SICK Safe Entry Exit Operating Instructions Manual
Safe Entry Exit
Safety System
O P E R A T I N G I N S T R U C T I O N S
Described product
S
afe Entry Exit
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.
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Contents
CONTENTS
1 About this document........................................................................ 6
1.1 Purpose of this document........................................................................ 6
1.2 Scope......................................................................................................... 6
1.3 Target groups and structure of these operating instructions................ 7
1.4 Symbols and document conventions...................................................... 7
1.5 Further information................................................................................... 8
2 Safety information............................................................................ 9
2.1 General safety note.................................................................................. 9
2.2 Intended use............................................................................................. 9
2.3 Requirements for the qualification of personnel.................................... 9
2.4 Safe state.................................................................................................. 10
3 Product description........................................................................... 11
3.1 Product identification............................................................................... 11
3.2 Application description............................................................................. 11
3.3 Components of the safety system........................................................... 11
3.4 Components required............................................................................... 11
3.4.1 Requirements for hold to run device...................................... 12
3.4.2 Reset pushbutton requirements............................................. 12
3.4.3 Requirements for Flexi Soft safety controller........................ 12
3.4.4 Requirements for the higher-level control.............................. 13
3.4.5 Requirements for the electro-sensitive protective device..... 13
3.5 Construction and function........................................................................ 14
3.6 Limits of the safety system...................................................................... 14
3.7 Functions................................................................................................... 15
4 Project planning................................................................................ 16
4.1 Manufacturer of the machine.................................................................. 16
4.1.1 Calculation of the performance level..................................... 16
4.2 Operating entity of the machine.............................................................. 17
4.3 Safety Functions....................................................................................... 17
4.3.1 Identifying hazards.................................................................. 17
4.3.2 Enabling material throughput................................................. 17
4.4 Design........................................................................................................ 17
4.4.1 Type 4 electro-sensitive protective device.............................. 17
4.4.2 Minimum distance between the Type 4 electro-sensitive
otective device and the hazardous point............................ 18
pr
4.4.3 Design of the material opening............................................... 18
4.4.4 Conveyor speed........................................................................ 19
4.4.5 Calculating response times and stopping times................... 19
4.5 Integrating the equipment into the electrical control............................. 20
4.5.1 Circuit diagram......................................................................... 20
4.5.2 Testing plan.............................................................................. 21
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CONTENTS
5 Mounting............................................................................................. 22
5.1 Mounting conditions for the electro-sensitive protective device........... 22
6 Electrical installation........................................................................ 23
6.1 General requirements.............................................................................. 23
6.2 Safety controller pin assignment............................................................. 23
6.3 Interfaces and signals.............................................................................. 24
7 Configuration..................................................................................... 26
7.1 Requirements on software and firmware................................................ 26
7.2 Pre-configured project files...................................................................... 26
7.2.1 Checking the checksums of the project files......................... 26
7.2.2 Standard values for timing sets.............................................. 27
7.3 Opening project file................................................................................... 28
7.4 Configuring logics for Flexi Soft CPU....................................................... 28
7.4.1 Creating or deleting links......................................................... 28
7.5 Transfer configuration.............................................................................. 28
7.6 Adjust configuration.................................................................................. 29
7.6.1 Configuration of S
7.6.2 Configuration of Time monitoring............................................... 31
7.6.3 Configuration of PLC monitoring & override................................ 35
equence monitoring....................................... 29
8 Commissioning.................................................................................. 37
8.1 Safety......................................................................................................... 37
8.2 Thorough check........................................................................................ 37
9 Maintenance...................................................................................... 38
10 Troubleshooting................................................................................. 39
11 Operation............................................................................................ 40
11.1 Description of signals............................................................................... 40
11.2 Muting function......................................................................................... 40
11.3 Time Extension Function.......................................................................... 41
11.4 Hold to run device..................................................................................... 42
11.5 1 of n timing sets...................................................................................... 43
12 Technical data.................................................................................... 44
12.1 Data sheet................................................................................................. 44
13 Ordering information........................................................................ 45
13.1 Scope of delivery....................................................................................... 45
13.2 Safe Entry Exit ordering data................................................................... 45
13.3 Ordering data for Safe Entry Exit components....................................... 46
14 Spare parts......................................................................................... 47
14.1 Safe Entry Exit spare parts....................................................................... 47
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CONTENTS
15 Annex.................................................................................................. 48
15.1 Checklist for initial commissioning and commissioning........................ 48
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1 ABOUT THIS DOCUMENT
1 About this document
1.1 Purpose of this document
These operating instructions contain the information required during the life cycle of the
afety system. This document describes:
s
The individual components
•
The project planning
•
The mounting and electrical installation, insofar as special measures are neces‐
•
sary for the safety system
The configuration
•
The necessary thorough checks
•
The commissioning
•
The maintenance
•
The troubleshooting
•
1.2 Scope
These operating instructions contain information regarding the Safe Entry Exit safety
ystem.
s
NOTICE
he operating instructions of the components also apply. In the event of contradictions
T
between the operating instructions, the information specified in the operating instruc‐
tions for the safety system applies.
The relevant information must be made available to the employees for all work per‐
formed on the safety system.
The following documents contain information about the possible components of the
S
afe Entry Exit:
Table 1: Available documents
Document type Title Part number
Operating instructions Flexi Soft Modular Safety Controller
ardware
H
Operating instructions Flexi Soft in the Flexi Soft Designer
tware
sof
Operating instructions deTec4 Prime 8017724
Operating instructions deTec4 Core 8014251
Operating instructions miniTwin4 8012731
Operating instructions C4000 Standard 8009855
Operating instructions C4000 Standard ATEX II 3G/3D 8013551
Operating instructions C4000 Advanced 8009855
Operating instructions C4000 Advanced Ex 8017105
Operating instructions C4000 Advanced ATEX II 3G/3D 8013551
Operating instructions C4000 Select 8012198
Operating instructions C4000 Select Ex 8017106
Operating instructions M4000 Advanced Curtain 8010794
Operating instructions deTec4 Core IP69K 8021546
Operating instructions deTec4 Core Ex 8017107
Operating instructions deTem4 Core 8020445
8012999
8012998
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ABOUT THIS DOCUMENT 1
Document type Title Part number
Operating instructions M4000 Standard 8011190
Operating instructions M4000 Standard A/P 8011190
Supplement to operating instructions M4000 Standard A/P in IP69K
Housin
g
Operating instructions M4000 Advanced 8010794
Operating instructions M4000 Advanced A/P 8010794
Operating instructions M4000 area 8010794
Operating instructions deTem4 Core IP69K 8021557
This document is included with the following SICK part numbers (this document in all
vailable language versions):
a
8021672
1.3 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, operators, and mainte‐
nance personnel.
8014815
These operating instructions are organized by the life phases of the safety system:
project planning, mounting, electrical installation, commissioning, operation and main‐
tenance.
1.4 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
ates a situation presenting imminent danger, which will lead to death or serious
Indic
injuries if not prevented.
WARNING
Indic
ates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indic
ates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
ates a situation presenting possible danger, which may lead to property damage if
Indic
not prevented.
NOTE
ates useful tips and recommendations.
Indic
Instructions to action
The 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
1.5 Further information
www.sick.com
T
he following information is available via the Internet:
■
This document in other languages
■
Operating instructions and mounting instructions of SICK components suitable for
the safety system
■
The Flexi Soft Designer configuration software
■
Other configuration tools (e.g. Excel tool)
■
Pre-configured project file for Flexi Soft Designer for this safety system
■
Export file of the pre-configured project file for use in various Flexi Soft CPU mod‐
ules
■
Complete subsystems for SISTEMA for this safety system
■
Circuit diagram for the safety system (ePLAN)
■
■
Guide for Safe Machinery (“Six steps to a safe machine”)
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2 Safety information
2.1 General safety note
The information and tools will not fulfill the safety requirements for your application
ithout further adjustments being made. The project planning provided by way of exam‐
w
ple is intended to serve as the basis to allow you to perform your own project planning
and programming in line with your specific requirements. What this means is that the
information and tools merely provide an example to demonstrate how a safety function
can be taken care of.
When it comes to your own project planning and programming, you will need to rely on
qualified staff given that it is your responsibility to ensure that the following require‐
ments are complied with at the very least:
Carrying out a risk assessment
b
Taking into account applicable standards
b
Verifying and validating the safety function
b
2.2 Intended use
The Safe Entry Exit safety system is used in hazardous areas with material transporta‐
t
ion via a conveyor (e.g., conveyor belt), e.g., a robot cell. Safe Entry Exit reduces the
risk of personal injury caused by passing through the machine’s material transporta‐
tion. Safe Entry Exit can be used both at the entry area as well as the exit area of the
material transportation.
SAFETY INFORMATION 2
Safe Entry Exit is suitable for applications with the following properties:
The material is moved by a conveyor into the hazardous area.
•
The conveyor moves at a defined speed (maximum of 4 different speeds) during
•
the transportation of the material.
The material is at least 500 mm long.
•
The length of the material is always identical or can be determined automatically
•
(e.g. via a combination of existing process signals).
2.3 Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and ser‐
iced by qualified safety personnel only.
v
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, electrical installation, and commissioning
For the task, a person is considered qualified when he/she has the expertise and expe‐
rience in the relevant field and is sufficiently familiar with the application of the protec‐
tive device on the machine to be able to assess whether it is in an operationally safe
state.
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.
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2 S
AFETY INFORMATION
2.4 Safe state
In the safe state, the accordingly configured safe switching outputs are in the OFF state.
he safe state is initiated in the following cases:
T
The muting function is not correctly terminated because the detected object is too
•
short or too long.
The muting function is not correctly initiated.
•
Deviation from preset timing detected.
•
Deviation from preset sequence detected.
•
When the muting function is active, the connection between the higher-level con‐
•
trol and the safety controller is interrupted.
When the muting function is inactive, the connection between the higher-level con‐
•
trol and the Type 4 electro-sensitive protective device is interrupted.
When the muting function is inactive, the Type 4 electro-sensitive protective device
•
detects an object.
The voltage supply of the higher-level control, the Type 4 electro-sensitive protec‐
•
tive device or the safety controller is interrupted.
Internal fault detected in the Type 4 electro-sensitive protective device.
•
Internal fault detected in the safety controller or one of its components.
•
When the safety system initiates the safe state, the machine manufacturer and user
t ensure that the safe switching outputs are evaluated appropriately and that the
mus
hazard is rectified.
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3 Product description
3.1 Product identification
The part number of the safety system is located on the packaging.
Further topics
dering information", page 45
"Or
•
3.2 Application description
The Safe Entry Exit safety system is used on machines in which it is not possible to
ent
er the hazardous area as long as the machine is in a dangerous state. Appropriate
protective devices (e.g., fixed guards) prevent access to the hazardous area. The haz‐
ardous area can only be accessed via an opening that enables the material to pass
through via the conveyor.
Safe Entry Exit is used to monitor the opening provided for material transport and to
place the machine in the safe state if anything other than the expected material passes
through the opening. To accomplish this, the safety system monitors the time it takes
for the expected material to pass through the Type 4 electro-sensitive protective device,
but not the height of the material, see "Construction and function", page 14.
PRODUCT DESCRIPTION 3
3.3 Components of the safety system
Safe Entry Exit components (hardware and software)
F
lexi Soft safety controller main module
•
Flexi Soft safety controller expansion module – I/O module (8 inputs, 4 outputs)
•
Optional, if the conveyor is going to switch between different speeds: Flexi Soft
•
safety controller, expansion module – I/O module (8 inputs)
Memory Plug (MLP)
•
Type 4 electro-sensitive protective device
•
Higher-level control
•
Hold to run device
•
Pushbutton for reset function
•
Configuration file for the Flexi Soft safety controller
•
Implementing all the safety functions for the application requires a complete system
consisting of sensors, a controller, actuators, and control switches. This safety system
comprises sensors and a controller only and is therefore only a subsystem. The user is
responsible for the safe design of the complete system and all safety functions.
3.4 Components required
The following components are essential for using the Safe Entry Exit safety system in an
applic
ation:
Type 4 electro-sensitive protective device
•
Flexi Soft safety controller main module
•
Flexi Soft safety controller expansion module
•
Higher-level control
•
Hold to run device
•
Pushbutton for reset function
•
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RODUCT DESCRIPTION
3 P
NOTE
All nece
to safety technology. The components must therefore have a MTTFd value that is suit‐
able for the entire application and satisfies the necessary performance level. The nec‐
essary performance level results from the risk assessment. For evaluating the perfor‐
mance level achieved, subsystems for SISTEMA are available under:
www.sick.com
3.4.1 Requirements for hold to run device
The pushbutton must be installed outside of the hazardous area. From the position of
t
he pushbutton, there must be a complete view of the hazardous area. It must not be
possible for a person to enter the hazardous area while activating the pushbutton.
The pushbutton must be designed according to the following standard:
•
NOTICE
T
sure to prevent unauthorized use is a key-operated spring-back pushbutton.
ssary components influence the parameters of the entire application that relate
EN 60204
he pushbutton should only be operable by authorized personnel. An example of a mea‐
The hold to run device is supplied via test output X2 of the XTIO module, which it is con‐
ted to. Test output X2 of this module must not be used for other devices.
nec
3.4.2 Reset pushbutton requirements
Reset pushbutton requirements
T
he pushbutton must be installed outside of the hazardous area. From the position of
the pushbutton, there must be a complete view of the hazardous area. Activating the
pushbutton must not initiate any movement of the machine.
The reset pushbutton must be designed in accordance with the following standard:
EN 60204
•
Complementary information
he reset pushbutton resets the muting function of the safety system. If the reset push‐
T
button is also to be used to reset the machine, the risk assessment must show that
there is no possibility of this causing a hazard.
3.4.3 Requirements for Flexi Soft safety controller
The Flexi Soft safety controller must be installed in a control cabinet with an enclosure
r
ating of IP 54.
Please note the following for installation:
Continuous equipotential bonding via conductive connections between machine
•
parts and systems
Physically separate supply unit (voltage supply/actuator systems/inverter)
•
Do not use the shielding to conduct equipotential bonding current
•
Keep the shielding short and use the full surface
•
Use every existing or available functional earth (FE)
•
Carefully connect all available communications cables. Twisted lines are often nec‐
•
essary for fault-free data transmission (fieldbus).
12
The voltage supply for the main module and each expansion module for input and out‐
put mus
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t be limited to a maximum of 4 A, either by the power supply unit or by a fuse.
Subject to change without notice
3.4.4 Requirements for the higher-level control
The signals of the higher-level control are part of the initiation of the muting function.
T
he higher-level control can be a standard programmable logic controller that controls
the machine process or an existing safety controller.
The control requires information about the position and speed of the material on the
conveyor. If material with different sizes is transported, the size of the current material
must also be available.
This information must be processed such that the programmable logic controller can
change the status of the signals according to the sequence. Moreover, this information
must also originate from a source that is difficult to manipulate.
Recommended sources are, for example:
Code reader
•
Process information
•
...
•
The entire chain of signal generation must exhibit at least a MTTFd value of three years.
According to EN ISO 13849-1, a MTTFd value of ten years must be assumed for the indi‐
vidual components of the chain if no manufacturer information is available and simple
determination according to appendix C and D is not possible.
PRODUCT DESCRIPTION 3
Examples:
Example 1: In a chain of three non-safe components with an assumed MTTFd value of
10 years, this results in a total MTTFdvalue of 3.3 years. Such a chain is permitted.
Example 2: In a chain of four non-safe components with an assumed MTTFd value of
10 years, this results in a total MTTFdvalue of 2.5 years. Such a chain is not permitted.
If PL e is required, the higher-level control and signal source must also correspond to
PL e and have a MTTFd value of at least 100 a.
Measures must be taken with regard to the voltage supply for the higher-level control so
as to prevent voltage drops, voltage fluctuations, as well as overcurrent and undercur‐
rent.
The wiring of the signals SR (Muting Request) and TE (Time Extension) influences the
safety application and must be validated at the time of commissioning.
3.4.5 Requirements for the electro-sensitive protective device
The Type 4 electro-sensitive protective device must meet the requirements of EN ISO
61496-1 and ha
out in accordance with EN ISO 13855.
If the Type 4 electro-sensitive protective device has additional functions that affect the
direct relationship between the status of the output signal switching devices and the
interruption of the protective field by the material being conveyed, these must be deac‐
tivated.
ve an MTTFd value of at least 100 a. The positioning must be carried
Such functions are, for example, integrated reset functions.
This does not apply to functions – for example a blanking function – that ignore contin‐
uously interrupted signal pathways.
The following must also be taken into account:
The penetration distance required to calculate the minimum distance depends on
•
the resolution of the Type 4 electro-sensitive protective device.
The approach speed of the material depends on the speed of the conveyor.
•
If it is possible to step onto the conveyor, the speed at which a person is moving
•
must be considered in the calculation.
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13
1
3
2
7
4 5
6
3 PRODUCT DESCRIPTION
NOTE
his safety system only covers the positioning of a Type 4 electro-sensitive protective
T
device for monitoring an opening for material transport. The positioning of other equip‐
ment, such as safety fences, is not covered.
3.5 Construction and function
Functionality
he Type 4 electro-sensitive protective device monitors the material opening. When a
T
light beam is unexpectedly interrupted, the safety controller outputs a dual-channel sig‐
nal to place the machine in the safe state.
When material on the conveyor approaches the opening, the material is identified (e.g.
via a combination of existing process signals) or is known to the higher-level control
because of process information. Based on the type of material and speed of the con‐
veyor, an exact time window is determined during which the material will pass through
the opening and therefore also pass by the Type 4 electro-sensitive protective device.
The higher-level control sends the safety controller a signal to request the muting func‐
tion. When the muting function is active, an interruption of the Type 4 electro-sensitive
protective device does not cause the machine to stop. While the material is passing
through the opening, the safety controller continues to monitor the signals from the
Type 4 electro-sensitive protective device. If the actual duration of the interruption dif‐
fers from the expected duration, the machine is placed in the safe state.
Error-free ending of the muting function is performed by the Type 4 electro-sensitive
protective device being released along with the respective signal change of the higherlevel control.
Complementary information
W
hen the muting function is requested, the safety controller expects an interruption of
the Type 4 electro-sensitive protective device. This interruption must take place within
the initialization time window, otherwise this is seen as an error and the muting func‐
tion is not started (see "Conveyor speed", page 19 ).
3.6 Limits of the safety system
The safety system ends at all inputs and outputs that are not used to wire the compo‐
nent
s of the safety system.
For detailed information about the interfaces see "Electrical installation", page 23.
The limits of the safety system are presented in abstract and general terms in the figure
below:
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Figure 1: Limits of the safety system
Sensors
1
Subject to change without notice
3.7 Functions
PRODUCT DESCRIPTION 3
Logic (safety relay or safety controller)
2
Sub-safety function
3
Wiring between sensors and logic
4
Wiring between safety system components and components outside the safety system
5
Limit of the safety system
6
Components outside the safety system, e.g., actuators, safety capable input devices, or
7
gher-level controller
hi
The Safe Entry Exit safety system offers the following functions:
ing function
Mut
•
The safety controller monitors the signal change from requesting the muting
°
function and from the output signal switching devices of the Type 4 electrosensitive protective device and if necessary, switches to the safe state, see
"Muting function", page 40.
Time Extension Function
•
After a correct initiation sequence of the muting function, the maximum dura‐
°
tion of the muting function can be extended, see "Time Extension Function",
page 41.
Hold to run device
•
When the safety system has switched to the safe state, the hold to run device
°
is used to place the conveyor in motion while the material is blocking the pro‐
tective field of the Type 4 electro-sensitive protective device. see "Hold to run
device", page 42.
1 of n timing sets
•
This function makes it possible to select different transport speeds and mate‐
°
rial lengths, see "1 of n timing sets", page 43.
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4 P
ROJECT PLANNING
4 Project planning
4.1 Manufacturer of the machine
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.
Use of the safety system requires a risk assessment. Check whether additional
b
protective measures are required.
Comply with the applicable national regulations derived from the application (e.g.,
b
work safety regulations, safety rules, or other relevant safety guidelines).
The safety system was developed under consideration of typical application cases. A
tial safety function can be implemented with the safety system in these application
par
cases. The manufacturer must check whether the safety system is suitable for its spe‐
cific application case (risk assessment).
If the thorough check shows that the safety system is not suitable for the specific appli‐
cation case, the safety system can be used as a basis for an individualized develop‐
ment suitable for the specific application case. This case will not be considered further
in this document.
In any event, additional work is necessary for the safety system to be used, e.g. subse‐
quent configuration of the safety controller.
The manufacturer has the following duties:
Executing a risk assessment.
b
Verifying and validating the safety functions.
b
Integrating the individual components in accordance with the appropriate stan‐
b
dards.
Please note that C standards have priority compared to statements about this
b
safety system.
4.1.1 Calculation of the performance level
Complete subsystems for SISTEMA available on the internet for this safety system can
be used t
Three subsystems are available:
•
•
•
WARNING
C
ertain indicators for the individual components were used as the basis for calculating
the values for the subsystems. Accordingly, the subsystems are only valid if the selected
components of the safety system meet all requirements, see "Components required",
page 11.
o calculate the achieved performance level.
Safe Entry Exit with a standard control as a higher-level control (requirements see
"Requirements for the higher-level control", page 13)
Safe Entry Exit with a safety controller as a higher-level control (requirements see
"Requirements for the higher-level control", page 13)
A separate subsystem for the hold to run device
16
During the development of the safety system, certain measures against common-cause
aults were implemented or defined. Some of these measures must be taken into
f
account during implementation, see "General requirements", page 23.
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