Sick STR1 User Manual

O P E R A T I N G I N S T R U C T I O N S

STR1

Safety switch

Draft 2016-10-19

Described product

STR1

Manufacturer

SICK AG

Erwin-Sick-Str. 1

79183 Waldkirch

Germany

Legal information

This work is protected by copyright. Any rights derived from the copyright shall be 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

This document is an original document of SICK AG.

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CONTENTS

Contents

1	About this document........................................................................		5
	1.1	Function of this document.......................................................................	5
	1.2	Scope.........................................................................................................	5
	1.3	Target groups and structure of these operating instructions................	5
	1.4	Additional information..............................................................................	5
	1.5	Symbols and document conventions......................................................	6

2	Safety information............................................................................		8
	2.1	General safety notes.................................................................................	8
	2.2	Intended use.............................................................................................	8
	2.3	Requirements for the qualification of personnel....................................	8

3	Product description...........................................................................		10
	3.1	Setup and function...................................................................................	10
	3.2	Product characteristics.............................................................................	10
4	Project planning................................................................................		12
	4.1	Manufacturer of the machine..................................................................	12
	4.2	Operating entity of the machine..............................................................	12
	4.3	Design........................................................................................................	13
	4.4	Integration into the electrical control......................................................	13
	4.5	Thorough check concept..........................................................................	17
5	Mounting.............................................................................................		18
	5.1	Safety.........................................................................................................	18
	5.2	Unpacking..................................................................................................	18
	5.3	Possible mounting types..........................................................................	18
	5.4	Mounting...................................................................................................	20
6	Electrical installation........................................................................		22
	6.1	Safety.........................................................................................................	22
	6.2	Notes on cULus.........................................................................................	23
	6.3	Device connection (flying leads)..............................................................	24
	6.4	Device connection (M12, 5-pin)..............................................................	24
	6.5	Device connection (M12, 8-pin)..............................................................	24
	6.6	Connecting a cascade..............................................................................	25

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7	Commissioning..................................................................................		28
	7.1	Safety.........................................................................................................	28
	7.2	Switching on..............................................................................................	28
	7.3	Teach-in.....................................................................................................	28
	7.4	Thorough check........................................................................................	29

8 Troubleshooting.................................................................................		30
8.1 Safety.........................................................................................................		30
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CONTENTS

	8.2	Diagnostic LEDs........................................................................................	30
9	Maintenance......................................................................................		33
	9.1	Cleaning.....................................................................................................	33
	9.2	Regular thorough check...........................................................................	33
10	Decommissioning.............................................................................		34
	10.1	Protection of the environment.................................................................	34
	10.2	Disposal.....................................................................................................	34
11	Technical data....................................................................................		35
	11.1	Technical data...........................................................................................	35
	11.2	Dimensional drawings..............................................................................	38
	11.3	Response time and enable time in cascade..........................................	39
12	Ordering information........................................................................		40
	12.1	Scope of delivery......................................................................................	40
	12.2	STR1 ordering information.......................................................................	40
13	Spare parts.........................................................................................		42
	13.1	Actuator.....................................................................................................	42
	13.2	Sensors.....................................................................................................	42
14	Accessories........................................................................................		43
	14.1	Connectivity...............................................................................................	43
15	Annex..................................................................................................		45
	15.1	Compliance with EU directives.................................................................	45
	15.2	FCC and IC radio approval........................................................................	46
16	List of figures.....................................................................................		47
17	List of tables.......................................................................................		48

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ABOUT THIS DOCUMENT 1

1About this document

1.1Function of this document

These operating instructions contain the information needed during the life cycle of the safety switch.

They must be made available to all people who work with the safety switch.

1.2Scope

The operating instructions only apply to the STR1 safety switch with the following infor mation on the product packaging: Operating Instructions 8018074.

These operating instructions are included with SICK part number 8018074 (all availa ble languages of this document).

1.3Target groups and structure of these operating instructions

These operating instructions are intended for the following target groups: project devel opers (planners, developers, designers), installers, electricians, safety experts (such as CE authorized representatives, compliance officers, people 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 switch: project planning, mounting, electrical installation, commissioning, opera tion, and maintenance.

In many applications, the target groups consist of the manufacturer and the operating entity of the machine in which the safety switch is integrated:

Area of responsibility	Target group	Special chapters of these operating instruc
		tions 1)
Manufacturer	Project developers	Project planning, page 12
	(planners, developers,	Technical data, page 35
	designers)	Accessories, page 43
	Installers	Mounting, page 18
	Electricians	Electrical installation, page 22
	Safety experts	Project planning, page 12
		Commissioning, page 28
		Technical data, page 35
Operating entity	Operators	Troubleshooting, page 30
	Maintenance person	Maintenance, page 33
	nel	Troubleshooting, page 30
		Ordering information, page 40

1)Chapters not listed here are intended for all target groups. All target groups must follow all of the safety and warning instructions in all chapters of the operating instructions!

In other applications, the operating organization is also the manufacturer of the equip ment with the corresponding allocation of the target groups.

1.4Additional information

www.sick.com

The following information is available on the Internet:

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1ABOUT THIS DOCUMENT

•versions 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)

1.5Symbols and document conventions

The following symbols and conventions are used in this document:

Safety notes and other notes

DANGER

Indicates a situation presenting imminent danger, which will lead to death or serious injuries if not prevented.

WARNING

Indicates a situation presenting possible danger, which may lead to death or serious injuries if not prevented.

CAUTION

Indicates a situation presenting possible danger, which may lead to moderate or minor injuries if not prevented.

NOTICE

Indicates a situation presenting possible danger, which may lead to property damage if not prevented.

NOTE

Indicates useful tips and recommendations.

Instructions for action

bThe arrow denotes instructions for action.

1.The sequence of instructions for action is numbered.

2.Follow the order in which the numbered instructions are given.The check mark denotes a result of an instruction for action.

LED symbols

These symbols indicate the status of an LED:The LED is off.

The LED is flashing.

The LED is illuminated continuously.

Terminology Dangerous state

A dangerous state is a status of the machine or facility, where people may be injured. Protective devices prevent this risk if the machine is operated within its intended use.

The figures in this document always show the dangerous state of the machine as move ment of a machine part. In practice, there are different dangerous states, such as:

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ABOUT THIS DOCUMENT 1

•Machine movements

•Electrical parts

•Visible and invisible beam

•A combination of multiple hazards

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2SAFETY INFORMATION

2Safety information

2.1General safety notes

This chapter contains general safety information about the safety switch.

Further information about specific product use situations can be found in the relevant chapters.

DANGER

Hazard 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.

bRead this document carefully and ensure that you have fully understood the con tents before you work with the device.

bPay particular attention to all safety notes in this document.

Incorrect installation or manipulation can lead to severe injuries.

2.2Intended use

The safety switch is a transponder safety switch that is switched in a non-contact man ner by means of actuators, and is suitable for the following applications:

•Movable physical guards

The safety switch must only be used within the limits of the prescribed and specified technical data and operating conditions at all times.

Incorrect use, improper modification, or manipulation of the safety switch will invalidate any warranty from SICK AG; in addition, any responsibility and liability of SICK AG for damage and secondary damage caused by this is excluded.

The safety switch is not suitable for certain ambient conditions, including:

•Radioactivity (with the exception of natural radioactivity)

•Vacuum or high pressure

•High UV exposure

•In the vicinity of low-frequency RFIDs

•In the vicinity of magnetic fields

The following can impair the function of the safety switch:

•Metal subsurfaces or metal in the immediate vicinity (see "Design", page 13)

•Flying metal chips

2.3Requirements for the qualification of personnel

The safety switch must be configured, mounted, connected, commissioned, and serv iced by qualified safety personnel only.

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.

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SAFETY INFORMATION 2

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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3PRODUCT DESCRIPTION

3Product description

3.1Setup and function

The safety switch consists of two components:

•Sensor

The sensor is mounted on the fixed part of the protective device.

•Actuator (transponder)

The actuator is mounted on the moving part of the protective device.

When the protective device is closed, the actuator is guided to the sensor. When the switch on distance is reached, the sensor detects the actuator code. If the sensor detects a taught-in code (valid actuator), it sets safety outputs OSSD 1 and OSSD 2 (semiconductor outputs) to High and application diagnostic output Aux to Low.

When the protective device is opened, the actuator is removed from the response range of the sensor. The sensor sets safety outputs OSSD 1 and OSSD 2 to Low and applica tion diagnostic output Aux to High.

3.2Product characteristics

3.2.1Product variants

The safety switch is delivered in different variants. You will find an overview of impor tant distinguishing features of the variants in the following.

•Universally coded, unique coded, and permanently coded safety switches

•Actuator design: “Standard”, “Flat”, or “Mini”

•Cable with M12 plug connector (5-pin or 8-pin) or flying leads (3 m or 10 m)

Complete overview of all variants: see "STR1 ordering information", page 40.

Coding

•Universally coded

All actuators are accepted. No teach-in is required.

•Unique coded

An actuator must be taught in during commissioning. Up to 8 actuators may be taught in one after the other. Only the most recently taught-in actuator is valid. Previously taught-in actuators can no longer be used.

•Permanently coded

An actuator must be taught in during commissioning. Teach-in only needs to be performed once. It is not possible to teach in any further actuators.

3.2.2Active sensor surfaces

The sensor has 3 active sensor surfaces:

•Front: black surface

•2 x sides: yellow surface with long black edge

3.2.3Fault detection

Faults that arise, including internal device faults, are detected no later than the next requirement to close the safety contacts (e.g., when the machine starts). The safety switch then switches to the safe state. If a fault is detected, the safety circuit is switched off and the DIAG and STATE light emitting diodes display the fault (see table 10).

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PRODUCT DESCRIPTION 3

3.2.4Cascading

In the case of cascading, up to 30 safety switches are connected in series.

For more information, see "Cascading", page 16 and see "Connecting a cascade", page 25

3.2.5State indicators

The STATE light emitting diode (red/green) and the DIAG light emitting diode (yellow) signal the operational state of the safety switch.

Complete overview of the light emitting diode states and their meanings: see "Diagnos tic LEDs", page 30.

3.2.6Protective functions

The safety switch has the following internal protective functions:

•Short-circuit protection at all outputs

•Cross-circuit monitoring at OSSDs

•Overload protection at OSSDs

•Reverse polarity protection for the supply voltage

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4PROJECT PLANNING

4Project planning

4.1Manufacturer of the machine

DANGER

Failure to comply with manufacturer’s obligations

Hazard due to lack of effectiveness of the protective device

bPerform a risk assessment before using the safety switch.

bDo not manipulate, open, or modify components of the safety switch.

bDo not repair defective devices; replace them instead.

bMake sure the switch-on commands that cause the machine to enter a dangerous state only take effect when the protective device is closed.

bMake sure a stop command is triggered when the protective device is opened in a hazardous machine state.

bSafety switches must not be bypassed (i.e., the contacts jumpered), swiveled out of the way, removed, or rendered ineffective in any other way. If necessary, take measures to reduce the possibility of bypassing.

If multiple devices are connected in series (cascaded) and the simplified procedure according to ISO 13849 is used to determine the performance level (PL), the PL may drop.

As the number of safety switches in a cascade increases, so too does the response time.

4.2Operating entity of the machine

DANGER

Failure to comply with operating entity’s obligations

Hazard due to lack of effectiveness of the protective device

bModifications to the machine and modifications to the mechanical mounting of the safety switch necessitate a new risk assessment. The results of this risk assessment may require the operating entity of the machine to fulfill the manufac turer’s obligations.

bApart from during the procedures described in this document, the components of the safety switch must not be opened or modified.

bDo not perform repair work on the components. Improper repair of the safety switch can lead to a loss of the protective function.

bMake sure that bypassing is not carried out by substitute actuators. Restrict access to actuators for unlocking.

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PROJECT PLANNING 4

4.3Design

DANGER

Bypassing the protective device

Hazard due to lack of effectiveness of the protective device

bPrevent incentives to manipulate the safety switch by taking at least one of the fol lowing measures:

Universally coded variant only:

°Cover the sensor and the actuator with additional equipment or protect them against access.

°If possible, use non-detachable mounting methods for actuators (such as welding, gluing, safety screws, or rivets).

Mounting location

bWhen the protective device is closed, the sensor and actuator must face each other at the safe switch on distance of Sao or closer (see table 3).

bSelect a mounting location that allows the sensor and actuator to be accessed for maintenance work and protects them against damage.

bIf possible, mount the sensor and actuator on non-ferrous subsurfaces and at a distance from metallic parts in order to avoid affecting the sensing range. If this is not possible, the effect on the safe switch on distance Sao and the safe switch off distance Sar must be checked.

bMake sure that there is no possibility of hazards arising when the protective device is opened, even if the actuator has not yet reached the safe switch off distance Sar.

bIf the actuator is approaching the sensor in a parallel position, observe the mini mum distances (see table 3).

bIf necessary, attach an additional stop for the moving protective device.

Distance

If multiple safety switches are mounted on the machine, they must be mounted with a minimum distance in relation to one another; see "Mounting", page 20.

Alignment

The sensor can be mounted in any alignment see "Mounting", page 20, see "Possible mounting types", page 18.

Actuating direction

The actuator may approach the front or the long side of the sensor.

NOTE

If the actuator does not move directly onto the sensor when the protective device is closed, but instead approaches it in a parallel position, the specified minimum distance must be adhered to. This prevents the sensor from enabling the safety outputs despite the protective device not being fully closed.

4.4Integration into the electrical control

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Switch-on commands that cause the machine to enter a dangerous state may only take effect when the protective device is closed. In cases where the machine is in a danger ous state, a stop command must be triggered if the protective device opens. Depending on the safety concept, the signal is analyzed by, e.g., safety relays or a safety controller.

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4 PROJECT PLANNING

4.4.1OSSDs

Safety switches with local inputs and outputs can be directly integrated into the machine controller.

DANGER

Hazard 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.

bMake sure that the following control and electrical requirements are met so the protective function can be fulfilled.

•The output signals from an OSSD pair must not be connected to each other.

•In the machine controller, both signals from an OSSD pair must be processed sep arately.

Figure 1: Dual-channel and isolated connection of OSSD 1 and OSSD 2

•The machine must switch to the safe state at any time if at least one OSSD in an OSSD pair switches to the OFF state.

•Prevent the formation of a potential difference between the load and the protec tive device. If you connect loads to the OSSDs (safety outputs) that then also switch if controlled with negative voltage (e.g., electro-mechanical contactor with out reverse polarity protection diode), you must connect the 0 V connections of these loads and those of the corresponding protective device 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.

Figure 2: No potential difference between load and protective device

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PROJECT PLANNING 4

DANGER

Hazard 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.

Downstream contactors must be positively guided and monitored depending on appli cable national regulations or required reliability of the safety function.

bMake sure that downstream contactors are monitored (external device monitoring, EDM).

Requirements for the electrical control of the machine

•Use the control without test pulses. The safety switch is self-testing.

•The safety switch tests the OSSDs at regular intervals. To do this, it switches each OSSD briefly (for max. 1 ms) to the OFF state and checks whether this channel is voltage-free during this time.

Make sure that the machine’s control does not react to these test pulses and the machine does not switch off.

•The inputs of a connected evaluation unit must be positive-switching (PNP), as the two outputs of the safety switch send a level of the supply voltage in the switchedon state.

The OSSDs are short-circuit protected to 24 V DC and 0 V. When the actuator is in the sensor’s response range, the OSSDs signal the ON state with the HIGH signal level (non-isolated). If the actuator is removed from the sensor’s response range or there is a device fault, the OSSDs signal the OFF state with the LOW signal level.

The safety switch complies with the regulations for electromagnetic compatibility (EMC) for the industrial sector (Radio Safety Class A). Radio interference cannot be ruled out when used in residential areas.

DANGER

Hazard 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.

bMake sure that the following control and electrical requirements are met so the safety switch can fulfill its protective function.

•The external voltage supply of the safety switch must be capable of buffering brief power failures of 20 ms as specified in IEC 60204-1.

•The power supply unit must provide safe isolation according to IEC 61140 (SELV/ PELV). Suitable power supply units are available as accessories from SICK.

4.4.2Application diagnostic output

The application diagnostic output signal changes as soon as the actuator is moved into or leaves the response range of the safety switch. In other words, it does so when the moving protective device is opened and closed. This is not a safety output.

Actuator	Application diagnostic output
Actuator not in response range.	ON
Actuator in response range.	OFF

Table 1: Application diagnostic output switching behavior

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4 PROJECT PLANNING

4.4.3Cascading

Cascading makes it possible to connect multiple safety switches. The connected devi ces act like a single device. Cascading is only possible with the variant that includes the 8-pin M12 male connector.

1	1		1	1	1	2
	OSSD1	OSSD1	OSSD1	OSSD1		OSSD1
	OSSD2	OSSD2	OSSD2	OSSD2		OSSD2

Figure 3: Circuit with 5 cascaded safety switches

Safety switch

Safe evaluation unit

It is not possible to use more than 30 safety switches in a cascade.

The maximum number of safety switches depends on the following factors:

•Applied supply voltage

•Length of cables used

•Cross-section of cables used

The voltage drop in the cascade must be checked to ensure that the defined minimum voltage is still present at the last safety switch.

In the case of connection cables with a length of 2 m and a cable cross-section of 0.25 mm², the maximum number of cascadable safety switches is relative to the volt age, as explained below:

	Voltage	Connection cables,	Input voltage at 30th	Maximum number of
		the same kind for the	safety switch	cascadable safety
		entire cascade		switches
	24 V	Length: 2 m	17.8 V	24
		Cable cross-section:
	26.8 V		19.2 V	30
		0.25 mm²

Table 2: Maximum number of cascadable safety switches relative to the voltage

The number of safety switches in a cascade affects the response time of the system (see "Response time and enable time in cascade", page 39).

The cascade can be created using special T-pieces and an end connector (see "Con necting a cascade", page 25).

NOTE

In the case of safety switches cascaded using T-connectors, it is not possible to evalu ate the application diagnostic output.

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