O P E R A T I N G I N S T R U C T I O N S
Safe AGV Easy
Safety system
Described product
S
afe AGV Easy
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
T
his 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
T
his document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 4
1.1 Scope......................................................................................................... 4
1.2 Symbols and document conventions...................................................... 4
1.3 Further information................................................................................... 5
2 Safety information............................................................................ 6
2.1 Intended use............................................................................................. 6
2.2 Requirements for the qualification of personnel.................................... 6
3 Product description........................................................................... 7
3.1 Application description............................................................................. 7
3.2 Components.............................................................................................. 7
3.3 Limits of the safety system...................................................................... 7
4 Project planning................................................................................ 9
4.1 Manufacturer of the machine.................................................................. 9
4.2 Operating entity of the machine.............................................................. 9
4.3 Integrating the equipment into the electrical control............................. 9
5 Mounting............................................................................................. 13
6 Electrical installation........................................................................ 14
7 Configuration..................................................................................... 15
8 Commissioning.................................................................................. 16
9 Operation............................................................................................ 17
10 Maintenance...................................................................................... 18
11 Troubleshooting................................................................................. 19
12 Technical data.................................................................................... 20
12.1 Data sheet................................................................................................. 20
13 Ordering information........................................................................ 21
13.1 Ordering information for the Safe AGV Easy........................................... 21
14 Spare parts......................................................................................... 22
14.1 Spare parts for the Safe AGV Easy.......................................................... 22
15 Annex.................................................................................................. 23
15.1 Checklist for initial commissioning and commissioning........................ 23
CONTENTS
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Subject to change without notice
1 About this document
1.1 Scope
These operating instructions contain information regarding the Safe AGV Easy safety
s
ystem.
NOTICE
T
he operating instructions of the components also apply. In the event of contradictions
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 regarding the Safe AGV Easy safety sys‐
t
em:
Table 1: Documents available for Safe AGV Easy 1
Document type Title Part number
Operating instructions S300 Mini Standard 8014167
Operating instructions UE48-30S safety relay 8010593
Table 2: Documents available for Safe AGV Easy 2 and 3
Document type Title Part number
Operating instructions S300 Mini Professional 8010947
Operating instructions Flexi Classic 8011737
This document is included with the following SICK part numbers (this document in all
available language versions):
8020642
1.2 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
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
Indic
ates a situation presenting possible danger, which may lead to property damage if
not prevented.
1 ABOUT THIS DOCUMENT
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NOTE
Indic
ates useful tips and recommendations.
Instructions to action
b
T
he arrow denotes instructions to 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 the result of an instruction.
LED symbols
These symbols indicate the status of an LED:
o
The LED is off.
Ö
The LED is flashing.
O
The LED is illuminated continuously.
Terminology
D
angerous 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:
•
Machine movements
•
Electrical parts
•
Visible and invisible beam
•
A combination of multiple hazards
1.3 Further information
www.sick.com
T
he following information is available via the Internet:
■
This document in other languages
■
Operating instructions and installation instructions of suitable SICK components
for the functional safety system
■
Guide for Safe Machinery (“Six steps to a safe machine”)
ABOUT THIS DOCUMENT 1
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2 Safety information
2.1 Intended use
Safe AGV Easy is a safety system used to carry out a sub-safety function for automated
guided v
ehicles and transport carts (AGVs and AGCs). Safe AGV Easy is used to protect
people.
An example application of the Safe AGV Easy safety system and its components is
described below. Implementing all the safety functions for the application requires a
complete system consisting of sensors, a controller, actuators, and control switches.
The user is responsible for the safe design and project planning of the complete system
and all safety functions.
2.2 Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and
ser
viced 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.
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.
2 S
AFETY INFORMATION
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3 Product description
3.1 Application description
The safety system is used on automated guided vehicles (AGVs) to reduce the risk of a
collision be
tween a vehicle and people. A safety laser scanner monitors the area in
front of the vehicle. A safety relay (Safe AGV Easy 1) or a safety controller (Safe AGV
Easy 2 and 3) evaluates the signals of the safety laser scanner. If the AGV also
reverses, the area behind the vehicle must also be monitored by a second safety laser
scanner (Safe AGV Easy 3). If a person is present in the monitored area, the vehicle
should stop.
The Safe AGV Easy is available in 3 variants:
Table 3: Features of the Safe AGV Easy
Features Safe AGV Easy
1 2 3
Supply voltage 24 V DC (20.4 V DC ... 26.4 V DC)
Protective field range 3 m
Number of main directions of travel 1 1 2
Switchable protective fields No Yes Yes
Enclosure rating
Safety laser scanner IP65 (EN 60529)
Safety relay/safety controller IP40 (EN 60529)
1)
IP20 (EN 60529)
2)
Ambient operating temperature –10 °C ... +50 °C
Storage temperature –25 °C ... +50 °C
–25 °C ... +50 °C
3)
Safe status when a fault occurs At least one output signal switching device
(O
SSD) is in the OFF state.
1)
Housing
2)
Terminals
3)
For short-term storage < 24 h
3.2 Components
The Safe AGV Easy safety system is available in 3 variants:
C
omponents of the Safe AGV Easy 1
•
1 × S300 Mini safety laser scanner
•
1 × UE48-30S safety relay
Components of the Safe AGV Easy 2
•
1 × S300 Professional safety laser scanner
•
1 × Flexi Classic safety controller
Components of the Safe AGV Easy 3
•
2 × S300 Professional safety laser scanners
•
1 × Flexi Classic safety controller
3.3 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 further information about the interfaces, see "Electrical installation", page 14.
PRODUCT DESCRIPTION 3
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The limits of the safety system are presented in abstract and general terms in the figure
be
low:
1
3
2
7
4 5
6
Figure 1: Limits of the safety system
1
Sensors
2
Logic (safety relay or safety controller)
3
Sub-safety function
4
Wiring between sensors and logic
5
Wiring between safety system components and components outside the safety system
6
Limit of the safety system
7
Components outside the safety system, e.g., actuators, safety capable input devices, or
hi
gher-level controller
3 P
RODUCT DESCRIPTION
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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.
b
Use of the functional safety system requires a risk assessment. Check whether
additional protective measures are required.
b
Comply with the applicable national regulations derived from the application (e.g.,
work safety regulations, safety rules, or other relevant safety guidelines).
4.2 Operating entity 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.
b
Changes to the electrical integration of the safety system in the machine control
and changes to the mechanical mounting of the safety system necessitate a new
risk assessment. The results of this risk assessment may require the entity operat‐
ing the machine to meet the obligations of a manufacturer.
b
Changes to the safety system’s configuration may impair the protective function.
The effectiveness of the safety system must be checked after any change to the
configuration. The person carrying out the change is also responsible for maintain‐
ing the protective function of the safety system.
4.3 Integrating the equipment into the electrical control
NOTE
Se
veral safety functions are generally necessary in order to ensure a safe design for the
entire application. This requires additional components that are not part of the safety
system, such as switches, fuses, and contactors. The circuit diagrams contain informa‐
tion on wiring the safety system with additional components within an application.
4.3.1 Safe AGV Easy 1
1. Incorporate the components as per the circuit diagram. Follow the operating
ins
tructions for the components.
PROJECT PLANNING 4
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+24 V DC
FE
0 V DC
E158472/01/2016-08-03
BN
GN
YE
PK
BU
FE
WH
GY
S300 Mini Standard
2
3
4
5
6
7
H
1
H = Housing
K2 K3K1
S34 S21S
35 S22
S33 S12S11 S31
14A2 24 34
13A1 23 33
UE48-3OS2D2S1
L–
L
+
F1
F2 F3 F4
H1 H2
Warning
f
ield
Contam-
ination
error
S3
Stand by
k3
k1
k2
F1 ... F4 Fuse
H Housing
H1 Warning field light interrupted
H2 Contamination light
k1 ... k3 Auxiliary contact for external device monitoring
K1 ... K3 Contactor
1)
L+ Switching voltage source (positive side of the contactor input cir‐
c
uit)
L– Switching voltage sink (negative side of the contactor input circuit)
S3 Switch for standby mode
1)
Up to 3 contactors are possible. In a typical application with one dual-channel actuator switch-off, 2
cont
actors will suffice.
2. Configure the safety laser scanner (see operating instructions 8014167).
3.
Validate the safety laser scanner as per the checklist (see operating instructions
8014167).
4.3.2 Safe AGV Easy 2
1. Incorporate the components as per the circuit diagram. Follow the operating
ins
tructions for the components.
4 P
ROJECT PLANNING
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S300 Professional
1
15
19
7
10
16
18
13
4
2
5
6
20
8
9
21
17
14
3
FE
+24 V DC
FE
0 V DC
E158473/02/2016-11-10
UE410-MU3T5
FE
Function
Q1
A1
9
A2 EN
I2
I1
X1 X2
Q2 Q4
S2 S3
Q3
S1
I4I3
0
1
2
7
8
9
6
54
3
x 1 s
0
0
1
4
5
3
2
S1
k2
k1
S2
S3A1 A2 B1 B2
H1 H2 H3
K1 K2
Warning
f
ield
Stand by
Reset
E-stop
Error Contam-
ination
error
Field switching
A1, A2, B1, B2 Monitoring case switching
H1 Warning field light interrupted
H2 Fault light
H3 Contamination light
k1 ... k2 Auxiliary contact for external device monitoring
K1 ... K2 Contactor
1)
S1 Emergency stop pushbutton
S2 Reset pushbutton
S3 Switch for standby mode
1)
In a typical application with one dual-channel actuator switch-off, 2 contactors will suffice.
2. Configure the safety laser scanner (see operating instructions 8010947).
3.
Validate the safety laser scanner as per the checklist (see operating instructions
8010947).
4. At the safety controller rotary switch, set the switch-off delay to 0.
5. Set the safety controller to program 9 (see operating instructions 8011737).
4.3.3 Safe AGV Easy 3
1. Incorporate the components as per the circuit diagram. Follow the operating
ins
tructions for the components.
PROJECT PLANNING 4
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S300 Professional
Host
1
11
19
7
10
16
18
13
4
2
5
6
20
8
9
15
17
14
3
FE
S300 Professional
Guest
1
6
20
10
21
22
18
14
3
FE
5
19
7
8
9
17
13
4
2
+24 V DC
FE
0 V DC
E158474/03/2016-11-18
UE410-MU3T5
FE
Q1
A1
A2 EN
I2
I1
X1 X2
Q2 Q4
S2 S3
Q3
S1
I4I3
S1
k2
k1
S2
S3
A1 A2 B1
B2
C1
C2
H1 H2
K1 K2
Error
Stand by
Field switching
Reset
E-stop
Warning
field
Function
9
0
1
2
7
8
9
6
54
3
x 1 s
0
0
1
4
5
3
2
A1, A2, B1, B2, C1,
C2
Monitoring case switching
H1 Warning field light interrupted
H2 Fault light
k1 ... k2 Auxiliary contact for external device monitoring
K1 ... K2 Contactor
1)
S1 Emergency stop pushbutton
S2 Reset pushbutton
S3 Switch for standby mode
1)
In a typical application with one dual-channel actuator switch-off, 2 contactors will suffice.
2. Configure the safety laser scanners (see operating instructions 8010974).
3.
Validate the safety laser scanners as per the checklist (see operating instructions
8010974).
4. At the safety controller rotary switch, set the switch-off delay to 0.
5. Set the safety controller to program 9 (see operating instructions 8011737).
4 P
ROJECT PLANNING
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5 Mounting
NOTE
Inf
ormation is included in the operating instructions for the components.
MOUNTING 5
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6 Electrical installation
NOTE
Inf
ormation is included in the operating instructions for the components.
6 ELECTRICAL INSTALLATION
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7 Configuration
NOTE
Inf
ormation is included in the operating instructions for the components.
CONFIGURATION 7
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8 Commissioning
When delivered, the safety laser scanner is in the safe status. The output signal switch‐
in
g devices (OSSDs) are and remain in the OFF state. It is only possible to put the safety
system into operation once the safety laser scanner has been configured in accordance
with its operating instructions.
8 C
OMMISSIONING
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9 Operation
Operation is dependent on integration of the safety system into the application.
OPERATION 9
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10 Maintenance
NOTE
Inf
ormation is included in the operating instructions for the components.
10 MAINTENANCE
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11 Troubleshooting
NOTE
Inf
ormation is included in the operating instructions for the components.
TROUBLESHOOTING 11
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12 Technical data
12.1 Data sheet
Table 4: Features of the Safe AGV Easy
Features Safe AGV Easy
1 2 3
Supply voltage 24 V DC (20.4 V DC ... 26.4 V DC)
Protective field range 3 m
Number of main directions of travel 1 1 2
Switchable protective fields No Yes Yes
Enclosure rating
Safety laser scanner IP65 (EN 60529)
Safety relay/safety controller IP40 (EN 60529)
1)
IP20 (EN 60529)
2)
Ambient operating temperature –10 °C ... +50 °C
Storage temperature –25 °C ... +50 °C
–25 °C ... +50 °C
3)
Safe status when a fault occurs At least one output signal switching device
(O
SSD) is in the OFF state.
1)
Housing
2)
Terminals
3)
For short-term storage < 24 h
12 TECHNICAL DATA
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