SICK Safe Presence Detection Safety system Operating instructions
- Type
- Operating instructions
O P E R A T I N G I N S T R U C T I O N S
Safe Presence Detection
Safety system
Described product
S
afe Presence Detection
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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Subject to change without notice
Contents
1 Ordering information........................................................................ 5
1.1 Scope of delivery....................................................................................... 5
1.2 Safe Presence Detection order data....................................................... 5
2 About this document........................................................................ 6
2.1 Purpose of this document........................................................................ 6
2.2 Scope......................................................................................................... 6
2.3 Target groups and structure of these operating instructions................ 6
2.4 Symbols and document conventions...................................................... 7
2.5 Further information................................................................................... 7
3 Safety information............................................................................ 8
3.1 Intended use............................................................................................. 8
3.2 Requirements for the qualification of personnel.................................... 8
3.3 Safe state.................................................................................................. 8
4 Product description........................................................................... 10
4.1 Product identification............................................................................... 10
4.2 Application description............................................................................. 10
4.3 Components of the functional safety system......................................... 10
4.4 Limits of the safety system...................................................................... 10
4.5 Structure and function............................................................................. 11
4.6 Product characteristics............................................................................ 11
5 Project planning................................................................................ 12
5.1 Manufacturer of the machine.................................................................. 12
5.2 Operating entity of the machine.............................................................. 13
5.3 Safety Functions....................................................................................... 13
5.4 Design........................................................................................................ 15
5.5 Integrating the equipment into the electrical control............................. 15
5.6 Testing plan............................................................................................... 17
6 Mounting............................................................................................. 18
7 Electrical installation........................................................................ 19
8 Configuration..................................................................................... 20
9 Commissioning.................................................................................. 21
9.1 Safety......................................................................................................... 21
9.2 Thorough check........................................................................................ 21
10 Maintenance...................................................................................... 22
11 Troubleshooting................................................................................. 23
CONTENTS
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3
Subject to change without notice
12 Operation............................................................................................ 24
13 Technical data.................................................................................... 25
13.1 Data sheet................................................................................................. 25
14 Annex.................................................................................................. 26
14.1 Checklist for initial commissioning and commissioning........................ 26
CONTENTS
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1 Ordering information
1.1 Scope of delivery
Table 1: Safe Presence Detection scope of delivery
Component Safe Presence Detection variants
SPD-300 SPD-450 SPD-600
LC-C4C-300 safety light curtain 1× – –
LC-C4C-450 safety light curtain – 1× –
LC-C4C-600 safety light curtain – – 1×
Accessories for safety light curtain
(t
est rod, 4 × QuickFix brackets, T-
connector, connection cable (M12, 5-
pin, 1 m), connection cable M12, 5-
pin, 2 m))
1×
SC-UE410 safety controller 1×
PM-ES11 emergency stop pushbut‐
ton
1×
DSC-1208T000025KM0 T-piece 1×
DSL-1208-G0M6C connection cable 1×
STE–1208–G, Male connector, M12,
8-pin
1×
DOS–1208–G, Female connector,
M12, 8-pin
1×
Safety note 1×
Operating instructions for download www.sick.com
1.2 Safe Presence Detection order data
The differences between the Safe Presence Detection variants are in the height of the
s
afety light curtain.
Table 2: Safe Presence Detection order data
Protective field height of the safety light curtain Type (Safe Presence
D
etection variants)
Part number
300 mm SPD-300 1093038
450 mm SPD-450 1093039
600 mm SPD-600 1093040
Table 3: Safe Presence Detection accessories
Type Part number
Safety relay SR-UE10 1092502
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2 About this document
2.1 Purpose of this document
These operating instructions contain the information required during the life cycle of the
s
afety system. This document describes:
•
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
2.2 Scope
These operating instructions contain information regarding the Safe Presence Detec‐
t
ion safety system.
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 Presence Detection
s
afety system:
Table 4: Documents available for Safe AGV Forklift
Document type Title Part number
Operating instructions deTec4 Core
L
C-C4C-300, LC-C4C-450, LC-
C4C-600
8022156
Operating instructions Flexi Classic
SR
-FC1
8021964
Operating instructions ES11
P
M-ES11
8022327
Operating instructions UE10-30S
SR
-UE10
8022170
This document is included with the following SICK part numbers (this document in all
a
vailable language versions):
8022323
2.3 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.
2 A
BOUT THIS DOCUMENT
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These operating instructions are organized by the life phases of the safety system:
pr
oject planning, mounting, electrical installation, commissioning, operation and main‐
tenance.
2.4 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indic
ates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
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.
2.5 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 SICK components suitable
for the safety system
■
Example project data for SISTEMA for this safety system
■
Guide for Safe Machinery (“Six steps to a safe machine”)
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3 Safety information
3.1 Intended use
The Safe Presence Detection safety system is used in testing/inspection machines for
whic
h all the following features apply:
•
The separation of man and machine by a physical guard (e.g., machine housing) is
the primary safety concept.
•
Access to dangerous areas is only possible through an access opening.
•
The access opening has a maximum size of 600 mm × 1,500 mm.
•
Each access opening is secured with its own safety system.
•
The stopping time of the machine is short enough to ensure that the dangerous
state that is present when the access opening is interrupted comes to an end
before it is possible to reach the hazardous area.
Safe Presence Detection is used to protect people.
3.1.1 Improper use
•
Ris
k analysis results in a required performance level of PL e
3.2 Requirements for the qualification of personnel
The protective device must be configured, installed, connected, commissioned, and ser‐
v
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.
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.
3.3 Safe state
In the safe state, the accordingly configured safe output signal switching devices are in
t
he OFF state. The safe state is initiated in the following cases:
•
Safety light curtain detects an object.
•
Connection between the safety light curtain and the safety controller is inter‐
rupted.
•
Voltage supply of the safety controller or the safety light curtain is interrupted.
•
Internal error on the safety light curtain is detected.
•
Internal error is detected at the safety controller or one of its components.
3 S
AFETY INFORMATION
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When the safety system initiates the safe state, the machine manufacturer and user
mus
t ensure that the safe output signal switching devices are evaluated appropriately
and that the hazard is rectified.
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4 Product description
4.1 Product identification
The part number of the safety system is located on the packaging.
4.2 Application description
The Safe Presence Detection safety system is used on stationary machines to reduce
the risk of someone being injured.
The safety system is used so that people can reach safely through the access opening
of the machine. It ensures that the dangerous state of the machine comes to an end as
soon as the safety light curtain detects an object or body part.
An emergency switching off function with reset pushbutton is also integrated. Auto‐
mated restart of the machine is not possible if the emergency switching off function is
triggered. Restart is only possible once a manual reset has been performed.
4.3 Components of the functional safety system
•
L
C-C4C-xxx safety light curtain
•
SC-UE410 safety controller
•
PM-ES11 emergency stop pushbutton
•
Optional: SR-UE10 safety relay
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.
4.4 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.
The limits of the safety system are presented in abstract and general terms in the figure
below:
1
3
2
7
4 5
6
Figure 1: Limits of the safety system
1
Sensors and safety capable input devices
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 or higher-level controller
4 PRODUCT DESCRIPTION
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4.5 Structure and function
If the access opening is penetrated, the machine is stopped via the signal from the
s
afety light curtain.
As soon as all work in the hazardous area is complete and the safety light curtain no
longer detects anything in its light path, the machine is automatically restarted.
A stop command can be triggered manually in every operational status.
4.6 Product characteristics
4.6.1 Safety light curtain resolution
The resolution describes the size of the smallest object detected by the safety light cur‐
t
ain in the protective field. The resolution corresponds to the diameter of the test rod
belonging to the safety light curtain, which is reliably detected when in the protective
field.
The safety light curtain has a resolution of 14 mm. This resolution provides finger pro‐
tection.
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5 Project planning
5.1 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 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).
The safety system was developed under consideration of typical application cases. A
par
tial safety function can be implemented with the safety system in these application
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:
b
Executing a risk assessment.
b
Verifying and validating the safety functions.
b
Integrating the individual components in accordance with the appropriate stan‐
dards.
b
Please note that C standards have priority compared to statements about this
safety system.
5.1.1 Calculating the performance level
The performance level can be calculated with the SISTEMA files that are available
online f
or this safety system.
5.1.2 Calculating the stopping time
The stopping time T
s
top time
is calculated based on the safety system response time
T
response
and the machine delay time T
deceleration
.
T
stop time
= T
response
+ T
deceleration
The safety system response time T
response
is based on the sum of the response times of
the individual components.
T
response
= T
sensor
+ T
safety controller
+ T
relay/contactors
Formula Meaning
T
sensor
Safety light curtain response time
L
C-C4C-300: 11 ms
LC-C4C-450: 12 ms
LC-C4C-600: 13 ms
T
s
afety controller
SC-UE410 response time in program 9
29 ms
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Formula Meaning
T
r
elay/contactors
SR-UE10 response time
20 ms
T
dece
leration
Time period between the safety relay or the
safe output signal switching devices dropping
out and the dangerous state coming to an end
(application-dependent).
The stopping time T
s
top time
is therefore calculated as follows:
Table 5: Stopping time T
stop time
Safe Presence Detection
Safety relay used Safe Presence Detection variant
SPD-300 SPD-450 SPD-600
SR-UE10 60 ms + T
dec
eleration
61 ms + T
deceleration
62 ms + T
deceleration
Other safety relay 40 ms + T
r
elay/contactors
+ T
deceleration
41 ms + T
relay/contactors
+ T
deceleration
42 ms + T
relay/contactors
+ T
deceleration
5.1.3 Reference standards
•
IS
O 13849-1 Safety of machinery – Safety-related parts of control systems – Part
1: General principles for design
•
ISO 13849-2 Safety of machinery – Safety-related parts of control systems – Part
2: Validation
•
IEC 60204-1 Safety of machinery – Electrical equipment of machines – Part 1:
General requirements
•
ISO 13857 Safety of machinery – Safety distances to prevent hazard zones being
reached by upper and lower limbs
•
ISO 13855 Safety of machinery – Positioning of safeguards with respect to the
approach speeds of parts of the human body
•
ISO 13850 Safety of machinery – Emergency stop function – Principles for design
•
IEC 61496 Safety of machinery - Electro-Sensitive Protective Equipment - Part 1:
General requirements and tests
5.2 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.
5.3 Safety Functions
5.3.1 Initiating a stop
A safety-related stop function places the machine in a safe state on demand (e.g., viola‐
t
ion of a protective field).
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This safety function consists of the following sub-functions:
•
T
he protective field of the safety light curtain is monitored.
•
The state of the external devices connected via external device monitoring is moni‐
tored.
Table 6: Initiating a stop
Trigger Breaching the protective field of the safety light curtain
Reaction The safety-related semiconductor outputs are in the OFF state. The machine
is s
topped.
Safe state No dangerous movement
Table 7: Expected frequency for requests of the safety function
2,160 times per
d
ay (every 40 s)
Replacement of the test material
Total
788,400 times
per y
ear
Request for the safety function
NOTE
T
he expected frequency of the safety function request influences the SISTEMA calcula‐
tion. If other frequencies are to be expected – more frequent requests in particular –
the SISTEMA calculation must then be adjusted accordingly.
5.3.2 Emergency stop
Emergency stop is a complementary protective measure; it is not a primary means of
r
educing risk.
The safety function is available at all times and has priority before other functions.
Stopping in the event of an emergency must be designed as follows:
•
At the time of triggering, the dangerous movements and states of the machine are
ended in an appropriate manner
•
Aside from triggering the emergency stop function, no other action is needed from
a person to create a safe status
•
No additional dangers are created when ending the dangerous movement and sta‐
tuses
Table 8: Emergency stop
Trigger The emergency stop pushbutton is actuated.
Condition At any time
Reaction The safety-related semiconductor outputs are in the OFF state.
Safe state No dangerous movement
Table 9: Expected frequency of requesting the safety function
Once per day The emergency stop pushbutton is actuated.
Total
365 times per
y
ear
Request for the safety function
Implementing all the safety functions for the application requires a complete system
consis
ting 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.
5 P
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5.4 Design
This chapter contains information about implementing the design of the safety system.
An
y design-related contents of the relevant operating instructions also apply.
5.4.1 Emergency stop pushbutton
The emergency stop pushbutton must be integrated in accordance with ISO 13850.
5.5 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.
5.5.1 Requirements for the electrical installation work
•
Ensur
e equipotential bonding between the safety system and higher-level control.
If equipotential bonding is not possible, ensure galvanic separation between
safety the system and higher-level control using other means.
•
The signal “estop activated” is a pulsed signal (test pulse width 12 ms; test pulse
interval 40 ms). Ensure that the higher-level control interprets the pulsed signal as
a static 24 V signal (filtering).
5.5.2 interfaces
Table 10: Interfaces for higher-level control
Designation according to circuit
dia
gram
Type Description
“Signal light reset” command Input signal This signal can be used to control the reset
pushbutton light. Lights are controlled at the
signal level HIGH (24 V)
“Reset required” status Output HIGH signal level (24 V) indicates that the
r
eset pushbutton has been activated.
“Estop activated” status Output LOW signal level (0 V) indicates that the emer‐
gency stop pushbutton has been activated.
The HIGH signal level (24 V) is assigned a test
pulse.
Test pulse interval: 40 ms
Test pulse width: 12 ms
Due to the test pulse, the evaluation signal
must be filtered. Only the signal level LOW (0 V)
> 12 ms indicates activation of the emergency
stop pushbutton.
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5.5.3 Circuit diagram
M12x5
3
5
2
1 4
M12x5
3
5
2
1 4
LC-C4C-300/1219673
LC-C4C-450/1219769
LC-C4C-600/1219771
-BG1
OSSD1
0VDC
OSSD2
+24VDC
NC
The communication between the
standard plc with the safety plc
requires equipotential bonding.
Safety PLC Setting:
- Restart interlock for Estop
- Automatic restart for light curtain
The communication between the
standard plc with the safety plc
requires equipotential bonding.
DSC-1208T/6058647
-XD1
7
3
2
5
1
4
5
3
2
4
1
6
8
7
6
8
PM-ES11/6044629
-SF1
Estop
3
2
1
7
6
4
5
8
Signal light
"reset required"
Push button
"reset"
Function
Delay
0
9
SC-UE410/1090480
-KF1
A1
A2
X1
X2
I1
I2
I3
I4
Q1
Q2
Q3
Q4
EN
S1
S2
S3
K1
K2
Y1
41
13
23
33
B1
B3
Y2
42
B2
B4
14
24
34
SR-UE10/1092502
-KF2
LC-C4C-xxx/6030664
-XD2
1
3
2
5
1
3
4
5
1
2
3
4
5
2
4
1
2
3
4
5
Reserviert
0VDC
Reserviert
+24VDC
NC
1 2 3 4 5
LC-C4C-300/1219672
LC-C4C-450/1219768
LC-C4C-600/1219770
-BG2
1
2
3
4
5
1 2
4A
-FC1
Circuit-Breaker
Power supply
Option
732 541 6 8
X2
/ 1.6
Testpuls
X1
/ 1.6
Testpuls
I1
/ 1.6
Estop Ch1
I2
/ 1.6
Estop Ch2
S2
/ 1.7
EDM
24V
/1.5
0V
/1.5
X1
/1.4
Testpuls
X2
/
1.4
1.6
Testpuls
I1
/1.4
Estop Ch1
I2
/1.4
Estop Ch2
I3
/1.4
OSSD1
I4
/1.4
OSSD2
24V
/ 1.5
Q3
/ 1.6
Q4
/ 1.6
S1
/ 1.4
Reset
I3
/ 1.6
OSSD1
I4
/ 1.6
OSSD2
24V
/ 1.5
S1
/ 1.7
Reset
S2
/ 1.7
EDM
Q3
/1.7
Q4
/1.7
X2
/1.6
Testpuls
0V
/ 1.5
24V
/
1
.4
1.4
1.6
1.7
1.7
0V
/
1
.6
1.4
1.4
1.7
0V
/ 1.5
24V
/ 1.5
24V
/ 1.5
0V
/ 1.5
OUT1
/
Command "signal light Reset" from PLC
IN2
/
Status "reset required" to PLC
IN1
/
Status "estop activated" to PLC
+24VDC
0VDC
Figure 2: Safe Presence Detection circuit diagram
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5.6 Testing plan
The safety system must be thoroughly checked by appropriately qualified safety person‐
ne
l during commissioning, after changes at regular intervals.
The regular thorough checks serve to assess the effectiveness of the safety system and
to identify defects as a result of changes or other influences (e.g., damage or manipula‐
tion).
The manufacturer and user must define the type and frequency of the thorough checks
on the basis of the application conditions and the risk assessment. Determination of
the thorough checks must be documented in a traceable manner.
•
A thorough check must be carried out during commissioning and following modifi‐
cations.
•
The regular thorough checks of the safety system must fulfill certain minimum
requirements. The minimum requirements for the thorough check of the safety
system comply at least with the sum of the minimum requirements for the thor‐
ough check of the components of the safety system (see operating instructions of
the components).
•
In many cases, depending on the application conditions, the risk assessment can
determine that further thorough checks are required.
Further chapters
•
T
horough check, see "Commissioning", page 21
•
Checklist for initial commissioning and commissioning, see "Annex", page 26
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6 Mounting
NOTE
Inf
ormation is included in the operating instructions for the components.
6 MOUNTING
18
O P E R A T I N G I N S T R U C T I O N S | Safe Presence Detection 8022325/2018-04-12 | SICK
Subject to change without notice
7 Electrical installation
Prerequisites
F
or the electrical installation, observe the following:
•
All connections must comply with the requirements of the selected category
according to ISO 13849 (e.g., protected cable laying or shielded sheaths).
•
OSSDs and external device monitoring (EDM) must be wired inside the control cab‐
inet.
•
The control cabinet and the wiring it contains must meet the requirements of IEC
60204.
Approach
1.
Connect the components as follows:
1 m
2 m
ß
2 3
9
8
1
5
6
7
4
1
DM-ES11
2
DSL-1208-G0M6C connection cable
3
6058647 T-connector
4
SC-UE410
5
LC-C4C-XXX receiver
6
LC-C4C-XXX sender
7
DSL-1205-G02MC connection cable
8
DSL-1205-G01MC connection cable
9
6030664 T-connector
ß
Connection to the higher-level control or to the SC-UE410 safety controller must be
c
arried out by the customer: see "Circuit diagram", page 16. Appropriate plug con‐
nectors are included in the scope of delivery.
Complementary information
NOTE
A
dditional information is included in the operating instructions for the components.
Further topics
•
"Cir
cuit diagram", page 16
ELECTRICAL INSTALLATION 7
8022325/2018-04-12 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Presence Detection
19
Subject to change without notice
8 Configuration
Prerequisites
•
F
lat-head screwdriver
Important information
NOTE
A
dditional information is included in the operating instructions for the components.
Approach
S
C-UE410 safety controller
1. Switch off the voltage supply.
2. Rotate the Function rotary switch to position 9.
3. Rotate the Delay rotary switch to position 0.
4. Set the control functions using terminals S1 and S2 in the external circuitry.
5. Switch on the voltage supply while pressing the ENTER pushbutton.
CAUTION
D
o not press any of the connected reset buttons while this state is present!
6. As soon as the ERR display starts to flash, release the ENTER pushbutton within
3 s
.
NOTE
If t
he ENTER pushbutton remains pressed for longer than 3 s, the entire system
will change into an error status. The ERR display flashes.
8 CONFIGURATION
20
O P E R A T I N G I N S T R U C T I O N S | Safe Presence Detection 8022325/2018-04-12 | SICK
Subject to change without notice
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SICK Safe Presence Detection Safety system Operating instructions
- Type
- Operating instructions
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