Figure 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 2 BT-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.
Leuze electronic MLC 520 EX 28
Figure 6.7: Mounting via BT-NC60 sliding blocks
6.2.4 Fastening with BT-R swivel mount
With the swivel mount (see table 15.5), 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.
Mounting
Figure 6.8: Mounting via BT-R swivel mount
6.2.5 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-R 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.
Leuze electronic MLC 520 EX 29
Mounting
Figure 6.9: Mounting directly on the machine table
WARNING
Impairment of the protective function due to reflections on the machine table!
Make sure that reflections on the machine table are prevented reliably.
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 figure 9.1).
6.3 Mounting accessories
6.3.1 Deflecting mirror for multiple-side guarding
For multiple-side guarding, redirecting the protective field with one or two deflecting mirrors is economical.
To do this, Leuze electronic supplies
• the UM60 deflecting mirror for mounting on the machine in various lengths (see table 15.5)
• suitable BT-UM60 swivel mounts
• UMC-1000-S2 … UMC-1900-S2 deflecting mirror columns with spring-damped base for free-standing floor mounting
The range is reduced by approx. 10 % per deflection. A laser alignment aid with red light laser is recommended for the alignment of transmitter and receiver (see chapter 8.3 "Aligning of deflecting mirrors with
the laser alignment aid").
Note that the distance between the transmitter and the first deflecting mirror cannot be larger than 3 m.
Leuze electronic MLC 520 EX 30
2
2
1
3
1
3
1 Transmitter
2 Receiver
3 UM60 deflecting mirror
Figure 6.10: Arrangement with deflecting mirror for 2-side guarding of a point of operation
Mounting
1 Transmitter
2 Receiver
3 UMC deflecting mirror column
Figure 6.11: Arrangement with deflecting mirror columns for two-side guarding of a point of operation
Leuze electronic MLC 520 EX 31
7 Electrical connection
WARNING
Faulty electrical connection or improper function selection may result in serious injury!
Only allow competent persons to perform the electrical connection.
Make certain that the safety sensor is protected against overcurrent.
For access guarding, activate the start/restart interlock and make certain that it cannot be unlocked
from within the danger zone.
Select the functions so that the safety sensor can be used as intended (see chapter 2.1).
Select the safety-relevant functions for the safety sensor (see chapter 4 "Functions").
Always loop both safety related switching outputs OSSD1 and OSSD2 into the work circuit of the
machine.
Signal outputs must not be used for switching safety-relevant signals.
DANGER
Faulty electrical connection in potentially explosive areas may result in serious injury!
Only disconnect the electrical connections of the device while in a voltage-free state.
Always switch off the voltage supply before disconnecting a connection cable.
Make certain that all electrical connections are plugged in or protected. To do this, use, e.g., the pro-
vided K-VM12-Ex interlocking guard (see figure 7.1).
Affix the provided Do not disconnect electrical connection under voltage! stickers in highly visible
locations on the device or near the electrical connection.
Electrical connection
NOTICE
SELV/PELV
Acc. to EN 60204-1, the external power supply must demonstrate the ability to bridge short-term mains
failures of up to 20 ms. The power supply unit must ensure safe mains separation (SELV/PELV) and
a current reserve of at least 2 A.
For special EMC influences, the use of shielded cables is recommended.
Figure 7.1: K-VM12-Ex interlocking guard
Leuze electronic MLC 520 EX 32
7.1 Pin assignment transmitter and receiver
2
3
1
4
5
FE
VIN1
1
RNG
4
VIN23FE
5
-A1
MLCx00T
n.c.
2
7.1.1 MLC 500 transmitter
MLC 500 transmitters are equipped with a 5-pin M12 connector.
Figure 7.2: Pin assignment transmitter
Table 7.1: Pin assignment transmitter
Pin Core color (CB-M12-xx000E-5GF) Transmitter
Electrical connection
Figure 7.3: Connection diagram 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 = +24 V, VIN2 = 0 V: transmission channel C1
• VIN1 = 0 V, VIN2 = +24 V: transmission channel C2
The wiring of pin 4 determines the transmitting power and thereby the range:
• Pin 4 = +24 V: standard range
• Pin 4 = 0 V or open: reduced range
Leuze electronic MLC 520 EX 33
Electrical connection
VIN1
1
RNG
4
VIN23FE
5
-A1
MLCx00T
n.c.
2
+ 24V
FE
0V
+ 24V
FE
0V
1
WH
GY
BU
BN
BK
VIN1
1
RNG
4
VIN23FE
5
-A1
MLCx00T
+ 24V
FE
0V
+ 24V
FE
0V
2
n.c.
2
WH
GY
BU
BN
BK
VIN2
3
RNG
4
VIN11FE
5
-A1
MLCx00T
+ 24V
FE
0V
+ 24V
FE
0V
3
n.c.
2
WH
GY
BN
BU
BK
VIN2
3
RNG
4
VIN11FE
5
-A1
MLCx00T
+ 24V
FE
0V
+ 24V
FE
0V
4
n.c.
2
WH
GY
BN
BU
BK
3
4
1
7
8
FE
2
6
5
Figure 7.4: Connection examples transmitter
7.1.2 MLC 520 receiver
MLC 520 receivers are equipped with an 8-pin M12 connector.
Figure 7.5: Pin assignment receiver
1 Transmission channel C1, reduced range
2 Transmission channel C1, standard range
3 Transmission channel C2, reduced range
4 Transmission channel C2, standard range
Start
Restart
MLCx20R
0V
7
21
+24V
FE
8
EDM
RES active
-A2
Figure 7.6: Connection diagram receiver
643 5
OSSD1
OSSD2
Leuze electronic MLC 520 EX 34
Electrical connection
Table 7.2: Pin assignment receiver
Pin Core color (CB-M12-xx000E-5GF) Receiver
1 White IO1 - control input reset button, signal output
Start/restart normal open contact against
ground 24 V DC weak signal/fault:
24 V DC strong light reception
0 V weak light reception or fault
2 Brown VIN1 - supply voltage
24 V DC for transmission channel C1
0 V for transmission channel C2
3 Green IN3 - control-input contactor monitoring (EDM)
24 V DC: without EDM
0 V: with EDM and feedback circuit closed
High-impedance: with EDM and feedback circuit open
4 Yellow IN4 - control input for start/restart interlock
(RES)
24 V DC: with RES
Bridge to pin 1: without RES (notice: signal output remains functional)
5 Gray OSSD1 - safety-related switching output
6 Pink OSSD2 - safety-related switching output
7 Blue VIN2 - supply voltage
0 V: for transmission channel C1
24 V DC for transmission channel C2
8 Red FE - functional earth, shield
Wired in device interior on the housing
FE FE - functional earth, shield
The polarity of the supply voltage selects the transmission channel of the receiver:
• VIN1 = +24 V, VIN2 = 0 V: transmission channel C1
• VIN1 = 0 V, VIN2 = +24 V: transmission channel C2
Leuze electronic MLC 520 EX 35
7.2 Circuit diagram examples
EDM
OSSD1
MSI-RM2
OSSD2
Start
MLCx20R
Restart
0V
FE
+24V
WH
A1
A2
-K3
A1
A2
-K4
PK
GN
1
2
1
2
BU
SH
8
-W1
BU
SH
-W2
-S1
A2
5
14B36Y1
BN
B1
4
-A3
11
3
12 22
YE
-K4
-K3
21Y2
-W1
BK
BN
5
-W2
7
21
-A2
4321
-A1
24
GY
PE
+24V
0V
+24V
PE
0V
L+L+
L- L-
RES active
*
*
VIN1
RNG
MLCx00T
FE
VIN2
n.c.
7.2.1 MLC 520 circuit diagram example
Electrical connection
Figure 7.7: Circuit diagram example with downstream MSI-RM2 safety relay
Leuze electronic MLC 520 EX 36
8 Starting up the device
WARNING
Improper use of the safety sensor may result in serious injury!
Make certain that the entire device and the integration of the optoelectronic protective device was
inspected by competent and instructed persons.
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
After start-up, check the function of the safety sensor (see chapter 9.1 "Before the initial start-up and
following modifications").
8.1 Switching on
Starting up the device
Requirements for the supply voltage (power supply unit):
• Reliable mains separation is ensured.
• Current reserve of at least 2 A is available.
• The RES function is activated - either in the safety sensor or in the downstream control
Switch on the safety sensor.
The safety sensor performs a self test and then displays the response time of the receiver (see table 3.3).
Check operational readiness of sensor
Check whether LED1 is permanently lit green or red (see table 3.2).
The safety sensor is ready for use.
8.2 Aligning the sensor
NOTICE
Faulty or incorrect alignment may result in an operating fault!
The alignment performed during start-up should only be performed by qualified personnel.
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 3.3 "Display elements").
Loosen the screws on the mounting brackets or device columns.
Loosen the screws only enough so that the devices can just be moved.
Turn the receiver to the left until LED1 still flashes green but does not yet illuminate red. If necessary,
you may have to turn the transmitter beforehand.
The receiver with activated alignment display shows flashing segments in the 7-segment display.
Leuze electronic MLC 520 EX 37
Note the value of the twist angle.
Turn the receiver to the right until LED1 still flashes green but does not yet illuminate red.
Note the value of the twist angle.
Set the optimum position of the receiver. This lies in the middle of the two values for the twist angle to
the left and right.
Tighten the fastening screws of the receiver.
Now align the transmitter according to the same method, paying attention to the display elements of the
receiver while doing so (see chapter 3.3.1 "Operating indicators on the MLC 520 receiver").
8.3 Aligning of deflecting mirrors with the laser alignment aid
When using deflecting mirrors for multiple-side point of operation guarding and access guarding in particular, an external laser alignment aid is recommended (see table 15.5).
With its clearly visible red light spot, the external laser alignment aid facilitates the correct setting
of the transmitter and receiver as well as the deflecting mirrors.
Fasten the laser alignment aid on top on the side groove of the transmitter (mounting instructions are
included in the accessories).
Switch on the laser. Take note of the operating instructions of the laser alignment aid concerning the
safety notices and the activation of the laser alignment aid.
Loosen the mounting bracket of the transmitter and turn or tilt or pitch the device so that the laser spot
strikes the top of the first deflecting mirror (see chapter 6.2.2 "Definition of directions of movement").
Now set the laser below on the transmitter and adjust it so that the laser spot strikes the bottom of the
deflecting mirror.
Now set the laser back up top on the transmitter and check if the laser spot still strikes the top of the
deflecting mirror. If it does not, the mounting height of the transmitter must be changed, if applicable.
Repeat the process until the laser strikes the respective point of the deflecting mirror, both on top and
on bottom.
Turn, tilt or pitch the deflecting mirror so that the laser spot strikes either the next deflecting mirror or the
receiver in both positions.
Repeat the process in reverse after setting the laser alignment aid above and below on the receiver.
The laser beam must strike the transmitter in both cases if the receiver has been correctly aligned.
Remove the laser alignment aid from the safety sensor.
The protective field is free. LED1 on the receiver is permanently lit green. The OSSDs switch on.
Starting up the device
8.4 Unlocking start/restart interlock
The reset button can be used to unlock the start/restart interlock. 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).
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.
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).
Make certain that the active protective field is clear.
Make certain that there are no people in the danger zone.
Press and release the reset button within 0.15 to 4 s.
The receiver switches to the ON state.
Leuze electronic MLC 520 EX 38
Starting up the device
If you keep the reset button pressed longer than 4 s:
• Starting at 4 s: the reset request is ignored.
• Starting at 30 s: a +24 V 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 error?").
Leuze electronic MLC 520 EX 39
9Test
NOTICE
Safety sensors must be replaced at the end of their service life (see chapter 14 "Specifications").
Always exchange entire safety sensors.
Observe any nationally applicable regulations regarding the tests.
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!
Make certain that there are no people in the danger zone.
Before they begin work, train the operators on their respective tasks. The training is the responsibility of
the operating company.
Attach notices 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).
Test the electrical function and installation according to this document.
Test
Acc. to IEC TS 62046 and national regulations (e.g. EU directive 2009/104/EC), tests are to be performed
by competent persons in the following situations:
• Prior to the initial start-up
• Following modifications to the machine
• After longer machine downtime
• Following retrofitting or new configuration of the machine
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 competent person!
Not until proper function of the safety sensor is ascertained may it be integrated in the control circuit of the
system.
9.1.1 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 competent person!
If you answer one of the items on the checklist (see table 9.1) with
no
, the machine must no longer be
operated.
IEC/TS 62046 contains additional recommendations on testing protective devices
Table 9.1: Checklist for integrator – to be performed prior to the initial start-up and following
modifications
Check: Yes No
n. a.
a)
Is the safety sensor operated acc. to the specific environmental conditions that
are to be maintained (see chapter 14 "Specifications")?
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)?
Leuze electronic MLC 520 EX 40
Test
Check: Yes No
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?
n. a.
a)
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 table 9.2)?
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.: muting, 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?
Were the operators instructed prior to starting work?
a) not applicable
9.2 To be performed periodically by competent persons
The reliable interaction of safety sensor and machine must be periodically tested by competent persons 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 competent persons at regular intervals. Testing intervals may
be regulated by nationally applicable regulations (recommendation acc. to IEC/TS 62046: 6 months).
Have all tests performed by competent persons.
Leuze electronic MLC 520 EX 41
Observe the nationally applicable regulations and the time periods specified therein.
As preparation, observe the checklist (see chapter 9.1 "Before the initial start-up and following modifi-
cations").
9.3 Periodically by the operator
The function of the safety sensor must be checked periodically depending on the given risk (e.g.: daily or
on change of shifts) according to the following checklist so that damages or prohibited tampering can be
detected.
Due to complex machines and processes, it may be necessary under certain circumstances to check some
points at longer time intervals. Therefore, observe the classification in Test at least and Test when
possible.
For larger distances between transmitter and receiver and when using deflecting mirrors, a sec-
ond person may be necessary.
WARNING
Unpredictable machine behavior during the test may result in serious injury!
Make certain that there are no people in the danger zone.
Before they begin work, train the operators on their respective tasks and provide suitable test objects
and an appropriate test instruction.
Test
9.3.1 Checklist – periodically by the operator
NOTICE
If you answer one of the items on the checklist (see table 9.1) with
operated.
no
, the machine must no longer be
Leuze electronic MLC 520 EX 42
Table 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 obvious changes made to access or entry possibilities?
Test the effectiveness of the safety sensor:
• The LED 1 on the safety sensor must illuminate green (see chapter "").
• Interrupt an active beam or the protective field (see figure 9.1) with a suitable,
opaque test object:
Test
Figure 9.1: Checking the protective field function with test rod (only for safety light cur-
tains with a resolution of 14 to 40 mm)
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?
Leuze electronic MLC 520 EX 43
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.
Do not use chemical cleaners.
Prerequisites for cleaning:
• The system is safely shut down and protected against restart.
Clean the safety sensor periodically depending on the degree of contamination.
NOTICE
Prevent electrostatic charging of the front screens!
To clean the front screens of transmitter and receiver, use only damp cloths.
Maintenance
Leuze electronic MLC 520 EX 44
11 Troubleshooting
11.1 What to do in case of error?
After switching the safety sensor on, the display elements (see chapter 3.3) 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 7segment display. With the error message you can determine the cause of the error and initiate measures
to rectifying it.
NOTICE
If the safety sensor responds with an error display, you will often be able to eliminate the cause yourself.
Switch off the machine and leave it switched off.
Analyze and eliminate the cause of the fault using the following table (see table 11.1, see table 11.2,
see table 11.3).
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 displays of the LEDs
Troubleshooting
Table 11.1: Transmitter LED displays - causes and measures
LED State Cause Measure
LED1 OFF Transmitter without sup-
ply voltage
Red Transmitter defective Exchange the transmitter.
Check the power supply unit and the electrical connection. Exchange the power supply
unit, if applicable.
Leuze electronic MLC 520 EX 45
Table 11.2: Receiver LED displays - 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, slowly flashing,
approx. 1 Hz
Red, flashing fast,
approx. 10 Hz
(7-segment display
F x y)
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
Remove all objects from the protective field.
Align the transmitter and receiver to each
other or place blanked objects correctly concerning size and position.
External fault Check the connection of the cables and the
control signals.
Internal fault If restart fails, exchange the device.
Green, slowly flashing,
approx. 1 Hz
Weak signal due to contamination or poor alignment
LED2 Yellow Start/restart interlock is
locked and protective
field is free - ready for
unlocking
Yellow flashing The control circuit is
open in operating
mode 1, 2 and 3
11.3 Error messages 7-segment display
Table 11.3: Messages of the 7-segment display (F: internal device error, E: external error, U: usage
info during application errors)
Faults Cause/description Measures Sensor behav-
F[No. 0-255] Internal fault In the event of an unsuccessful
OFF Very high overvoltage (
Clean the front screens and check the alignment of transmitter and receiver.
If there are no people in the danger zone,
operate the reset button.
Close the input circuit with the correct polarity and timing.
ior
restart, contact customer service.
40 V) Supply the device with the correct
voltage.
E01 Cross connection between
OSSD1 and OSSD2
Leuze electronic MLC 520 EX 46
Check the wiring between OSSD1
and OSSD2.
Automatic reset
Troubleshooting
Faults Cause/description Measures Sensor behav-
ior
E02 Overload on OSSD1 Check the wiring or exchange the
connected component (reducing
the load).
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 +24 V at
OSSD1
E08 Short circuit against GND at
OSSD2
E09 Short circuit against +24 V 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.
Automatic reset
Automatic reset
Automatic reset
Automatic reset
Automatic reset
Automatic reset
Automatic reset
Automatic reset
Automatic reset
E14 Undervoltage (< +15 V) Supply the device with the correct
voltage.
E15 Overvoltage (> +32 V) Supply the device with the correct
voltage.
E16 Overvoltage (> +40 V) Supply the device with the correct
voltage.
E17 Foreign transmitter detected Remove foreign transmitters and
increase the distance to the reflective surfaces. Actuate the start button if available.
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. Automatic reset
pin 3. Signal output: output signal
is not equal to the signal input
read-back value: it switches simultaneously with the other signal
line.
Automatic reset
Automatic reset
Locking
Locking
Automatic reset
Automatic reset
Leuze electronic MLC 520 EX 47
Troubleshooting
Faults Cause/description Measures Sensor behav-
ior
E23 Interference detected on plug
Check the wiring. Automatic reset
pin 4. 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. Automatic reset
pin 8. Signal output: output signal
is not equal to the signal input
read-back value: it switches simultaneously with the other signal
line.
E30 EDM does not open Actuate the start button if avail-
able.
E31 EDM does not close Actuate the start button if avail-
able.
E37 EDM operating mode changed
during operation
Check the correctness of the
selected operating mode, correct
the operating mode if required, and
restart.
E38 Restart interlock operating mode
changed during operation
Check the correctness of the
selected operating mode, correct
the operating mode if required, and
restart.
Locking
Locking
Locking
Locking
E39 Actuation duration (2.5 min)
exceeded for reset button or cable
short circuited
E41 Invalid change of operating mode
due to reversal of the supply voltage polarity during operation
E80 … E86 Invalid operating mode due to set-
ting error, general operating mode
change
Press the reset button. If the
restart is unsuccessful, check the
wiring of the reset button.
Check the wiring and programming
of the device which controls this
signal.
E.g. reset button pressed during
start-up, check the circuit diagram
and the wiring and restart.
E87 Operating mode changed Check the wiring. Restart the sen-
sor.
Automatic reset
Locking
Locking
Locking
Leuze electronic MLC 520 EX 48
12 Disposing
For disposal observe the applicable national regulations regarding electronic components.
Disposing
Leuze electronic MLC 520 EX 49
13 Service and support
24-hour on-call service at:
+49 (0) 7021 573-0
Service hotline:
+49 (0) 8141 5350-111
Monday to Thursday, 8.00 a.m. to 5.00 p.m. (UTC+1)
Friday, 8.00 a.m. to 4.00 p.m. (UTC+1)
E-mail:
service.protect@leuze.de
Return address for repairs:
Service center
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Service and support
Leuze electronic MLC 520 EX 50
14 Specifications
14.1 General specifications
Table 14.1: Protective field data
Specifications
Physical resolution
Operating range [m] Protective field height [mm]
[mm]
min. max. min. max.
20 0 15 600 1500
30 0 10 600 1500
Table 14.2: Safety-relevant technical data
Type in accordance with IEC/EN 61496 Type 4
SIL in accordance with IEC 61508 SIL 3
SILCL in accordance with IEC/EN 62061 SILCL 3
Performance Level (PL) in accordance with EN ISO 13849-1 PL e
Category in accordance with EN ISO 13849-1 Cat. 4
Average probability of a failure to danger per hour (PFH
Service life (T
) 20 years
M
) 7.73x10-9 1/h
d
Table 14.3: Explosion protection
Ex device group/category II, 3G
II, 3D
Ex-zone 2, 22
Permissible surface tempera-
T<85° (T4)
ture
Ignition protection type "nA" non-sparking, "tc" protection through housing
Marking acc. to EN 60079-0,
EN 60079-15, EN 60079-28 for
II, 3G Ex nA op is IIB T4 Gc X
II, 3D Ex tc IIIB T85°C DC IP54, 0°C £ T
£ 55°C
a
3G and EN 60079-0, EN 6007931 for 3D
Table 14.4: General system data
Connection technology M12, 5-pin (transmitter)
M12, 8-pin (receiver)
Supply voltage U
, transmitter and receiver +24 V, 20 %, compensation necessary
v
at 20 ms voltage dip, min. 250 mA
(+ OSSD load)
Residual ripple of the supply voltage 5 % within the limits of U
v
Current consumption - transmitter 50 mA
Current consumption receiver 150 mA (without load)
Common value for ext. fuse in the supply line for transmitter
2 A semi time-lag
and receiver
Leuze electronic MLC 520 EX 51
Specifications
Synchronization optical between transmitter and receiver
Safety class III
Degree of protection IP65
Temperature range, operation 0 … 55 °C
Temperature range, storage -25 … 70 °C
Relative humidity (non-condensing) 0 … 95 %
Vibration fatigue limit 5 g, 10 - 55 Hz in accordance with IEC/
EN 60068-2-6; amplitude 0.35 mm
Shock resistance 10 g, 16 ms in accordance with IEC/
EN 60068-2-6
Profile cross-section 29 mm x 35.4 mm
Dimensions see figure 14.1 andsee table 14.8
Weight see table 14.8
Table 14.5: System data - transmitter
Transmitter diodes, class in acc. with EN 60825-1:
1
1994 + A1: 2002 + A2: 2001
Wavelength 940 nm
Pulse duration 800 ns
Pulse pause 1.9 s (min.)
Mean power <50 W
Input current pin 4 (range) Against +24 V: 10 mA
Against 0 V: 10 mA
Table 14.6: System data receiver, indication signals and control signals
Pin Signal Type Electrical data
1 RES/STATE Input:
Output:
Against +24 V: 15 mA
Against 0 V: 80 mA
3 EDM Input: Against 0 V: 15 mA
4 RES Input: Against 24 V: 15 mA
Table 14.7: Technical data of the electronic safety-related switching outputs (OSSDs) on the receiver
Safety-related PNP transistor outputs (short-circuit
Minimum Typical Maximum
monitored, cross-circuit monitored)
Switching voltage high active (U
- 1.5V) 18 V 22.5 V 27 V
v
Switching voltage low 0 V +2.5 V
Switching current 300 mA 380 mA
Residual current < 2
200 A
a)
Load capacity 0.3 F
Leuze electronic MLC 520 EX 52
Specifications
M12
R
R
B
A
H
PFN
C
29
35,4
Safety-related PNP transistor outputs (short-circuit
Minimum Typical Maximum
monitored, cross-circuit monitored)
Load inductivity 2 H
Permissible wire resistance for load <200
Permissible wire cross section 0.25 mm
Permissible cable length between receiver
2
100 m
b)
and load
Test pulse width 60 s340 s
Test pulse distance (5 ms) 60 ms
OSSD restart delay time after beam interruption 100 ms
a) In the event of a failure (if the 0V cable is interrupted), each output behaves as a 120 k resistance to Uv. A down-
stream safety PLC must not detect this as a logical 1.
b) Note the additional restrictions due to cable length and load current.
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 con-
siderably extend the decay times of inductive switching elements.
14.2 Dimensions, weight, response time
Dimensions, weight and response time are dependent on
• the resolution
• the length
Figure 14.1: Dimensions of transmitter and receiver
goes beyond the dimensions of the optics area to the outer borders of
PFE
Effective protective field height H
Leuze electronic MLC 520 EX 53
the circles labeled with R.
Calculation of the effective protective field height
H
[mm] = Effective protective field height
PFE
[mm] = Nominal protective field height (see table 14.8)
H
PFN
A [mm] = Total height
B [mm] = Additional dimensions for calculation of the effective protective field height (see
table 14.9)
C [mm] = Value for calculating the effective protective field height (see table 14.9)
Table 14.8: Dimensions (nominal protective field height), weight and response time
Device type Transmitter and receiver Receiver
Dimensions [mm] Weight [kg] Response time [ms] acc. to resolution
Specifications
Type
a)
H
PFN
A=H
PFN
+66
b)
14 mm 20 mm 30 mm 40 mm 90 mm
MLC…-600 600 666 0.75 14 12 7 7 3
MLC…-750 750 816 0.90 17 14 8 8 4
MLC…-900 900 966 1.05 20 17 9 9 4
MLC…-1050 1050 1116 1.20 23 19 10 10 4
MLC…-1200 1200 1266 1.35 26 22 12 12 5
MLC…-1350 1350 1416 1.50 30 24 13 13 5
MLC…-1500 1500 1566 1.65 33 26 14 14 6
a) H
= nominal protective field height = length of the yellow housing part
PFN
b) Total height, see figure 14.1
Table 14.9: Additional dimensions for calculating the effective protective field height
R = resolution B C
20 mm 1.5 mm 18 mm
30 mm 13 mm 17 mm
Leuze electronic MLC 520 EX 54
14.3 Dimensional drawings: Accessories
73
61
6.2
6.2
R3.1
R10
R10
22
10
R3.1
10.8
4
25
12.1
Ø6,2
Ø6,2
34
20
8,2
28,3
23,75
9,1
41,2
8
7
51
Ø18
Ø28
37
41,4
17,3
12,8
21,8
8,2
20
34
8
7
37
51
Ø18
Ø28
0,75
29,4
R10
Specifications
4
39
R3.1
29
16
18.4
31.7
R3.1
12
30
R3.1
R10
12
Figure 14.2: BT-L mounting bracket
R6
Figure 14.3: BT-Z parallel bracket
Leuze electronic MLC 520 EX 55
Figure 14.4: BT-R swivel mount
Figure 14.5: BT-P40 clamp bracket for mounting in UDC device columns
65
80
40
20
14
~26.5
11. 3
a
b
~40
~34
70
10
35
60
270
26,5
40
34
35
235
11,3
7
6
Specifications
Leuze electronic MLC 520 EX 56
Figure 14.6: BT-SSD and BT-SSD-270 swiveling mounting
brackets
15 Ordering information and accessories
Nomenclature
Part designation:
MLCxyy-za-hhhhei-ooo
Table 15.1: Part number code
MLC Safety sensor
x Series: 3 for MLC 300
x Series: 5 for MLC 500
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
Ordering information and accessories
z Device type:
T: transmitter
R: receiver
a Resolution:
14: 14 mm
20: 20 mm
30: 30 mm
40: 40 mm
90: 90 mm
hhhh Protective field height:
150 … 3000: from 150 mm to 3000 mm
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)
Table 15.2: Part designations, examples
Examples for part designation
MLC500T20-900-EX2 Type 4 transmitter, PL e, SIL 3, resolution 20 mm, protective field height
MLC520R30-600-EX2 Type 4 Standard receiver, PL e, SIL 3, resolution 30 mm, protective field height
Leuze electronic MLC 520 EX 57
Features
900 mm, explosion protection
600 mm, explosion protection
Ordering information and accessories
Scope of delivery
• Transmitter including 2 sliding blocks, 1 instruction sheet
• Receiver including 2 sliding blocks, 1 self-adhesive notice sign Important notices and notices for the
machine operator, 1 set of connecting and operating instructions (PDF file on CD-ROM)
• K-VM12-Ex interlocking guard, 2 x
Table 15.3: Article numbers of MLC 500 EX transmitter depending on resolution and protective field
height
Protective
field height
hhhh [mm]
20 mm
MLC500T20hhhh-EX2
30 mm
MLC500T30hhhh-EX2
600 68040206 68040306
750 68040207 68040307
900 68040209 68040309
1050 68040210 68040310
1200 68040212 68040312
1350 68040213 68040313
1500 68040215 68040315
Table 15.4: Article numbers of MLC 520 EX receiver depending on resolution and protective field
height
Protective
field height
hhhh [mm]
20 mm
MLC520R20hhhh-EX2
30 mm
MLC520R30hhhh-EX2
600 68042206 68042306
750 68042207 68042307
900 68042209 68042309
1050 68042210 68042310
1200 68042212 68042312
1350 68042213 68042313
1500 68042215 68042315
Table 15.5: Accessories
Part no. Article Description
Connection cables for MLC 500 EX transmitter, shielded
678055 CB-M12-5000E-5GF Connection cable, 5-pin, 5 m long
678056 CB-M12-10000E-5GF Connection cable, 5-pin, 10 m long
678057 CB-M12-15000E-5GF Connection cable, 5-pin, 15 m long
678058 CB-M12-25000E-5GF Connection cable, 5-pin, 25 m long
Connection cables for MLC 500 EX transmitter, unshielded
429087 CB-M12-5000-5GF Connection cable, 5-pin, 5 m long
Leuze electronic MLC 520 EX 58
Ordering information and accessories
Part no. Article Description
429280 CB-M12-10000-5GF Connection cable, 5-pin, 10 m long
429088 CB-M12-15000-5GF Connection cable, 5-pin, 15 m long
429089 CB-M12-25000-5GF Connection cable, 5-pin, 25 m long
429281 CB-M12-50000-5GF Connection cable, 5-pin, 50 m long
Connection cables for MLC 520 EX receiver, shielded
678060 CB-M12-5000E-8GF Connection cable, 8-pin, 5 m long
678061 CB-M12-10000E-8GF Connection cable, 8-pin, 10 m long
678062 CB-M12-15000E-8GF Connection cable, 8-pin, 15 m long
678063 CB-M12-25000E-8GF Connection cable, 8-pin, 25 m long
Connection cables for MLC 520 EX receiver, unshielded
429285 CB-M12-5000-8GF Connection cable, 8-pin, 5 m long
429286 CB-M12-10000-8GF Connection cable, 8-pin, 10 m long
429287 CB-M12-15000-8GF Connection cable, 8-pin, 15 m long
429288 CB-M12-25000-8GF Connection cable, 8-pin, 25 m long
429289 CB-M12-50000-8GF Connection cable, 8-pin, 50 m long
User-configurable connectors for MLC 500 EX transmitter
429175 CB-M12-5GF Cable socket, 5-pin, metal housing, shield on
housing
User-configurable connectors for MLC 520 EX receiver
429178 CB-M12-8GF Cable socket, 8-pin, metal housing, shield on
housing
Interlocking guard
50109217 K-VM12-Ex Mechanical interlocking guard for M12 connector,
5 x
Mounting technology
429056 BT-2L L mounting bracket, 2 x
429057 BT-2Z Z mounting bracket, 2 x
429046 BT-2R1 360° swivel mount, 2 x incl. 1 MLC cylinder
424417 BT-2P40 Clamp bracket for slot mounting, 2 x
429058 BT-2SSD Swivel mount with shock absorber,
8°, 70 mm
long, 2 x
429059 BT-4SSD Swivel mount with shock absorber,
8°, 70 mm
long, 4 x
429049 BT-2SSD-270 Swivel mount with shock absorber, 8°, 270 mm
long, 2 x
425740 BT-10NC60 Sliding block with M6 thread, 10 x
Leuze electronic MLC 520 EX 59
Ordering information and accessories
Part no. Article Description
425741 BT-10NC64 Sliding block with M6 and M4 thread, 10 x
425742 BT-10NC65 Sliding block with M6 and M5 thread, 10 x
Device columns
549855 UDC-900-S2 Device column, U-shaped, profile height 900 mm
549856 UDC-1000-S2 Device column, U-shaped, profile height 1000 mm
549852 UDC-1300-S2 Device column, U-shaped, profile height 1300 mm
549853 UDC-1600-S2 Device column, U-shaped, profile height 1600 mm
549854 UDC-1900-S2 Device column, U-shaped, profile height 1900 mm
549857 UDC-2500-S2 Device column, U-shaped, profile height 2500 mm
Deflecting mirror columns
549780 UMC-1000-S2 Continuous deflecting mirror column 1000 mm
549781 UMC-1300-S2 Continuous deflecting mirror column 1300 mm
549782 UMC-1600-S2 Continuous deflecting mirror column 1600 mm
549783 UMC-1900-S2 Continuous deflecting mirror column 1900 mm
Deflecting mirrors
529606 UM60-600 Deflecting mirror, mirror length 660 mm
529607 UM60-750 Deflecting mirror, mirror length 810 mm
529609 UM60-900 Deflecting mirror, mirror length 960 mm
529610 UM60-1050 Deflecting mirror, mirror length 1110 mm
529612 UM60-1200 Deflecting mirror, mirror length 1260 mm
529613 UM60-1350 Deflecting mirror, mirror length 1410 mm
529615 UM60-1500 Deflecting mirror, mirror length 1560 mm
430105 BT-2UM60 Mounting bracket for UM60, 2 x
Laser alignment aids
560020 LA-78U External laser alignment aid
520004 LA-78UDC External laser alignment aid for fastening in
Device Column
Test rods
349945 AC-TR14/30 Test rod 14/30 mm
349939 AC-TR20/40 Test rod 20/40 mm
Leuze electronic MLC 520 EX 60
16 EU Declaration of Conformity
Leuze elec tron ic Gmb H + Co. KG
In der Braike 1
D-73277 Owen
Telefon +49 (0) 7021 573-0
Leuze electronic GmbH + Co. KG, Sitz Owen, Registergericht Stuttgart, HRA 230712
Persönlich haftende Gesellschafterin Leuze electronic Geschäftsführungs-GmbH,
Sitz Owen, Registergericht Stuttgart, HRB 230550
Geschäf tsfü hrer: Ulrich Balbach
2014
/
10
EG-KONFORMITÄTS-
ERKLÄRUNG
(ORIGINAL)
EC DECLARATION OF
CONFORMITY
(ORIGINAL)
DECLARATION CE DE
CONFORMITE
(ORIGINAL)
Der Hersteller The Manufacturer Le constructeur
Leuze electronic GmbH + Co. KG
In der Braike 1, PO Box 1111
73277 Owen, Germany
erklärt, dass die nachfolgend aufgeführten Produkte den einschlägigen Anforderungen der genannten EG-Richtlinien und Normen
entsprechen.
declares that the following listed
products full the relevant provisions of the mentioned EC Directives and standards.
déclare que les produits identiés
suivants sont conformes aux directives CE et normes mentionnées.
Produktbeschreibung: Description of product: Description de produit:
Sicherheits- Lichtvorhang,
Berührungslos wirkende
Schutzeinrichtung,
Sicherheitsbauteil nach 2006/42/EG
Anhang IV
MLC 100, MLC 300, MLC 500
Seriennummer siehe Typschild
Safety Light Curtain,
Active opto-electronic protective
device,
safety component in acc. with
2006/42/EC annex IV
MLC 100, MLC 300, MLC 500
Serial no. see name plates
Barrière immatérielle de sécurité,
Èquipement de protection électro-
sensible,
Èlément de sécurité selon
2006/42/CE annexe IV
MLC 100, MLC 300, MLC 500
N° série voir plaques signalétiques
Kennzeichnung Gas/Staub: Cert ication gas/dust: Cert ication gaz / poussière :
II, 3G Ex nA op is IIB T4 Gc X
II, 3D Ex tc IIIB T85°C DC IP54, 0°C ≤ Ta ≤ 55°C
Angewandte EG-Richtlinie(n): Applied EC Di rective(s): Directive(s) CE appliquées:
2006/42/EG 2006/42/EC 2006/42/CE
2004/108/EG
94/9/EG
2004/108/EC
94/9/EC
2004/108/CE
94/9/CE
Angewandte Normen: Applied standards: Normes appliquées:
EN 61496-1:2009; IEC 61496-2:2006; EN 55011/A2:2007; EN 50178:1997; EN ISO 13849-1: 2008 (Kat. 4, Ple) ;
IEC 61508 :2010; EN 60079-0:2009; EN 60079-15:2010; EN 60079-28:2007; EN 60079-31:2009
Benannte Stelle:
Notied Body: Organisme notié:
TÜV-SÜD PRODUCT SERVICE GmbH
Zertifizierungsstelle
Ridlerstraße 65
D-80339 München
Bevollmächtigter für die Zusam-
menstellung der technischen Un-
terlagen:
Authorized person to compile the
technical le:
Personne autorisée à constituer le
dossier technique:
André Thieme; Leuze electronic GmbH + Co. KG
Liebigstr. 4; 82256 Fuerstenfeldbruck; Germany
4102.01.61 ,newO
Datum / Date / Date Ulrich Balbach, Geschäftsführer / Director / Directeur
EU Declaration of Conformity
Leuze electronic MLC 520 EX 61
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