SICK miniTwin4 Operating Instructions Manual
miniTwin4
Safety light curtain
O P E R A T I N G I N S T R U C T I O N S
Described product
mini
Twin4
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
his work is protected by copyright. Any rights derived from the copyright shall be
T
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
T
his document is an original document of SICK AG.
Change history of the device
T
he table below describes the technical changes made to the device in the course of
product maintenance. The change history of the device can be seen on the type label in
the Ident No. field with the additional change number “(Rev. #)”.
Change number in Ident No.
f
ield
No change number Initial device version
(Rev. 1) Addition to the Cross-circuit
Change Additional information
see "Structure and function",
monit
oring field
page 11
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Contents
CONTENTS
1 About this document........................................................................ 6
1.1 Scope......................................................................................................... 6
1.2 Target groups and structure of these operating instructions................ 6
1.3 Additional information.............................................................................. 7
1.4 Symbols and document conventions...................................................... 7
2 Safety information............................................................................ 9
2.1 General safety notes................................................................................ 9
2.2 Intended use............................................................................................. 9
2.3 Requirements for the qualification of personnel.................................... 10
3 Product description........................................................................... 11
3.1 Structure and function............................................................................. 11
3.2 Product characteristics............................................................................ 13
3.2.1 Device overview....................................................................... 13
3.2.2 Absence of blind zones........................................................... 14
3.2.3 Beam coding............................................................................ 14
3.2.4 Restart interlock...................................................................... 14
3.2.5 External device monitoring (EDM).......................................... 14
3.2.6 Cascading................................................................................. 15
3.2.7 System plug.............................................................................. 15
3.2.8 Flexible control cabinet cabling and status indication on
th sides................................................................................. 16
bo
3.2.9 Status indicators...................................................................... 17
3.3 Example applications............................................................................... 19
4 Project planning................................................................................ 21
4.1 Manufacturer of the machine.................................................................. 21
4.2 Operator of the machine.......................................................................... 21
4.3 Design........................................................................................................ 21
4.3.1 Scanning range and protective field width............................. 22
4.3.2 Minimum distance from the hazardous point....................... 23
4.3.3 Minimum distance from reflective surfaces.......................... 25
4.3.4 Minimum distance for cascaded systems............................. 26
4.3.5 Protection against interference from systems in close prox‐
imity to each other................................................................... 28
4.4 Integrating the equipment into the electrical control............................. 29
4.4.1 Protective operation without reset and/or without EDM...... 31
4.4.2 Restart interlock...................................................................... 32
4.4.3 External device monitoring (EDM).......................................... 34
4.4.4 Cascading................................................................................. 35
4.4.5 Connection diagrams.............................................................. 38
4.5 Testing plan............................................................................................... 40
4.5.1 Test rod check.......................................................................... 41
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CONTENTS
4.5.2 Visual check of the machine and the protective device........ 43
5 Mounting............................................................................................. 44
5.1 Safety......................................................................................................... 44
5.2 Unpacking.................................................................................................. 44
5.3 Mounting the system plug........................................................................ 45
5.4 Mounting................................................................................................... 47
5.4.1 Mounting direction of the twin stick....................................... 49
5.4.2 Mounting options..................................................................... 49
5.4.3 Mounting with O-Fix bracket................................................... 50
5.4.4 Mounting with C-Fix bracket.................................................... 52
5.4.5 Mounting with L-Fix bracket..................................................... 53
5.4.6 Mounting with C-Fix bracket and L-Fix bracket...................... 55
5.4.7 Mounting with C-Fix-Flex bracket............................................ 56
5.5 Resolution at the end of the twin sticks.................................................. 58
6 Electrical installation........................................................................ 60
6.1 Safety......................................................................................................... 60
6.2 System connection................................................................................... 62
7 Configuration..................................................................................... 63
7.1 Factory settings......................................................................................... 63
7.1.1 Changing the configuration later............................................ 63
7.2 Configuring beam coding......................................................................... 63
7.3 Reset and external device monitoring (EDM)......................................... 64
7.3.1 Configuring reset..................................................................... 64
7.3.2 Configuring external device monitoring (EDM)...................... 65
7.3.3 Deactivating reset and EDM................................................... 66
7.4 Cascading.................................................................................................. 68
7.4.1 Cascading new devices........................................................... 71
7.4.2 Connecting a new device in an existing cascade.................. 71
7.4.3 Cascading pre-configured devices.......................................... 72
7.5 Status indication on both sides............................................................... 72
8 Commissioning.................................................................................. 73
8.1 Safety......................................................................................................... 73
8.2 Overview.................................................................................................... 73
8.3 When it is switched on.............................................................................. 74
8.4 Alignment of the twin stick....................................................................... 74
8.4.1 Aligning the twin sticks to one another.................................. 75
8.4.2 Indication of the alignment quality......................................... 77
8.5 Check during commissioning and modifications.................................... 77
9 Operation............................................................................................ 78
9.1 Safety......................................................................................................... 78
9.2 Regular thorough check........................................................................... 78
9.3 LEDs........................................................................................................... 79
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CONTENTS
10 Maintenance...................................................................................... 81
10.1 Safety......................................................................................................... 81
10.2 Regular cleaning....................................................................................... 81
10.3 Regular thorough check........................................................................... 82
11 Troubleshooting................................................................................. 83
11.1 Safety......................................................................................................... 83
11.2 Diagnostic LEDs........................................................................................ 83
11.2.1 Indications when switching on................................................ 83
11.2.2 Status indicator........................................................................ 85
11.2.3 Fault indicators........................................................................ 86
12 Decommissioning............................................................................. 88
12.1 Protection of the environment................................................................. 88
12.2 Disposal..................................................................................................... 88
13 Technical data.................................................................................... 89
13.1 Data sheet................................................................................................. 89
13.2 Response time.......................................................................................... 91
13.3 Power consumption.................................................................................. 92
13.4 Table of weights........................................................................................ 92
13.5 Dimensional drawings.............................................................................. 94
14 Ordering information........................................................................ 95
14.1 Scope of delivery....................................................................................... 95
14.2 Ordering information miniTwin4............................................................... 95
14.3 Weld spark guard...................................................................................... 99
14.4 Alignment aid............................................................................................ 100
15 Accessories........................................................................................ 101
15.1 Brackets.................................................................................................... 101
15.2 Connectivity............................................................................................... 102
15.3 Deflector mirrors....................................................................................... 104
15.3.1 Change in scanning range using deflector mirrors................ 104
15.3.2 PNS75 deflector mirror........................................................... 104
15.3.3 PNS125 deflector mirror......................................................... 105
16 Annex.................................................................................................. 106
16.1 Compliance with EU directives................................................................. 106
16.2 Checklist for initial commissioning and commissioning........................ 107
17 List of figures..................................................................................... 108
18 List of tables....................................................................................... 110
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1 ABOUT THIS DOCUMENT
1 About this document
These operating instructions contain information required during the life cycle of the
afety light curtain.
s
These operating instructions are available to all those who work with the safety light
curtain.
Please read these operating instructions carefully and make sure that you understand
the content fully before working with the safety light curtain.
1.1 Scope
These operating instructions only apply to the miniTwin4 safety light curtain with one of
t
he following type label entries in the “Operating Instructions” field:
8012731
•
8012731/V114
•
8012731/YY20
•
8012731/YT85
•
This document is included with the following SICK part numbers (this document in all
available language versions):
8012731
1.2 Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: Project devel‐
oper
s (planners, developers, designers), installers, electricians, safety experts (e.g., CE
authorized representatives, compliance officers, persons who test and approve the
application), operators, and maintenance personnel.
The structure of these operating instructions is based on the life cycle phases of the
safety light curtain: Project planning, mounting, electrical installation, commissioning,
operation, and maintenance.
In many applications, the target groups are assigned as follows to the manufacturer
and the organization operating the machine in which the safety light curtain is inte‐
grated:
Area of responsibility Target group Specific chapters of these operating instruc‐
Manufacturer Project developers
(planners, developers,
designers)
Installers "Mounting", page 44
Electricians "Electrical installation", page 60
Safety experts "Project planning", page 21
1)
tions
"Project planning", page 21
"Configuration", page 63
"Technical data", page 89
"Accessories", page 101
onfiguration", page 63
"C
"Commissioning", page 73
"Technical data", page 89
"Checklist for initial commissioning and com‐
missioning", page 107
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ABOUT THIS DOCUMENT 1
Area of responsibility Target group Specific chapters of these operating instruc‐
Operating entity Operators "Operation", page 78
1)
Chapters not listed here are intended for all target groups. All target groups must follow all of the safety
and w
arning instructions in all chapters of the operating instructions!
In other applications, the operating organization is also the manufacturer of the equip‐
ment w
ith the corresponding allocation of the target groups.
1.3 Additional information
www.sick.com
T
he following information is available on the Internet:
This document in other languages
•
Data sheets and application examples
•
CAD data of drawings and dimensional drawings
•
Certificates (e.g. EU declaration of conformity)
•
Guide for Safe Machinery Six steps to a safe machine
•
Maintenance person‐
l
ne
1)
t
ions
"Troubleshooting", page 83
"Maintenance", page 81
"Troubleshooting", page 83
"Ordering information", page 95
1.4 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indic
ates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
ates a situation presenting possible danger, which may lead to death or serious
Indic
injuries if not prevented.
CAUTION
ates a situation presenting possible danger, which may lead to moderate or minor
Indic
injuries if not prevented.
NOTICE
Indic
ates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indicates useful tips and recommendations.
Instructions to action
T
he arrow denotes instructions to action.
b
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1 A
BOUT THIS DOCUMENT
1. The sequence of instructions for action is numbered.
2.
Follow the order in which the numbered instructions are given.
✓
The check mark denotes the result of an instruction.
LED symbols
These symbols indicate the status of an LED:
The LED is off.
o
The LED is flashing.
Ö
The LED is illuminated continuously.
O
Sender and receiver
T
hese symbols indicate the sender and receiver of the device:
The symbol indicates the sender.
s
The symbol indicates the receiver.
r
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2 Safety information
This chapter contains information on general safety for the safety light curtain.
e safety information about specific usage situations of the safety light curtain is
Mor
available in the respective chapters.
2.1 General safety notes
DANGER
H
azard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
Please read this document carefully and make sure that you understand the con‐
b
tent fully before working with the device.
Follow all safety notes in this document.
b
2.2 Intended use
SAFETY INFORMATION 2
Overview
he miniTwin4 safety light curtain is an electro-sensitive protective device (ESPE) and is
T
suitable for the following applications:
Hazardous point protection
•
Access protection
•
Hazardous area protection
•
The miniTwin4 safety light curtain must only be used within the limits of the prescribed
pecified technical data and operating conditions at all times.
and s
Any instance of improper use, incorrect modification, or manipulation of the miniTwin4
safety light curtain shall void any warranty provided by SICK AG; furthermore, SICK AG
shall not accept any responsibility or liability for any resulting damage and consequen‐
tial damage.
Important information
DANGER
azard due to lack of effectiveness of the protective device
H
Persons and parts of the body to be protected may not be recognized in case of nonobservance.
The safety light curtain works as an indirect protective measure and cannot provide pro‐
tection from parts thrown out nor from emitted radiation. Transparent objects are not
detected.
Only use the safety light curtain as an indirect protective measure.
b
Reasonably foreseeable misuse
g others, the miniTwin4 safety light curtain is not suitable for the following appli‐
Amon
cations:
Outdoors
•
Underwater
•
In explosion-hazardous areas
•
In environments with increased levels of ionizing radiation
•
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9
AFETY INFORMATION
2 S
2.3 Requirements for the qualification of personnel
The safety light curtain must be configured, installed, connected, commissioned and
viced only by qualified safety personnel.
ser
Project planning
For project planning, a person is considered competent when he/she has expertise and
experience in the selection and use of protective devices on machines and is familiar
with the relevant technical rules and national work safety regulations.
Mechanical mounting
For mechanical mounting, a person is considered competent when he/she has the
expertise and experience in the relevant field and is sufficiently familiar with the appli‐
cation of the protective device on the machine that he/she can assess its operational
safety status.
Electrical installation
For electrical installation, a person is considered competent when he/she has the
expertise and experience in the relevant field and is sufficiently familiar with the appli‐
cation of the protective device on the machine that he/she can assess its operational
safety status.
Configuration
For configuration, a person is considered competent when he/she has the expertise
and experience in the relevant field and is sufficiently familiar with the application of
the protective device on the machine that he/she can assess its work safety aspects.
Commissioning
For commissioning, a person is considered competent when he/she has the expertise
and experience in the relevant field and is sufficiently familiar with the application of
the protective device on the machine that he/she can assess its operational safety sta‐
tus.
Operation and maintenance
For operation and maintenance, a person is considered competent when he/she has
the expertise and experience in the relevant field and is sufficiently familiar with the
application of the protective device on the machine and has been instructed by the
machine operator in its operation.
An operator may clean the safety light curtain and carry out specific checks as
instructed.
Further topics
"Operation", page 78
•
"Regular cleaning", page 81
•
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3 Product description
s
s
r
r
! !
This chapter provides information on the operation of the safety light curtain and shows
xamples of its range of use.
e
3.1 Structure and function
Overview
T
he miniTwin4 safety light curtain consists of 2 identical twin sticks. Each twin stick
contains both the sender as well as the receiver unit, see figure 1, page 11. The two
twin sticks are installed so that each sender and receiver unit are located opposite one
another.
PRODUCT DESCRIPTION 3
Figure 1: Device components of the safety light curtain
Twin stick
!
Safety light curtain principle
he protective field is between the two twin sticks and is defined by the protective field
T
height and the protective field width.
The two twin sticks automatically synchronize themselves optically. Each twin stick pro‐
vides an OSSD and a so-called multifunctional connection. The OSSDs are integrated
into the machine controller. Either a reset button or an EDM can be connected to the
multifunctional connections.
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11
O
SSD2
O
SSD1
§
$
!
"
3 P
RODUCT DESCRIPTION
Figure 2: Safety light curtain principle
Protective field width
!
Protective field height
"
E.g. reset button
§
E.g. EDM
$
Protective field height
T
he protective field height indicates the range within which the test rod belonging to the
safety light curtain is reliably detected.
The size of the safety light curtain determines the protective field height.
Protective field width
T
he protective field width is the dimension of the light path between the twin sticks. The
maximum protective field width is limited by the scanning range.
Resolution
The resolution describes the size of the smallest object detected by the safety light cur‐
tain in the protective field. The resolution corresponds to the diameter of the test rod
belonging to the safety light curtain.
With the appropriate resolution, the safety light curtain provides finger and hand protec‐
tion.
12
Scanning range
The scanning range is the maximum protective field width. It is subject to the resolution
variant (14 mm or 30 mm).
The scanning range is reduced by the use of deflector mirrors and/or a weld spark
guard.
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!
"
§
PRODUCT DESCRIPTION 3
Cross-circuit monitoring
T
he following prerequisites apply for cross-circuit monitoring:
Cross-circuit monitoring is only done for devices which have a supplementary
•
change number “(Rev. no.)” on the type label in the Ident No. field.
When combining several devices, all devices must have a supplementary change
•
number “(Rev. no.)” on the type label in the Ident No. field, otherwise cross-circuit
monitoring is not provided.
Prerequisites for the protective function of the safety light curtain miniTwin4
he miniTwin4 safety light curtain can only fulfill its protective function when the follow‐
T
ing requirements are satisfied:
It must be possible to electrically influence the control of the machine.
•
It must be possible to change the dangerous state of the machine into a safe
•
state.
The miniTwin4 safety light curtain must be arranged so that objects are reliably
•
detected upon entry into the hazardous area.
The reset button must be mounted outside of the hazardous area so that it cannot
•
be actuated by a person who is inside the hazardous area. In addition, the opera‐
tor must have a complete overview of the hazardous area when actuating the reset
button.
When setting up and using the devices, the applicable statutory and regulatory
•
requirements must be observed.
Further topics
ata sheet", page 89
"D
•
"Deflector mirrors", page 104
•
"Weld spark guard", page 99
•
"Technical data", page 89
•
"Dimensional drawings", page 94
•
3.2 Product characteristics
3.2.1 Device overview
Figure 3: Device with system plug and system connection
System plug
!
System connection
"
Device connection
§
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13
!
$
"
§
3 P
RODUCT DESCRIPTION
Figure 4: Device with system plug and system connection and one extension connection
Extension connection
!
System plug
"
System connection
§
Device connection
$
3.2.2 Absence of blind zones
The design and construction of the safety light curtain extends the protective function
t
o the end of the housing without any blind spots. The absence of blind zones reduces
the space requirement when integrated in the machine.
3.2.3 Beam coding
Depending on its configuration, the safety light curtain operates with 1 of 2 beam cod‐
in
gs: code 1 or code 2. In order to avoid mutual interference between 2 neighboring
safety light curtains, one can be operated with code 1 and the other with code 2.
3.2.4 Restart interlock
The safety light curtain has an integrated restart interlock. The function can be config‐
ur
ed during commissioning.
A restart interlock prevents the machine from starting again once the protective device
has been triggered. First, the operator must press a reset pushbutton to return the pro‐
tective device to monitoring status. Then, in a second step, the operator can restart the
machine.
The reset pushbutton can be connected locally to the extension connection or in the
control cabinet.
3.2.5 External device monitoring (EDM)
The safety light curtain has integrated external device monitoring. The function can be
c
onfigured during commissioning.
14
The external device monitoring (EDM) monitors the status of downstream contactors.
In order to use the external device monitoring, positively guided contactors must be
used to switch off the machine. If the auxiliary contacts of the positively guided contac‐
tors are connected to the external device monitoring, the external device monitoring
checks whether the contactors drop off when the OSSDs are switched off.
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3.2.6 Cascading
FE
2
3
1
4
PRODUCT DESCRIPTION 3
3.2.7 System plug
Cascading allows up to 3 safety light curtains to be connected in series, e.g. f
or reliable
presence detection. The device connected to the control cabinet is the host device. The
subsequent sensors are called guest 1 and guest 2.
Overview
T
he safety light curtain requires a system plug.
The system plug is available in the following variants:
System plug with 5-pin system connection (M12×4 + FE male connector)
•
System plug with one 5-pin system connection (M12×4 + FE male connector) and
•
one 5-pin extension connection (M12×4 + FE female connector)
Figure 5: System connection pin assignment
Figure 6: System connection wires
Pre-assembled cables with open ends are available for connecting applications.
Functions of the safety light curtain
he following functions are available depending on the system plug used:
T
Restart interlock
•
External device monitoring (EDM)
•
Cascading
•
Table 1: Use of system plugs in a single system and in a cascade
System plug with 5-pin sys‐
em connection
t
Single system
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✓
w
ithout additional func‐
•
tion
RES or EDM can option‐
•
ally be configured on a
twin stick
System plug with 5-pin system
connection and 5-pin extension
connection
–
15
3 P
RODUCT DESCRIPTION
System plug with 5-pin sys‐
t
em connection
Host of a cascade –
First guest of a cascade
for cascade with 2 guest
(
devices)
Last guest of a cascade
✓
System plug suitable.
–
System plug not suitable.
–
✓
no addit
•
on the device
ional function
Further topics
"R
estart interlock", page 14
•
"External device monitoring (EDM)", page 14
•
"Cascading", page 15
•
"Connectivity", page 102
•
"Test rod check", page 41
•
3.2.8 Flexible control cabinet cabling and status indication on both sides
System plug with 5-pin system
connection and 5-pin extension
connection
✓
R
ES or EDM can optionally be
•
configured on a twin stick
✓
–
•
no addit
device
ional function on the
The safety light curtain can be connected to the control cabinet via separate connec‐
t
ion cables for each twin stick.
In a cascade, only the twin sticks of the host are connected to the control cabinet.
The OSSD status and the status of the protective field are indicated via LEDs, if applica‐
ble, the configured RES or EDM additional function is as well.
Further topics
"C
onnection diagrams", page 38
•
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3.2.9 Status indicators
!
!
!
!
!
!
!
!
180 mm
300 mm
120 mm
240 mm
&
"
§
$
%
PRODUCT DESCRIPTION 3
Figure 7: LEDs on the twin sticks
!
"
§
$
%
&
OUT
EDM
COM
RES
ERR
1, 2, 3, 4, 5
figure 7 sho
ular intervals above a protective field height of 180 mm and can light up red or green. It
is only labeled OUT in two locations on the safety light curtain.
ws the LEDs of the safety light curtain. The OUT LED (!) is mounted at reg‐
Lit up LEDs indicate a specific status of the safety light curtain. Flashing LEDs demand
action.
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3 P
RODUCT DESCRIPTION
Table 2: Meaning of LEDs
Position LED Display Comment
!
"
§
$
%
&
OUT
EDM
COM
RES
ERR
1, 2, 3, 4, 5
O Gr
een
O Red
O Or
ange
Ö Or
ange
hite
O W
Ö W
hite
O Or
ange
Ö Or
ange
O Red
Ö R
ed
O Blue
Ö Blue In combination with ERR-LED Ö r
LED lights up green when protective field is free
SSD on).
(O
LED lights up red when protective field is inter‐
rupted (OSSD off).
External device monitoring configured.
For the configuration of EDM at the first OSSD sta‐
us change, the safety light curtain expects the
t
change from 24 V to 0 V at the multifunctional
input.
Or:
In combination with the ERR-LED Ö red: External
device monitoring reports defective contactor
External communication active (e.g. for service)
No optical communication to another twin stick .
Or:
eedback when deactivating configuration.
F
Reset configured.
Reset configured.
Or:
In combina
Ö orange: error with configuration or cabling.
Protective field interrupted.
Error.
Indication of the alignment quality.
error.
tion with ERR-LED Ö red and EDM-LED
ed: display of an
o LED of
f. Ö LED flashes. O LED illuminates.
Further topics
"Dia
•
•
•
gnostic LEDs", page 83
"Status indicators", page 17
"Aligning the twin sticks to one another", page 75
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3.3 Example applications
PRODUCT DESCRIPTION 3
Figure 8: Hazardous point protection
Figure 9: Access protection
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3 PRODUCT DESCRIPTION
Figure 10: Hazardous area protection
Figure 11: Access protection with presence detection, implemented by cascade
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4 Project planning
This chapter includes important information about the proper integration of the safety
ght curtain in machines for planners, developers and designers.
li
4.1 Manufacturer of the machine
DANGER
H
azard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of nonobservance.
Conduct a risk assessment and check whether additional protective measures are
b
required.
Comply with the applicable national regulations derived from the application (e.g.,
b
work safety regulations, safety rules, or other relevant safety guidelines).
Do not combine the components of the safety light curtain with components from
b
other safety light curtains.
Apart from for the procedures described in this document, the components of the
b
safety light curtain must not be opened.
The components of the safety light curtain must not be tampered with or changed.
b
Do not carry out any repairs on the device components. Improper repair of the pro‐
b
tective device can lead to a loss of the protective function.
PROJECT PLANNING 4
4.2 Operator of the machine
DANGER
H
azard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of nonobservance.
Changes to the electrical integration of the safety light curtain in the machine con‐
b
trol and changes to the mechanical installation of the safety light curtain require
another risk assessment. The results of this risk assessment may require the
operator of the machine to meet the obligations of a manufacturer.
Apart from the procedures described in this document, the components of the
b
safety light curtain must not be opened.
The components of the safety light curtain must not be tampered with or changed.
b
Do not carry out any repairs on the device components. Improper repair of the pro‐
b
tective device can lead to a loss of the protective function.
4.3 Design
Overview
T
his chapter contains important information about the design.
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21
4 PROJECT PLANNING
Important information
DANGER
azard due to lack of effectiveness of the protective device
H
Persons and parts of the body to be protected may not be recognized in case of nonobservance.
Make sure that the following construction requirements are met so that the safety
b
light curtain can fulfill its protective function.
Twin sticks must be arranged such that persons or parts of the body are reli‐
°
ably detected when they enter the hazardous area.
Reaching under, over, and around as well as moving the safety light curtain
°
must be prevented.
Check whether additional safety measures (e.g. restart interlock) are neces‐
°
sary when it is possible for people to be located between the protective
device and the danger point without being detected.
DANGER
H
azard due to lack of effectiveness of the protective device
Certain types of light radiation can influence the protective device, e.g., light radiation
from fluorescent lamps with electronic ballast installed in the path of the beam, or
beams from laser pointers directed at the receiver unit of a twin stick.
If this type of light radiation is present in the environment of the protective device,
b
take additional measures to ensure that the protective device does not become
dangerous.
Further topics
"Mount
•
4.3.1 Scanning range and protective field width
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of nonobservance.
The safety light curtain can only be mounted on machines on which the protective
b
field width does not change when the safety light curtain is switched on.
Scanning range
he scanning range limits the maximum protective field width.
T
The scanning range is reduced by the use of deflector mirrors and/or a weld spark
guard.
ing", page 44
22
Protective field width
T
he protective field width is the dimension of the light path between the twin sticks of a
system.
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Further topics
"T
echnical data", page 89
•
"Deflector mirrors", page 104
•
"Weld spark guard", page 99
•
4.3.2 Minimum distance from the hazardous point
Overview
PROJECT PLANNING 4
A minimum dis
ardous point. This distance is required to prevent a person or part of their body from
reaching the hazardous point before the end of the machine’s dangerous state.
Calculating the minimum distance according to ISO 13855
The calculation of the minimum distance is based on international or national stan‐
dards and statutory requirements applicable at the place of installation of the machine.
If the minimum distance is calculated according to ISO 13855, it depends on the fol‐
lowing points:
Machine stopping time (time interval between triggering the sensor function and
•
the end of the machine’s dangerous state)
Response time of the protective device
•
Reach or approach speed of the person
•
Resolution (detection capability) of the safety light curtain
•
Type of approach: orthogonal (at right angles) or parallel
•
Parameters specified based on the application
•
For the USA (scope of OSHA and ANSI), different regulations may apply, e.g.:
a) Laws: Code of Federal Regulations, Title 29 (CFR 29), Part 1910.217
b) Standards: ANSI B11.19
Complementary information
A
dditional information is available in the ISO 13855 standard and in the Guide for Safe
Machinery.
tance must be maintained between the safety light curtain and the haz‐
SICK offers a stopping/run-down time measurement service in many countries.
Further topics
"R
esponse time", page 91
•
4.3.2.1 Calculating minimum distance from the hazardous point
Important information
DANGER
Minimum distance from the hazardous point is too small
The dangerous state of the machine may not be stopped or not be stopped in a timely
manner due to a minimum distance that is too small.
Calculate the minimum distances for the machine in which the safety light curtain
b
is integrated.
When mounting the safety light curtain, observe the minimum distance.
b
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23
!
"
§
S
4 P
ROJECT PLANNING
Approach
T
he example shows the calculation of the minimum distance in accordance with ISO
13855 for an orthogonal (right-angled) approach to the protective field. A different cal‐
culation may be required depending on the application and the ambient conditions
(e.g., for a protective field parallel to or at any angle to the direction of approach or an
indirect approach).
1. First calculate S with the following formula:
S = 2,000 mm/s × T + 8 ×(d – 14 mm)
where:
S = minimum dis
°
T = machine stopping time + response time of the protective device after
°
interruption in the light path in seconds (s)
d = resolution of the safety light curtain in millimeters (mm)
°
The reach or approach speed is already included in the formula.
tance in millimeters (mm)
2. If the result S is ≤ 500 mm, then use the determined value as the minimum dis‐
ance.
t
3. If the result S is > 500 mm, then recalculate S as follows:
S = 1,600 mm/s × T + 8 ×(d – 14 mm)
4. If the new value S is > 500 mm, then use the newly determined value as the mini‐
mum distance.
5. If the new value S is ≤ 500 mm, then use 500 mm.
24
Figure 12: Minimum distance to hazardous point for orthogonal (right-angled) approach to pro‐
t
ective field
Protective field height
!
Hazardous point
"
Depending on the application and distance, persons must be prevented from standing
§
behind the protective device.
Example calculation
Mac
hine stopping time = 290 ms
Response time after interruption of the light path = 30 ms
Resolution of the safety light curtain = 14 mm
T = 290 ms + 30 ms = 320 ms = 0.32 s
S = 2,000 mm/s × 0.32 s + 8 × (14 mm – 14 mm) = 640 mm
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S > 500 mm, therefore:
rs
D
a
S = 1,600 mm/s × 0.32 s + 8 × (14 mm – 14 mm) = 512 mm
4.3.2.2 Taking reach over into account
In accordance with ISO 13855, it must not be possible to defeat the ESPE. If access to
t
he hazardous area by reaching over a protective field cannot be prevented, the height
of the protective field and minimum distance of the ESPE must be determined. This is
done by comparing the calculated values based on the possible detection of limbs or
body parts with the values resulting from reaching over the protective field. The greater
value resulting from this comparison must be used.
PROJECT PLANNING 4
Figure 13: Representation of the accessibility of electro-sensitive protective device by reaching
ver. Left: Protective field that cannot be reached over. Right: Protective field that can be reached
o
over.
4.3.3 Minimum distance from reflective surfaces
Overview
T
he light beams from the sender unit may be deflected by reflective surfaces and dis‐
persive media. This can prevent an object from being detected.
Therefore, all reflective surfaces and objects (e.g. material bins, machine table, etc.)
must maintain a minimum distance (a) from the protective field. This minimum dis‐
tance (a) must be maintained on all sides of the protective field. This applies in horizon‐
tal, vertical and diagonal directions as well as at the end of the safety light curtain. The
same area must be free of dispersive media (e.g., dust, fog, or smoke).
The minimum distance (a) depends on the distance (D) between the twin sticks (protec‐
tive field width).
The weld spark guard can influence the optical properties of the safety light curtain,
meaning that reflective surfaces have to observe a larger minimum distance.
Figure 14: Minimum distance from reflective surfaces
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25
1000
900
800
700
600
14 16 18 20 22 242 4 6 8 10 12
500
400
300
200
100
0
0
D/m
a/mm
4 P
ROJECT PLANNING
Important information
DANGER
azard due to lack of effectiveness of the protective device
H
Reflective surfaces and dispersive media can prevent persons or parts of the body to
be protected from being properly reflected and, therefore, remain undetected.
Make sure that all reflective surfaces and objects maintain a minimum distance
b
from the protective field.
Make sure that no dispersive media (e.g., dust, fog, or smoke) are within the calcu‐
b
lated minimum distance from the protective field.
Determining minimum distance to reflective surfaces
T
he minimum distance can be determined as follows:
Determine the distance between the twin sticks D in meters (m).
b
Read the minimum distance a in millimeters (mm) in the graph or calculate it
b
based on the respective formula table 3:
Figure 15: Graph of minimum distance from reflective surfaces
T
able 3: Formula for calculating the minimum distance from reflective surfaces
Distance D between twin sticks in m Calculation of the minimum distance (a) from reflective
faces in mm
sur
D ≤ 3 m a = 131 mm
D > 3 m a = tan (2.5°) × 1000 mm/m × D = 43.66 × 1 mm/m ×
D
Further topics
eld spark guard", page 99
"W
•
4.3.4 Minimum distance for cascaded systems
Overview
In a c
ascade, the codes of the individual participants are automatically set to code 1 or
code 2 in alternation.
In a cascaded system with a protective field width of up to 3 m, a minimum distance of
262 mm between the host and guest 2 must be upheld during mounting.
26
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a min. 262
a min. 262
a min. 262
!
!
!
"
"
"
§ §
§
Figure 16: Minimum distance between host and guest 2 (mm)
a/mm
D/m
Guest 1
!
Guest 2
"
Host
§
PROJECT PLANNING 4
F
or protective field widths over 3 m, minimum distance a [mm] can be read in the
b
diagram:
Figure 17: Diagram minimum distance between host and guest 2
Or:
F
rom a 3 m protective field width, calculate the minimum distance with the follow‐
b
ing formula
a [mm] = tan 5° × D [m] × 1000
Example:
a = tan 5° × 4 m × 1000
a = 349.28 mm ~ 350 mm
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27
s
rs
r
!
"
4 P
ROJECT PLANNING
4.3.5 Protection against interference from systems in close proximity to each other
Overview
!
Figure 18: Preventing mutual interference from system
The infrared light beams of the sender unit of system ! can interfere with the receiver
unit of system ". This can disrupt the protective function of system ". This would
mean that the operator is at risk.
Important information
and system
"
DANGER
H
azard due to lack of effectiveness of the protective device
The external laser alignment aid may influence the receiver unit of a safety light curtain
in close proximity. In such cases, the neighboring safety light curtain may not detect
persons or parts of the body that require protection.
Perform an alignment or take other measures to ensure that the laser beam only
b
hits the front screen of the relevant twin stick. An external twin stick is a twin stick
that is not part of the same safety light curtain or same cascade.
During alignment in particular, make sure that the laser beam does not hit any
b
external twin stick.
DANGER
H
azard due to lack of effectiveness of the protective device
Systems of safety light curtains that operate in close proximity to each other can inter‐
fere with each other.
Use appropriate measures to prevent systems in close proximity from interfering
b
with each other.
Preventing interference between systems in close proximity to each other
he following measures prevent interference from systems in close proximity:
T
Different beam coding for neighboring systems
•
Optically opaque partitions
•
28
Further topics
"Using beam coding", page 29
•
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4.3.5.1 Using beam coding
s
Code 1
r
s
Code 2
r
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
Different beam codings only prevent mutual interference if both safety light curtains are
of type miniTwin4.
b
Using beam coding
PROJECT PLANNING 4
In the case of systems in close proximity that are of a different type, take different
measures to prevent mutual interference.
Use suit
b
The system automatically performs the coding. As soon as a system is influenced by
another system with an identical code, a fault occurs. During the next power-up, the
code is converted and operation is no longer possible.
Figure 19: Trouble-free operation due to beam coding
In t
The system with code 2 is not affected by the beams of the system with code 1.
able beam codings to prevent mutual interference from neighboring systems.
Configure one safety light curtain with code 1 and the other safety light curtain
with code 2.
he figure, the beam coding of systems in close proximity to each other is different.
4.4 Integrating the equipment into the electrical control
Overview
T
his chapter contains important information about integration in the electrical control.
Information about the individual steps for electrical installation of the device: see "Elec‐
trical installation", page 60.
Requirements for use
The output signals of the protective device must be analyzed by downstream controllers
in such a way that the dangerous state of the machine is ended safely. Depending on
the safety concept, the signal is analyzed by safety relays or a safety controller, for
example.
DANGER
azard due to lack of effectiveness of the protective device
H
In the case of non-compliance, it is possible that the dangerous state of the machine
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may not be stopped or not stopped in a timely manner.
Make sure that the following control and electrical requirements are met so that
b
the safety light curtain can fulfill its protective function.
29
OSSD1
OSSD2
OSSD1
OSSD2
O
S
SD
0 V
OSSD
0 V
4 PROJECT PLANNING
t be possible to electrically influence the control of the machine
It mus
•
The electrical control of the machine must meet the requirements of IEC 60204-1
•
When using a safety controller, different signal levels of both OSSDs must be
•
detected depending on applicable national regulations or required reliability of the
safety function. The maximum discrepancy time tolerated by the control must be
selected according to the application.
The OSSD1 and OSSD2 output signals must not be connected to each other
•
In the machine controller, the signals of both OSSDs must be processed sepa‐
•
rately
Figure 20: Dual-channel and isolated connection of OSSD1 and OSSD2
he machine must switch to the safe state at any time if at least one of the two
T
•
OSSDs switches to the OFF state
Prevent the formation of a potential difference between the load and the protec‐
•
tive device. If loads are connected to the OSSDs (switching outputs) that then also
switch if controlled with negative voltage (e.g., electro-mechanical contactor with‐
out reverse polarity protection diode), the 0 V connections of these loads and
those of the corresponding protective device must be connected individually and
directly to the same 0 V terminal strip. In the event of a fault, this is the only way to
ensure that there can be no potential difference between the 0 V connections of
the loads and those of the corresponding protective device.
30
Figure 21: No potential difference between load and protective device
DANGER
azard due to unexpected starting of the machine
H
A restart interlock must be implemented depending on applicable national regulations
or required reliability of the safety function.
Make sure that a restart interlock is implemented.
b
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