O P E R A T I N G I N S T R U C T I O N S
T4000 Multi
Transponder safety switches
Described product
T4000 Mult
i
Transponder safety switches
Manufacturer
SIC
K 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........................................................................ 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 Further 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 Structure and function............................................................................. 10
3.2 Product characteristics............................................................................ 11
4 Project planning................................................................................ 13
4.1 Manufacturer of the machine.................................................................. 13
4.2 Operating entity of the machine.............................................................. 13
4.3 Design........................................................................................................ 13
4.4 Integration into the electrical control...................................................... 14
4.5 Thorough check concept.......................................................................... 18
5 Mounting............................................................................................. 20
5.1 Safety......................................................................................................... 20
5.2 Unpacking.................................................................................................. 20
5.3 Mounting................................................................................................... 20
6 Electrical installation........................................................................ 23
6.1 Safety......................................................................................................... 23
6.2 Notes on cULus......................................................................................... 23
6.3 Sensor connection.................................................................................... 24
6.4 Evaluation unit connection....................................................................... 24
6.5 Block diagram........................................................................................... 26
7 Commissioning.................................................................................. 28
7.1 Safety......................................................................................................... 28
7.2 Switching on.............................................................................................. 28
7.3 Teach-in..................................................................................................... 28
7.4 Thorough check........................................................................................ 30
8 Troubleshooting................................................................................. 31
8.1 Safety......................................................................................................... 31
8.2 LED status indicators............................................................................... 31
8.3 System status........................................................................................... 32
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9 Maintenance...................................................................................... 33
9.1 Safety......................................................................................................... 33
9.2 Cleaning..................................................................................................... 33
9.3 Regular thorough check........................................................................... 33
9.4 Thorough check of the safety function.................................................... 33
9.5 Functional test (self-test).......................................................................... 34
10 Decommissioning............................................................................. 35
10.1 Disposal..................................................................................................... 35
11 Technical data.................................................................................... 36
11.1 Evaluation units T4000-1RCA02 and T4000-1RCA04.......................... 36
11.2 Sensors T4000-DNA................................................................................. 38
11.3 T4000-1KBA actuator.............................................................................. 39
11.4 Dimensional drawings.............................................................................. 40
12 Ordering information........................................................................ 42
12.1 Devices...................................................................................................... 42
12.2 Accessories............................................................................................... 42
13 Annex.................................................................................................. 43
13.1 Compliance with EU directives................................................................. 43
14 List of figures..................................................................................... 44
15 List of tables....................................................................................... 45
CONTENTS
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1 About this document
1.1 Function of this document
These operating instructions contain the information needed during the life cycle of the
s
afety switch.
They must be made available to all people who work with the safety switch.
1.2 Scope
These operating instructions apply only to the T4000 Multi transponder safety switches
a
s from the date of manufacture:
•
1007xxxx
You will find the date of manufacture of the device in the field Date Code on the type
label in the format yywwxxxx (yy = year, ww = calendar week, xxxx = serial number).
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, 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 Specific chapters of these operating instruc‐
t
ions
1)
Manufacturer Project developers
(planners, developers,
designers)
Project planning, page 13
Technical data, page 36
Accessories, page 42
Installers Mounting, pa
ge 20
Electricians Electrical installation, page 23
Safety experts Project planning, page 13
Commissioning, page 28
Technical data, page 36
Operating entity Operators Troubleshooting, pa
ge 31
Maintenance person‐
ne
l
Maintenance, page 33
Troubleshooting, page 31
Ordering information, page 42
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.
1.4 Further information
www.sick.com
T
he following information is available via the Internet:
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•
T
his document in other languages
•
CAD data for drawings and dimensional drawings
•
Certificates (such as the EU declaration of conformity)
•
Guide for Safe Machinery Six steps to a safe machine
1.5 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.
NOTE
Indic
ates useful tips and recommendations.
Instructions to action
b
The 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
1 A
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•
V
isible and invisible beam
•
A combination of multiple hazards
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2 Safety information
2.1 General safety notes
This chapter contains general safety information about the safety switch.
F
urther information about specific product use situations can be found in the relevant
chapters.
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
Please read this document carefully and make sure that you understand the con‐
tent fully before working with the device.
b
Follow all safety notes in this document.
2.2 Intended use
NOTICE
T
he user is responsible for ensuring that the device is correctly incorporated into a safe
overall system. This involves validating the overall system according to specifications
such as those defined in ISO 13849-2 or EN 62061.
The T4000 Multi transponder safety switch is switched by a non-contact actuator and is
suitable for the following applications:
■
Movable physical guards
■
Safe position monitoring
The safety switch must be used only on the machine on which it was planned, mounted,
installed and initially commissioned by qualified safety personnel in accordance with
these operating instructions.
Incorrect use, improper modification or manipulation of the safety switch will invalidate
any warranty from SICK; in addition, any responsibility and liability of SICK for damage
and secondary damage caused by this is excluded.
The safety switch is not suitable for the ambient conditions such as, but not limited, to
the following:
•
Radioactivity (exception: natural radioactivity)
•
Vacuum or high pressure
•
High UV load
•
In the vicinity of low-frequency RFID devices
•
In the vicinity of magnetic fields
The following may impair the function of the safety switch:
•
Metal subsurface or metal in direct proximity
•
Passing metal chips
2.3 Requirements for the qualification of personnel
The safety switch must be configured, mounted, connected, commissioned, and ser‐
v
iced by qualified safety personnel only.
2 S
AFETY INFORMATION
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Project planning
F
or 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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3 Product description
3.1 Structure and function
2
3
1
3
2
Figure 1: Components of the T4000 Multi transponder safety switch
1
Evaluation unit
2
Sensor
3
Actuator (transponder)
The T4000 Multi transponder safety switch consists of three components:
•
S
ensor
T
he sensor is mounted on the fixed part of the guard and is connected to the eval‐
uat
ion unit.
•
A
c
tuator (transponder)
The actuator is mounted on the movable part of the guard.
Each actuator has a unique electronic code.
•
Evaluation unit
The evaluation unit must be installed in a control cabinet with an enclosure rating
of a
t le
ast IP54. Depending on the evaluation unit variant (see "Product variants",
page 11), up to two or up to four sensors can be connected to the evaluation
unit.
Operating principle
The T4000 Multi transponder safety switch monitors movable physical guards:
■
Operation of the machine in automatic mode is possible only if the guards are
closed.
■
A stop command is triggered if the guard is opened while the machine is running.
The T4000 Multi transponder safety switch is uniquely coded: An actuator must be
taught in at the connected sensors during commissioning.
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RODUCT DESCRIPTION
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When a guard is closed, the actuator is moved towards the sensor. The sensor detects
t
he code of the actuator when it reaches the switch-on distance. If the sensor detects a
taught-in code (valid actuator), the evaluation unit sets the corresponding application
diagnostic output OUT to HIGH.
If valid actuator has been detected for all connected sensors, the system sets the
safety outputs (relay output) to HIGH.
When a guard is opened, the actuator is moved out of the sensor’s response range. The
system sets the safety outputs and the application diagnostic output OUT
01 … 04 assigned to the sensor to LOW.
Additional actuators can be taught in for the connected sensors (e.g. after replacement
of an actuator). Only the most recently taught-in actuator is valid.
3.2 Product characteristics
3.2.1 Product variants
The safety switch is delivered in different variants. You will find an overview of impor‐
t
ant distinguishing features of the variants in the following.
Sensor
•
Sensor with plug connector M8, 3-pin (with latching and screw connection)
•
Sensor with permanently connected cable and flying leads (5, 10 or 15 m)
Evaluation unit
•
T4000-1RCA02: for connection of up to two sensors
•
T4000-1RCA04: for connection of up to four sensors.
Complete overview of all variants: see "Ordering information", page 42.
3.2.2 Sensing face
The sensor has a sensing face, see "Dimensional dr
awings", page 40.
3.2.3 Fault detection
Any faults that occur, including internal device faults, are detected at the latest with the
ne
xt request to close the safe contacts (e.g. at the machine start). The safety switch
then switches to safe state. If a fault is detected, the safety circuit is switched off, the
diagnostic output DIA is set to HIGH and the LED DIA lights up red.
The evaluation unit enters safe status for every detectable fault due to dynamic interro‐
gation of the actuators and the redundant, diverse configuration of the safety electron‐
ics in combination with two safety outputs. The status of the safety outputs is moni‐
tored internally by positively guided N/C contacts (relay output).
3.2.4 Status indicators
The LEDs STATE (green), OUT (yellow ) and DIA (red) indicate the operational status of
t
he safety switch on the evaluation unit.
Overview of the LED statuses and their meanings: see "LED status indicators",
page 31.
3.2.5 Reset
The T4000 Multi transponder safety switch has a reset function. The function can be
t
aught in during commissioning.
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After the protective device has been tripped, the operator must press a reset pushbut‐
t
on to return the protective device to monitoring status. Then, in a second step, the
operator can restart the machine.
3.2.6 External device monitoring (EDM)
The T4000 Multi transponder safety switch has an external device monitoring (EDM)
f
unction. The function can be taught in during commissioning.
External device monitoring (EDM) monitors the status of downstream contactors.
In order to use external device monitoring, positively guided contactors must be used to
switch off the machine. If the auxiliary contacts of the positively guided contactors are
connected to the external device monitoring, the external device monitoring checks
whether the contactors drop out when the safety outputs are switched off.
If the contactors do not drop out, the T4000 Multi transponder safety switch will pre‐
vent the protective device from being reset.
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4 Project planning
4.1 Manufacturer of the machine
DANGER
F
ailure to comply with manufacturer’s obligations
Hazard due to lack of effectiveness of the protective device
b
Carry out a risk assessment before using the safety switch.
b
Do not tamper with, open, or modify the components of the safety switch.
b
Do not repair defective devices – they must be replaced instead.
b
Make sure that switch-on commands which bring about a dangerous state of the
machine are not enabled until the protective device is closed.
b
Make sure that a stop command is triggered when the protective device is opened
during the dangerous machine state.
b
The safety switches must not be defeated (contacts jumpered), rotated away,
removed, or rendered ineffective in any other way. If necessary, put measures in
place to reduce possibilities for defeat.
4.2 Operating entity of the machine
DANGER
F
ailure to comply with operating entity’s obligations
Hazard due to lack of effectiveness of the protective device
b
Modifications 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.
b
Apart from during the procedures described in this document, the components of
the safety switch must not be opened or modified.
b
Do not perform repair work on the components. Improper repair of the safety
switch can lead to a loss of the protective function.
b
Ensure that there is no bypassing by replacement actuators. Restrict access to
actuators.
4.3 Design
DANGER
B
ypassing the protective device
Hazard due to lack of effectiveness of the protective device
1. Avoid incentives to manipulate the safety switch by means of the following mea‐
sure:
°
Use permanent mounting methods for actuators (e.g. welding, adhesive
bonding, safety screws or rivets).
2. Observe the design requirements in accordance with ISO 14119 for mounting:
°
Reduction of bypass possibilities of an interlocking device
°
Mounting of safety switch and actuator
Mounting location
If the mounting location is not specified by the machine documentation, it must be cho‐
sen carefully, see "Mounting", page 20.
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Distance
If se
veral safety switches are mounted on the machine, they must be mounted at a min‐
imum distance to one another see "Mounting", page 20.
Alignment
The sensor and actuator must be mounted so that their sensing faces are directly
aligned facing each other, see "Dimensional drawings", page 40.
Actuating direction
The actuator must approach the sensing face of the sensor when the guard is closed.
4.4 Integration into the electrical control
Switch-on commands that put the machine in a dangerous state may only be activated
when t
he protective device is closed. When the machine goes into a dangerous state, a
stop command must be triggered if the protective device is opened. Depending on the
safety concept, the signal is analyzed by safety relays or a safety controller, for example.
The control that is connected and all devices responsible for safety must comply with
the required performance level and the required category (for example, according to
ISO 13849-1).
4.4.1 Safety outputs
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
Make sure that the following control and electrical requirements are met so the
protective function can be fulfilled.
•
T
he output signals of the safety outputs must not be connected to each other.
•
The two signals must be processed separately in the machine controller.
•
The machine must switch to the safe state at any time if at least one safety output
switches to the OFF state.
•
The safety outputs (relay outputs) KA (13/14) and KB (23/24) must be provided
with external fuse protection (use fuse 6 A gG or miniature circuit-breaker 6 A with
characteristic B or C).
•
A cross-circuit between safety output KA (13/14) and safety output KB (23/24)
can be detected only by external clocking. A cross-circuit in the cable can be
excluded by protected cable routing.
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.
Downstream contactors must be positively guided and monitored depending on applic‐
able national regulations or required reliability of the safety function.
b
Make sure that downstream contactors are monitored (external device monitoring,
EDM).
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4.4.2 Application diagnostic output
DANGER
Hazard due to lack of effectiveness of the protective device
The dangerous state may not be stopped in the event of non-compliance.
Application diagnostic outputs must not be used as safety outputs.
The signal of the application diagnostic output changes as soon as the actuator is
mo
ved into or leaves the response range of the safety switch. In other words, the output
signal changes when the guard is opened and closed.
Table 1: Switching behavior of application diagnostic output
Actuator Application diagnostic output
Actuator not in response range or safety switch
ha
s fault status
OFF
Actuator in response range ON
4.4.3 Preventing unexpected startup
DANGER
H
azard due to unexpected starting of the machine
b
Do not use the reset function of the T4000 Multi transponder safety switch as a
restart interlock.
b
A separate restart interlock must be provided for the machine.
Reset
E
ither manual or automatic reset can be configured for the T4000 Multi transponder
safety switch.
When a protective device has sent a stop command, the stopped state must be main‐
tained until a reset device is activated and the machine can be restarted in a second
step.
The reset brings the protective device back to the monitoring state after it has sent a
stop command. The reset also quits the start-up or restart interlock of a protective
device, so that the machine can be restarted in a second step.
The reset must only be possible, when all safety functions and protective devices are
functional.
The reset of the protective device must not introduce any movement or dangerous situ‐
ations itself. The machine is only permitted to start after the reset once a separate start
command has been sent.
•
Manual resets are performed using a separate, manually operated device, such as
a reset pushbutton.
•
Automatic resets by the protective device are only permitted in special cases, if
one of the following conditions is met:
°
It must not be possible for people to be in the hazardous area without trigger‐
ing the protective device.
°
It must be ensured that no people are in the hazardous area during or after
the reset.
4.4.4 External device monitoring (EDM)
The T4000 Multi transponder safety switch has an external device monitoring function.
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The external switching elements (external device monitoring, EDM) must be inspected
in line w
ith the regulations which apply at the place of installation or the required relia‐
bility of the safety function.
NOTE
Monit
oring of the series-connected contactors is necessary in order to realize category
4 in accordance with ISO 13849-1.
The external device monitoring (EDM) monitors the status of downstream contactors.
Requirements
Positively guided contactors are used for shutting down the machine.
If the auxiliary contacts of the positively guided contactors are connected to the exter‐
nal device monitoring, the external device monitoring checks whether the contactors
drop out when the safety outputs (relay outputs) are switched off.
Operating principle
If y
ou teach in external device monitoring, the T4000 Multi transponder safety switch
checks the contactors each time the safety outputs are switched off and before the
machine restarts. External device monitoring is then able to detect if one of the contac‐
tor’s contacts is welded, for instance. In this case, the safety outputs remain in the OFF
state.
24 V DC
k2
k1
K1
K2
0 V DC
A
EDM
B
1RCA02/04
Figure 2: Electrical diagram of external device monitoring (EDM)
Y
ou must implement external device monitoring electrically so that the two N/C con‐
tacts (k1, k2) close in a positively guided manner when the contactors (K1, K2) reach
their de-energized position once the protective device has responded. 24 V is then
present at the input of external device monitoring. If 24 V is not present when the pro‐
tective device has responded, one of the contactors is defective and external device
monitoring prevents the machine from restarting.
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4.4.5 Connection examples
Connection example with two sensors, including manual reset and external device
monit
oring (EDM)
Figure 3: Connection example T4000-1RCA02
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Connection example with four sensors, including automatic reset and external device
monit
oring (EDM)
Figure 4: Connection example T4000-1RCA04
4.5 Thorough check concept
The safety switch must be tested by appropriately qualified safety personnel during
commis
sioning, after modifications, and at regular intervals; see "Thorough check",
page 30.
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Regular thorough checks serve to investigate the effectiveness of the safety switch and
disco
ver defects resulting from modifications or external influences (such as damage or
manipulation).
The manufacturer and operating entity must define the type and frequency of the thor‐
ough checks on the machine on the basis of the application conditions and the risk
assessment. The process of defining the thorough checks must be documented in a
traceable manner.
4.5.1 Minimum requirements for the regular thorough check
The following thorough checks must be carried out at least once a year:
•
T
horough check of the protective function of the safety switch (see "Thorough
check of the safety function", page 33)
•
Thorough check of secure mounting of the devices and connections
•
Thorough check of the housing, cables and plug connectors for damage
•
Thorough check for contamination
•
Thorough check of assured switch-off distance S
ar
•
Thorough check of the safety switch for signs of misuse or manipulation
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5 Mounting
5.1 Safety
DANGER
H
azard due to unexpected starting of the machine
Death or severe injury
b
Make sure that the dangerous state of the machine is and remains switched off.
DANGER
B
ypassing the protective device
Hazard due to lack of effectiveness of the protective device
1. Avoid incentives to manipulate the safety switch by means of the following mea‐
sure:
°
Use permanent mounting methods for actuators (e.g. welding, adhesive
bonding, safety screws or rivets).
2. Observe the design requirements in accordance with ISO 14119 for mounting:
°
Reduction of bypass possibilities of an interlocking device
°
Mounting of safety switch and actuator
NOTICE
Incorrect mounting and unsuitable ambient conditions may damage the safety switch.
b
Arrange the sensor and actuator in a way that prevents damage from foreseeable
external influences.
b
Do not use the sensor and actuator as a stop.
b
The holder and mounting method for the sensor and actuator must be stable
enough to ensure that correct operation can take place.
b
Always use reliable mounting elements that can only be removed using tools.
b
If misalignment results in an opening on the physical guard, this must not impair
the protection that is provided.
5.2 Unpacking
b
Chec
k the components to ensure that all parts are complete and undamaged.
b
Please contact your respective SICK subsidiary should you have any complaints.
5.3 Mounting
Selecting the mounting location
CAUTION
Bypassing the safety switch in a simple way or unintentional actuation must be pre‐
vented by suitable installation measures in accordance with ISO 14119.
If the mounting location is not specified by the machine documentation, it must be cho‐
sen c
arefully.
5 MOUN
TING
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