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TMC 66
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Leuze electronic TMC 66 Connecting And Operating Instructions

TMC 66
Test Monitoring Unit with integrated muting controller
607109 - 2010/08
Subject to change
without prior notice
CONNECTING AND OPERATING INSTRUCTIONS
Original Instructions
Notes on Connecting and Operating Instructions
This connecting and operating instructions manual contains information on the proper use of the test monitoring unit with integrated muting controller TMC 66 in accordance with its intended purpose.
All the information contained herein, in particular the safety notes, need to be carefully observed.
Notes regarding safety and warnings are marked by this symbol .
Notes regarding important pieces of information are marked by the symbol .
This connecting and operating instructions manual must be stored carefully. It must be available for the entire operating time of the test monitoring unit with integrated muting controller TMC 66.
The Leuze electronic GmbH + Co. KG is not liable for damages caused by improper use. Acquaintance with these instructions is an element of the knowledge required for proper use.
© Reprints and reproduction, in whole or in part, are permitted only with the explicit permission of
Leuze electronic GmbH + Co. KG In der Braike 1 D-73277 Owen - Teck / Germany Telefon+49 (0) 7021 / 573-0 Fax+49 (0) 7021 / 573-199 info@leuze.de www.leuze.com
2 TMC 66 Leuze electronic
Inhaltsverzeichnis
1 General Information...........................................................................................................5
1.1 Certifications ........................................................................................................................5
1.2 General Information .............................................................................................................5
1.3 Definition of Terms...............................................................................................................5
1.4 Selection of Active Opto-electronic Protective Devices .......................................................6
2 Safety ..................................................................................................................................8
2.1 Approved purpose and foreseeable improper operation ...................................................... 8
2.1.1 Proper use............................................................................................................................8
2.1.2 Foreseeable misuse...........................................................................................................10
2.2 Competent personnel.........................................................................................................10
2.3 Responsibility for safety .....................................................................................................10
2.4 Exemption of liability ..........................................................................................................11
2.5 Fields of Application...........................................................................................................11
2.6 Organizing Measures .........................................................................................................11
3 Function and Commissioning.........................................................................................12
3.1 Function Characteristics of the Safety System ..................................................................12
3.2 Display and Operating Instruments....................................................................................13
3.2.1 Overview - Display and Operating Elements .....................................................................13
4 Mounting of the Safety System.......................................................................................15
4.1 Mounting of the Test Monitoring Unit TMC 66 ...................................................................15
4.2 Mounting of the Single Beam Safety Light Barrier .............................................................15
4.2.1 Multi-axis Installation.......................................................................................................... 17
4.2.2 Muting Basics.....................................................................................................................19
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5 Electrical Installation .......................................................................................................25
5.1 Supply Wiring .....................................................................................................................25
5.2 Start Input Wiring ...............................................................................................................25
5.3 Wiring of Single-beam Single Beam Safety Light Barriers ...........................................................27
5.4 Wiring of Single Beam Safety Light Barrier in Series Connection................................................28
5.5 Wiring Control Signals..................................................................................................................29
5.6 Wiring of the muting light signals .......................................................................................29
5.7 Wiring of the Muting Signals Start 1 and Start 2 ................................................................30
5.8 Wiring Safety Output ....................................................................................................................32
5.9 Wiring of the Signal Outputs ..............................................................................................33
5.10 Selecting of the Operating Mode..................................................................................................35
5.11 Starting the unit when the single beam safety light barrier is interrupted........................... 36
5.12 Operating Conditions without Muting Function .................................................................. 37
5.13 TMC 66 without muting function, with start- and restart interlock ......................................38
5.14 Modes with muting function................................................................................................40
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Inhaltsverzeichnis
6 Error Messages on the TMC 66 ...................................................................................... 46
7 Technical Data.................................................................................................................. 48
8 Appendix........................................................................................................................... 50
8.1 Wiring diagram with Single Beam Safety Light Barrier and PLC as muting sender........... 50
8.2 Remaining risks (EN ISO 12100-1).................................................................................... 50
4 TMC 66 Leuze electronic

1 General Information

1.1 Certifications

The test monitoring unit with integrated muting controller TMC 66 has been manufactured observing current European directives and international standards.
The manufacturer of the test monitoring unit TMC 66, Leuze electronic GmbH+Co. KG in D-73277 Owen/Teck, possesses a certified quality assurance system in accordance with ISO 9001.

1.2 General Information

An active optoelectronic protective device is part of the electrical equipment which has to be applied to those machines which contain the potential risk of bodily injury. They provide protection by causing the machine to move into a safe operating state before a person can get into a dangerous situation (EN 61496-1).

1.3 Definition of Terms

AOPD type 2
The EN 61496 describes two types of active active opto-electronic protective devices (AOPD) with respect to the requirements concerning safety relevant parts of control units
13849-1).
(ISO The AOPD type 2 fulfills the requirements of category 2 acc. to ISO 13849-1. A periodic
function test has to detect malfunctions in the safety function. In case of a failure, the next machine cycle may not be released. A malfunction of the AOPD type 2 between the testings can cause the loss of the safety function. In normal function, at least one safety output of the AOPD type 2 has to move into the OFF-position if the sensor reacts or if the power supply of the AOPD is interrupted.
General Information
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Safety output (OSSD)
The part of the AOPD which is connected to the machine control and which moves into the OFF-position as soon as the sensor part reacts during normal operation.
Start interlock
An equipment which disables the automatic machine start if the power supply of the contactless active protective device is switched on or if it had been interrupted and switched on again.
Start testing
A manual or automatic test which is performed after the contactless active protective device has been switched on. It tests the complete safety-relevant control system before the normal machine operation is induced.
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General Information
Muting
The intentional bypassing of the safety function, e.g. during material transport into the hazardous area.
Muting sensors
Muting sensors differentiate between persons and transported material. If the muting sensors are activated simultaneously or in the intended order, the safety function of the AOPD is bypassed. Material can be brought into the hazardous area without taking the machine out of operation.
Contactor monitoring
The contactor monitoring checks before every release of the switching outputs if the succeeding contactors are open. Only then, a new release is possible.
Restart interlock
An equipment which disables the automatic restart of the machine after the sensor part has reacted during a dangerous part of the machine cycle, a change of the operating mode, and/or operator mode of the machine.

1.4 Selection of Active Opto-electronic Protective Devices

The following strategy is to be applied (iterative process):
1. Determination of the protected area
2. Determination of the protective function
• Finger or hand protection
• Access protection for persons
• Presence detection
3. Determination of the control category
4. Calculation of the safety distance
Determination of the protected area
Through risk calculation, the following has to be observed:
• the size of the protective field
• the access points
• the hazardous areas
• Bypassing possibilities
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General Information
Determination of the protective function
Finger and hand protection: The user is close to the hazardous area.
Access protection: Access to the hazardous area is protected.
Presence detection: A hazardous area which is completely surrounded by
permanently installed protective devices is monitored for presence of objects or access protection and pres ence detection are combined.
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Safety

2 Safety

Before using the Test Monitoring Unit, a risk evaluation must be performed according to valid standards (e.g. EN
62061). The result of the risk assessment determines the required safety level of the
EN Test Monitoring Unit (see "TMC 66 Test Monitoring Units with integrated muting controller" 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 the affected personnel.
Before working with the Test Monitoring Unit, completely read and understand 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 Test Monitoring Units:
• Machinery directive 2006/42/EC
• Low voltage directive 2006/95/EC
• Electromagnetic compatibility directive 2004/108/EC
• Use of Work Equipment Directive 89/655/EEC supplemented by Directive 95/63 EC
• OSHA 1910 Subpart 0
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and Labor Protection Act
• Device Safety Act
Notice!
For safety-related information you may also contact the local authorities (e.g., industrial inspectorate, employer's liability insurance association, labor inspectorate, occupational safety and health authority).
ISO 14121, EN ISO 12100-1, ISO 13849-1, IEC 61508,
Tabelle 2.1-1). For mounting, operating and testing, document

2.1 Approved purpose and foreseeable improper operation

Warning!
A running machine can cause severe injuries! Make certain that, during all conversions, maintenance work and inspections, the system is securely shut down and protected against being restarted again.

2.1.1 Proper use

The Test Monitoring Unit must 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 occupational safety, and after it has been installed on the machine, connected, commissioned, and checked by a competent person.
When selecting the Test Monitoring Unit it must be ensured that its safety-related capability meets or exceeds the required performance level PL
8 TMC 66 Leuze electronic
ascertained in the risk assessment.
r
Safety
Listed in the following table are the safety-related characteristic parameters of the TMC 66 Test Monitoring Units with integrated muting controller.
Type in accordance with IEC/
61496
EN Performance Level (PL) in ac-
cordance with ISO 13849-1: 2008
Category in accordance with
13849-1
ISO Mean probability of a danger-
ous failure per hour (PFHd) as a function of the mean number of
annual switching cycles of the relay n
*
op
Mean time to dangerous failure
)
(MTTF
d
*nop = mean number of annual actuations, see C.4.2 and C.4.3 of ISO 13849-1: 2008
Use the following formula to calculate the mean number of annual actuations:
Type 2
PL d
Cat. 2
nop = 4,800: 1.4 x 10
nop = 28,800: 3.1 x 10
nop = 86,400: 7.9 x 10
nop = 4,800: 250 years nop = 28,800: 100 years nop = 86,400: 40 years
-8
1/h
-8
1/h
-8
1/h
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n
In doing so, make the following assumptions with regard to the use of the component: hop = mean operating time in hours per day
dop = mean operating time in days per year t
mean time between the start of two successive cycles of the component (e.g switching of a
cycle =
valve) in seconds per cycle
dophop3600s/h⋅⋅()t
op
÷=
Zyklus
Table 2.1-1: Safety-related characteristic parameters of the TMC 66 Test Monitoring
Units with integrated muting controller.
• The Test Monitoring Unit is used in combination with one or more Multiple Light Beam Safety Devices or Safety Light Curtains to safeguard danger zones or points of operation.
• The control of the machine or system that is to be safeguarded must be electrically influenceable. A switch command initiated by a TMC
66 must result in an immediate
shutdown of the dangerous movement.
• The "Reset" acknowledgment button for unlocking the start/restart interlock must be mounted in such a way that the entire danger zone can be seen from its mounting location.
• Message outputs (state outputs) must not be used for switching safety-relevant signals.
• The Test Monitoring Unit is designed for installation in a cabinet or a protective housing with a protection rating of at least IP
54.
• The 24 V DC ±20% power supply must guarantee safe isolation from the mains voltage and be able to bridge a power outage period of 20
ms.
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Safety
• Depending on external wiring, dangerous voltages may be present at the switching

2.1.2 Foreseeable misuse

outputs. In addition to the power supply, these must be switched off and safeguarded against being switched back on prior to all work on the TMC
• These operating instructions must be included with the documentation of the machine on which the protective device is installed so that they are available to the operator at all times.
• Manipulating the Test Monitoring Unit also voids all warranty claims against the manufacturer of the Test Monitoring Unit.
• The Test Monitoring Unit must be tested regularly by competent personnel.
• The safety distance between the AOPD and the point of operation is to be maintained. It is calculated according to the formulas for machine-specific C standards or given in the general B1 standard ISO braking time of the machine must be taken into account.
• Two switching contacts must always be looped into the switch-off circuit of the machine. To prevent welding, relay switching contacts must be fused/protected externally accord ing to the technical data.
The Test Monitoring Unit 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.
Any use other than that defined under the "intended use" or which goes beyond that use is considered improper use!
e.g.
• applications in explosive or easily flammable atmospheres
Attention!
Such instances can jeopardize the health and lives of the personnel operating the machinery and/or may cause damage to property.
66.
13855. The reaction time of the Test Monitoring Unit and the
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2.2 Competent personnel

Prerequisites for competent personnel:
• he has a suitable technical education
• he knows the rules and regulations for occupational safety, safety at work and safety technology and can assess the safety of the machine
• he knows the instructions for the Test Monitoring Unit and the machine
he has been instructed by the responsible person on the mounting and operation of the machine and of the Test Monitoring Unit

2.3 Responsibility for safety

Manufacturer and operating company must ensure that the machine and implemented Test Monitoring Unit 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.
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The manufacturer of the machine is responsible for:
• safe machine construction
• safe implementation of the Test Monitoring Unit
• imparting all relevant information to the operating company
• adhering to all regulations and directives for the safe starting-up of the machine
The company operating the machine is responsible for:
• instructing the operating personnel
• maintaining the safe operation of the machine
• adhering to all regulations and directives for occupational safety and safety at work
• regular testing by competent personnel

2.4 Exemption of liability

Leuze electronic GmbH + Co. KG is not liable in the following cases:
• Test Monitoring Unit 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
• changes are made to the Test Monitoring Unit

2.5 Fields of Application

The test monitoring unit TMC 66 may be used as isolating protective device for safeguar­ding of hazardous areas on power driven machines.
The following areas of application are thus possible (excerpt):
• Edge, frame, star and carcass press in lumber industry acc. to prEN 691 resp. ZH 1/3.19
• Printing and paper processing machines acc. to prEN 1010
• Power driven windows, doors and portals acc. to ZH 1/494
• Storage equipment and devices acc. to ZH 1/482 and DIN 15185 part 2
• Textile machines acc. to VBG and DIN EN ISO 11 111
• Food processing equipment acc. to prEN 1672-1 resp. VBG 77
• Packaging machinery acc. to prEN 415-1 to -7 resp. VBG 76
• Meat processing equipment acc. to prEN 12463 resp. VBG 79
• Machines of the chemical, rubber and plastic industry acc. to VBG 22
Safety
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2.6 Organizing Measures

Mounting, commissioning and maintenance of the device must only be carried out by qualified personnel. Electrical work must be carried out by a certified electrician.
Adjustment and change of the protective field for the protection of persons may only be carried out by an authorized person.
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Function and Commissioning
g

3 Function and Commissioning

3.1 Function Characteristics of the Safety System

The complete safety system consists of a TMC 66 and accompanying single beam safety light barriers or light barriers.
Single Beam Safety Light Barrier
Transmitter Receiver
active
Start/active
Input "contactor monitoring"
Status output "Error"
Status output "Safety on"
Start 1-active Start 1-
Start 2-active Start 2-
Safety output. 2
Safety output. 1
Light signal 1
Light signal 2
Control 2
Control 1
Sensor/ PLC
Sensor/ PLC
Redun­dance
Fig. 3.1-1: Architecture of the TMC safety system
After switching on of the TMC 66 via the start input, the function of the connected single beam safety light barriers or the integrated muting controller is cyclically monitored every 2 sec.
The electrical integration into the control has to be performed acc. to the corresponding safety category acc. to ISO 13849-1. The voltage free safety relay outputs can be directly used for shut-down of the dangerous movement.
Inside the test monitoring unit TMC 66, a selectable start- and restart interlock, as well as a selectable contactor monitoring input are integrated.
Emer shut­down
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3.2 Display and Operating Instruments

Inside the test monitoring unit TMC 66, LEDs and a 7-segment display for the system state are integrated.
The selection switch of the start- and restart interlock as well as the contactor monitoring are also located on the front panel under the transparent front screen.
The front screen can be removed for commissioning and for adjustment of start- and restart interlock as well as contactor monitoring (see

3.2.1 Overview - Display and Operating Elements

LED 1 Status display protective field state LED 2 Status display start/ activation input LED 3 Status display start and restart interlock LED 4 Status display contactor monitoring LED 5 Status display safety circuit closed LED 6 Status display safety circuit open LED 7 Status display muting sensor Start 1 LED 8 Status display muting sensor Start 2 LED 9 Status display muting preparation Control 1 LED 10 Status display muting preparation Control 2 LED 11 Status display muting lamp
Status 1 State of test monitoring unit - SLS Status 2 State of muting controller
Switch 1 Selection with/without start-/restart interlock Switch 2 Selection with/without contactor monitoring
Figure 3.2-2).
Function and Commissioning
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Switch 1
Switch 2
Fig. 3.2-1: Display and operating instruments
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Function and Commissioning
Removing and mounting the front screen
The housing has carvings on both sides of the transparent front screen. The front screen can be lifted by inserting a screw driver size 1 into these carvings.
Fig. 3.2-2: Removing the front screen
To remount the front screen, simply press it into the fastening frame. Observe the correct position of the code snugs.
Fig. 3.2-3: Remounting the front screen
The reset button can be activated through the hole in the transparent front screen. In case of a failure, the device can be reset, the self-containing mode activated, and the switch positions can be programmed by using the reset-button.
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Mounting of the Safety System

4 Mounting of the Safety System

4.1 Mounting of the Test Monitoring Unit TMC 66

The TMC 66 has been designed for mounting on a standard rail (snap-on) in a suitable switching cabinet.
Note!
The mounting instructions in this chapter have to be heeded for fault-free functioning of the whole safety system.

4.2 Mounting of the Single Beam Safety Light Barrier

It is absolutely mandatory that the valid guidelines and standards are observed when mounting the single beam safety light barriers.
Safety distance
A certain time delay applies between the interruption of the light beam of the single beam safety light barriers and the stand-still of the machine. The photo electric sensors have to be installed in such a way that the dangerous area can not be reached within this time delay. The minimum distance for safeguarding the hazardous area is 850
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mm.
Fig. 4.2-1: Safety distance from the hazardous area
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Mounting of the Safety System
Calculation of the safety distance
The safety distance S between photo electric sensor and hazardous area is calculated acc. to EN 999 using the following formula:

S = K * T + C

S = Safety distance between photoelectric sensor and hazardous area
K = Grip and approach speed
T = Time delay between interruption of the light beam and stand-still of the machine
C = Safety constant
1200 mm with single-axis installation,
850 mm multi-axis installation
Example for the calculation of the safety distance:
A machine with a system response time of 500 ms has to be equipped with a two-beam safeguarding. The response time of the two-beam AOPD and the test monitoring unit
66 is 20 ms.
TMC
Application of the formula: S = K * T + C
Assigned is:
S = the minimum distance of the two-beam AOPD from the hazardous area
K = approach speed 1600 mm/s (EN 999)
T = sum out of system response time of the machine and response time of the AOPD
C 850 mm multi-axis installation
Result:
S = (1600 mm/s * (500 ms+20 ms)) + 850 mm S = 1682 mm
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