SICK Safe Entry Exit – Function block for Siemens S7 Operating instructions

SICK
Brand
SICK
Model
Safe Entry Exit – Function block for Siemens S7
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 Entry Exit – Function block for Siemens S7
Safety System
Described product
S
afe Entry Exit – Function block for Siemens S7
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........................................................................ 5
1.1 Purpose of this document........................................................................ 5
1.2 Scope......................................................................................................... 5
1.3 Target groups and structure of these operating instructions................ 6
1.4 Symbols and document conventions...................................................... 6
1.5 Further information................................................................................... 7
1.6 Terminology used...................................................................................... 7
2 Safety information............................................................................ 8
2.1 General safety note.................................................................................. 8
2.2 Intended use............................................................................................. 8
2.3 Identifying hazards................................................................................... 8
2.4 Requirements for the qualification of personnel.................................... 8
2.5 Safe state.................................................................................................. 9
3 Product description........................................................................... 10
3.1 Application description............................................................................. 10
3.2 Components required............................................................................... 10
3.2.1 Requirements for the electro-sensitive protective device..... 11
3.2.2 Requirements for the manual muting pushbutton................ 11
3.2.3 Reset pushbutton requirements............................................. 11
3.3 Structure and function............................................................................. 11
3.4 Limits of the safety system...................................................................... 12
3.5 Product characteristics............................................................................ 12
3.5.1 Functions.................................................................................. 12
4 Project planning................................................................................ 14
4.1 Manufacturer of the machine.................................................................. 14
4.1.1 Calculating the performance level.......................................... 14
4.1.2 Reference standards............................................................... 14
4.2 Operating entity of the machine.............................................................. 15
4.3 Design........................................................................................................ 15
4.3.1 Design of the material passage.............................................. 15
4.3.2 Design of the material opening when using AGV/AGC.......... 16
4.3.3 Type 4 electro-sensitive protective device (ESPE)................. 18
4.3.4 Pushbutton requirements....................................................... 19
4.3.5 Process control........................................................................ 19
4.3.6 Conveyor speed........................................................................ 20
4.3.7 Height of the AGV/AGC............................................................ 20
4.4 Integrating the equipment into the electrical control............................. 20
4.4.1 Circuit diagram......................................................................... 20
4.4.2 Interfaces................................................................................. 22
4.4.3 Muting function........................................................................ 24
4.4.4 Time Extension Function......................................................... 27
CONTENTS
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4.4.5 Hold to run device.................................................................... 28
4.4.6 Calculating the total response time........................................ 29
4.4.7 Calculating minimum distance............................................... 30
4.4.8 Testing plan.............................................................................. 31
5 Mounting............................................................................................. 32
5.1 Requirements of the SIEMENS F-CPU safety controller......................... 32
6 Electrical installation........................................................................ 33
6.1 General requirements.............................................................................. 33
6.1.1 Safety extra-low voltage for fail-safe modules....................... 33
6.1.2 Additional requirements for actuators................................... 33
6.1.3 Additional requirement for the process controller as an
independent de
vice................................................................. 34
6.2 Pin assignment......................................................................................... 34
7 Configuration..................................................................................... 35
7.1 PLC hardware configuration..................................................................... 35
7.1.1 Activation of the test pulses for the safety outputs............... 35
7.1.2 Activation of the test pulses for the safety capable input..... 37
7.2 PLC software configuration...................................................................... 39
7.2.1 Structure of the “SICK Safe Entry Exit” function block.......... 40
7.2.2 Configuration of the function block interface........................ 42
8 Commissioning.................................................................................. 50
8.1 Safety......................................................................................................... 50
8.2 Thorough check........................................................................................ 50
9 Operation............................................................................................ 51
10 Maintenance...................................................................................... 52
11 Troubleshooting................................................................................. 53
12 Technical data.................................................................................... 57
12.1 Data sheet................................................................................................. 57
12.2 PFH
D
value.................................................................................................
57
13 Ordering information........................................................................ 59
13.1 Oder data Safe Entry Exit – Function block for Siemens S7.................. 59
13.2 Order data for the Type 4 electro-sensitive protective device................ 59
14 Annex.................................................................................................. 60
14.1 Checklist for initial commissioning and commissioning........................ 60
14.2 Overview of sensors and actuators......................................................... 63
CONTENTS
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1 About this document
1.1 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
1.2 Scope
These operating instructions contain information regarding the safety system Safe Entry
Exit – F
unction block for Siemens S7.
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 about possible components of the safety
s
ystem:
Table 1: Available documents
Document type Title Part number
Operating instructions deTec4 Prime 8017724
Operating instructions deTec4 Core 8014251
Operating instructions miniTwin4 8012731
Operating instructions C4000 Standard 8009855
Operating instructions C4000 Standard ATEX II 3G / 3D 8013551
Operating instructions C4000 Advanced 8009855
Operating instructions C4000 Advanced Ex 8017105
Operating instructions C4000 Advanced ATEX II 3G / 3D 8013551
Operating instructions C4000 Select 8012198
Operating instructions C4000 Select Ex 8017106
Operating instructions M4000 Advanced Curtain 8010794
Operating instructions deTec4 Core IP69K 8021546
Operating instructions deTec4 Core Ex 8017107
Operating instructions deTem4 Core 8020445
Operating instructions M4000 Standard 8011190
Operating instructions M4000 Standard A/P 8011190
Addendum to operating
ins
tructions
M4000 Standard A/P in IP69K
Housing
8014815
ABOUT THIS DOCUMENT 1
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Document type Title Part number
Operating instructions M4000 Advanced 8010794
Operating instructions M4000 Advanced A/P 8010794
Operating instructions M4000 area 8010794
Operating instructions deTem4 Core IP69K 8021557
Siemens document System manual S7-1500, ET 200MP
A
utomation system
A5E03461182-AE
Siemens document Cycle and response times functional
manual
A5E03461504-AC
Siemens document SIMATIC Industrial Software SIMATIC
Safety - Configuring and Program‐
ming
A5E02714439-AJ
This document is included with the following SICK part numbers (this document in all
a
vailable language versions):
8024066
1.3 Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: project devel‐
oper
s (planners, developers, designers), installers, electricians, operators, and mainte‐
nance personnel.
These operating instructions are organized by the life phases of the safety system:
project planning, mounting, electrical installation, commissioning, operation and main‐
tenance.
1.4 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
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.
1 ABOUT THIS DOCUMENT
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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.
1.5 Further information
www.sick.com
T
he following information is available via the Internet:
■
This document in other languages
■
Operating instructions and mounting instructions of SICK components suitable for
the safety system
■
Other configurations aids if necessary
■
Complete subsystems for SISTEMA for this safety system
■
Circuit diagram for the safety system (ePLAN)
■
Guide for Safe Machinery (“Six steps to a safe machine”)
1.6 Terminology used
The following terminology is used in these operating instructions:
Term Explanation
Electro-sensitive protective
de
vice (ESPE)
Combination of components that interact and effect presence
monitoring or trigger protective functions.
ESPE: Electro-sensitive protective equipment.
Muting function Temporary automated suspension of a safety function by safety-
r
elated parts of the control system.
Conveyor Includes conveyor belts as well as automated guided vehicles
(
AGC/AGV). If special conditions apply to AGC/AGV, this will be
explicitly indicated in these operating instructions; otherwise the
term conveyor applies.
Safety controller Controller for safety applications which logically evaluates signals
from safety sensors, safety command devices and other sources
and securely switches the actuators of the machine on and off via
safety outputs. In this case, a SIMATIC S7-15xx from Siemens.
Process control Controller for process signals. The process controller provides sig‐
nals for the safety controller. The process controller can be an
independent device or be integrated in the non-secure part of the
safety controller.
Safety system Combination of safety controller, safety sensors and logic.
Complete system Combination of safety system, process controller, machine and all
o
ther actuators, sensors and switching elements that interact in
the application.
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2 Safety information
2.1 General safety note
The information and tools will not fulfill the safety requirements for your application
w
ithout further adjustments being made. The project planning provided by way of exam‐
ple is intended to serve as the basis to allow you to perform your own project planning
and programming in line with your specific requirements. What this means is that the
information and tools merely provide an example to demonstrate how a safety function
can be taken care of.
When it comes to your own project planning and programming, you will need to rely on
qualified staff given that it is your responsibility to ensure that the following require‐
ments are complied with at the very least:
b
Carrying out a risk assessment
b
Taking into account applicable standards
b
Verifying and validating the safety function
2.2 Intended use
The safety system Safe Entry Exit – function block for Siemens S7 is used in hazardous
ar
eas with material transportation via a conveyor (e.g., conveyor belt or AGC/AGV), e.g.,
a robot cell. The safety system reduces the risk of personal injury caused by passing
through the machine’s material transportation. The safety system can be used both at
the entry area as well as the exit area of the material passage.
The safety system is suitable for applications with the following properties:
•
The material is moved by a conveyor into a hazardous area.
•
The conveyor moves at a defined speed (maximum of 4 different speeds) during
material passage.
•
The material has a length of at least 500 mm.
•
The length of the material is always identical or can be determined in an auto‐
mated manner (e.g., via a combination of existing process signals).
•
A SIMATIC S7-15xx fail-safe controller from Siemens is included.
2.3 Identifying hazards
This safety system will reduce mechanical hazards associated with the following
a
spects:
•
Reliable monitoring of material passage through a Type 4 electro-sensitive protec‐
tive device (ESPE)
•
Temporary deactivation of safety functions (manual muting)
Mechanical hazards
T
he hazards resulting from the machine depend on the type of machine. Sources of
hazards may include machine movements, robot arm movements or rotating saw
blades.
Other residual hazards, e.g., due to small parts being propelled, are not considered and
must be considered in detail in the risk assessment, see "Manufacturer of the
machine", page 14
2.4 Requirements for the qualification of personnel
The protective device must be configured, installed, 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.
2.5 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:
•
Type 4 electro-sensitive protective device (ESPE) detects an object during inactive
muting function.
•
Muting function is not correctly timed because the detected object is too short or
too long.
•
Muting function is not correctly initiated and the electro-sensitive protective device
(ESPE) is interrupted.
•
Deviation from preset timing detected.
•
Deviation from preset sequence detected.
•
Connection between the process controller or Type 4 electro-sensitive protective
device (ESPE) and the safety controller is interrupted.
•
Voltage supply of the process controller, Type 4 electro-sensitive protective device
(ESPE) or the safety controller is interrupted.
•
Internal fault detected at the Type 4 electro-sensitive protective device (ESPE).
•
Internal fault detected at the safety controller or one of its components.
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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3 Product description
3.1 Application description
The safety system Safe Entry Exit – function block for Siemens S7 is used on machines
in whic
h it is not possible to enter the hazardous area as long as the machine is in a
dangerous state. Appropriate protective devices (e.g., fixed guards) prevent access to
the hazardous area. The hazardous area can be accessed via an opening that enables
the material to pass through via the conveyor.
The safety system is used to monitor the opening provided for material transport and to
place the machine in the safe state if anything other than the expected material passes
through the opening. To accomplish this, the safety system monitors the time it takes
for the expected material to pass through the Type 4 electro-sensitive protective device
(ESPE), but not the height of the material, see "Structure and function", page 11.
3.2 Components required
The following components are essential for use of the safety system in an application:
•
A SIM
ATIC S7-15xx controller for fail-safe applications (hereinafter referred to as
Siemens F-CPU)
•
Type 4 electro-sensitive protective device (ESPE)
•
Process controller (The process controller provides signals for the safety system.
These process signals can be provided by a higher-level PLC or by the Siemens F-
CPU itself)
•
Function block for SIEMENS F-CPU
•
Hold to run device
•
Reset pushbutton
3 P
RODUCT DESCRIPTION
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NOTE
All nece
ssary components influence the parameters of the entire application that relate
to safety technology. The components must therefore have a MTTF
d
value that is suit‐
able for the entire application and satisfies the necessary performance level. The nec‐
essary performance level results from the risk assessment. For evaluating the perfor‐
mance level achieved, subsystems for SISTEMA are available under:
www.sick.com
3.2.1 Requirements for the electro-sensitive protective device
The Type 4 electro-sensitive protective device (ESPE) must meet the requirements of
EN IS
O 61496-1 and have an MTTF
d
value of at least 100 a.
3.2.2 Requirements for the manual muting pushbutton
The pushbutton must be designed according to the following standards:
•
EN 60204
NOTE
T
he pushbutton should only be operated by authorized personnel. An example of a
measure to prevent unauthorized use is a key-operated spring-back pushbutton.
3.2.3 Reset pushbutton requirements
The reset pushbutton must be designed in accordance with the following standard:
•
EN 60204
3.3 Structure and function
Type 4 electro-sensitive protective device (ESPE) monitors the material transport open‐
in
g. The material can be transported via, e.g., a conveyor or an access route for an
AGV/AGC (automated guided vehicle). The safety controller evaluates the output signal
switching devices of the Type 4 electro-sensitive protective device (ESPE) and decides if
a transported material interruption has been triggered and whether it is necessary to
put the machine into the safe state.
The machine must be secured against automated restart and must be put back into
operation manually, for example by pressing a reset pushbutton followed by a restart
button.
When material on the conveyor approaches the opening, the process controller can
determine the type of material, e.g. using a code reader or by evaluating existing
process information. Based on the type of material and speed of the conveyor, an exact
time window is determined during which the material will pass through the opening and
therefore also pass by the Type 4 electro-sensitive protective device (ESPE). This time
window must not exceed a maximum path of 200 mm. The 200 mm depend on the risk
assessment of the application.
The process controller sends a request to the safety controller for the expected time
window for initiation of the muting function. Only if the Type 4 electro-sensitive protec‐
tive device (ESPE) is interrupted during this time window does the muting function start.
As long as the ESPE is not interrupted, a machine stop is not triggered. If the Type 4
electro-sensitive protective device (ESPE) is not interrupted in this time window, this is
seen as an error and the muting function is not started.
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While the material is passing through the opening, the safety controller continues to
monit
or the signals from the Type 4 electro-sensitive protective device (ESPE). If the
actual duration of interruption differs from the expected interruption duration, the
machine is placed in the safe state.
Error-free ending of the muting function is performed by the Type 4 electro-sensitive
protective device (ESPE) being released along with the respective signal change of the
process controller.
The area of application for this safety system is the European Economic Area in which
the Machinery Directive and standards used are applicable.
Further topics
•
R
eference standards
3.4 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.
For detailed information about the interfaces, see “see "Electrical installation",
page 33”.
The limits of the safety system are presented in abstract and general terms in the figure
below:
1
3
2
7
4 5
6
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
pr
ocess controller
3.5 Product characteristics
3.5.1 Functions
The safety system offers the following functions:
•
Mut
ing function
°
The safety controller monitors the signal change from requesting the muting
function and from the output signal switching devices of the Type 4 electro-
sensitive protective device (ESPE) and if necessary, switches to the safe
state, see "Muting function", page 24.
•
Time Extension Function
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°
Af
ter a correct initiation sequence of the muting function, the maximum dura‐
tion of the muting function can be extended, see "Time Extension Function",
page 27.
•
Hold to run device
°
When the safety system has switched to the safe state, the hold to run device
is used to place the conveyor in motion while the material is blocking the pro‐
tective field of the Type 4 electro-sensitive protective device (ESPE), see "Hold
to run device", page 28.
•
Material selection (1 of n timing sets)
°
The signals for material selection make it possible to select different trans‐
port speeds and/or material lengths, see "Interfaces", page 22.
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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 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.
4.1.1 Calculating the performance level
Complete subsystems for SISTEMA available on the internet for this safety system can
be used t
o calculate the achieved performance level.
NOTE
F
or quantification of the safety functions, the safety-relevant data of the components
was taken into account wherever available. Where this data was not available, the typi‐
cal component values in accordance with EN ISO 13849-1 were used.
During the development of the safety system, certain measures against common-cause
faults were implemented or defined. Some of these measures must be actioned during
the implementation, see "General requirements", page 33.
4.1.2 Reference standards
•
IEC 61496-1 Safety of machinery – Electro-sensitive protective equipment – Part
1: General requirements and tests
•
EN ISO 12100 Safety of machinery – General principles for design – Risk assess‐
ment and risk reduction
•
EN ISO 13849 Safety of machinery – Safety-related parts of control systems
Part 1: General principles for design
Part 2: Validation
4 P
ROJECT PLANNING
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•
IE
C 62046 Safety of machinery. Application of protective equipment to detect the
presence of persons
•
EN ISO 13855 Safety of machinery – Positioning of safeguards with respect to the
approach speeds of parts of the human body
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 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.
4.3.1 Design of the material passage
The safety system is suitable for monitoring material which is at least 500 mm in
len
gth.
WARNING
H
azard if the hazardous area is entered while the muting function is active.
b
The design of the material passage (or the AGV/AGC) and the type of material
must not allow the hazardous area to be entered while the muting function is
active.
The material passage opening should be designed so as to provide free space of maxi‐
mum 200 mm ne
xt to the material when the material is passing through. If the risk
assessment concludes that even with a larger free space it is still impossible for per‐
sons to end up in the hazardous area by passing next to the material, the free space
can be adjusted accordingly.
If the lateral free space next to the material is larger than 200 mm, it should be
expanded to at least 500 mm to prevent the crushing of persons between the material
and the Type 4 electro-sensitive protective device (ESPE) or other machine parts. In this
case, additional protective measures must be taken, e.g., installation of electronically
monitored swing flaps.
It must be clarified in the risk assessment whether it is possible for a person or possi‐
bly several persons in a row to be on top of the material or the conveyor. If this is the
case, suitable measures must be taken, such as preventing the possibility of climbing
onto the material or monitoring the maximum material height.
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d1 d2
d3 b
a
1
2 3
4
3
Figure 1: Material passage and material conditions
1
Transported material
2
Type 4 electro-sensitive protective device
3
Fixed guard
4
Hazardous area
Table 2: Recommended values for the material opening
Variable Recommended value
d1 (maximum distance of the material before
s
tarting the requirement for the muting func‐
tion)
200 mm
d2 (maximum distance of the material/AGV
af
ter the ESPE is released)
200 mm
d3 min. 500 mm
a 200 mm or 500 mm
b 200 mm or 500 mm
4.3.2 Design of the material opening when using AGV/AGC
When using AGV/AGC, additional measures must be implemented to prevent the mater‐
ial openin
g from being released when the muting function is active.
Example scenario
An AGV/AGC travels until just before the Type 4 electro-sensitive protective device
(ESPE) so the muting function is requested. However, the AGV/AGC does not continue
moving forward as expected, but rather moves back and releases the material opening
while the muting function is active. This results in a time window where a person could
pass the material opening without being detected.
If an AGV/AGC moves past parallel to the access area, a muting function cannot be
requested.
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Entry into the access area
3
2
4
1
Figure 2: Example of access restriction with AGV
1
AGV
2
Hazardous area
3
Access restricted by a fence
4
Type 4 electro-sensitive protective device
If the AGV/AGC drives into the access, the muting function cannot be activated until the
A
GV/AGC is located directly before the Type 4 electro-sensitive protective device (ESPE).
WARNING
W
hen the AGV/AGC is driving into the access, there must be no shear points where a
person could be injured. Electrically monitored mechanical swing doors are a good pro‐
tection measure, as an example.
An opened swing door must trigger the safe state of the machine.
These measures are not part of this safety system. The manufacturer is responsible for
the implementation and must take this into account in the risk assessment.
Approaching the Type 4 electro-sensitive protective device (ESPE)
21
Figure 3: Example of access restriction with AGV
1
AGV
2
Hazardous area
If the AGV/AGC is located directly before the Type 4 electro-sensitive protective device
(E
SPE), then the request for the muting function is activated and the initialization time
begins.
The Type 4 electro-sensitive protective device (ESPE) must then be actually interrupted
within the specified time, otherwise the system will switch to the safe state in the event
of a faulty request.
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21
Figure 4: Example of access restriction with AGV
1
AGV
2
Hazardous area
The mechanical protective device must be designed to be long enough for the initializa‐
t
ion time to have elapsed by the time the AGV/AGC reaches the access area entry when
it departs after an activation.
4.3.3 Type 4 electro-sensitive protective device (ESPE)
NOTICE
T
he Type 4 electro-sensitive protective device (ESPE) must meet the requirements of
EN ISO 61496-1 and have an MTTFd value of at least 100 a.
b
P
osition Type 4 electro-sensitive protective device (ESPE) according to
EN ISO 13855.
b
If possible, mount the Type 4 electro-sensitive protective device (ESPE) such that
the pallet for transporting the material on the conveyor does not trigger the Type 4
electro-sensitive protective device.
The Type 4 electro-sensitive protective device (ESPE) should only be triggered by
t
he material on the pallet. The lowest beam of the Type 4 electro-sensitive protec‐
tive device (ESPE) should run just above the surface of the pallet. If this is not
practical, the Type 4 electro-sensitive protective device (ESPE) can also be aligned
to the pallet. In this case, the possibility of persons being situated in an empty pal‐
let must be considered in the risk assessment and, if applicable, measures must
be taken to prevent climbing onto an empty pallet. The height of the lowest beam
of the Type 4 electro-sensitive protective device (ESPE) must be chosen such that
it is not possible for persons to end up in the hazardous area by passing under‐
neath the beam.
b
Mount t
he Type 4 electro-sensitive protective device (ESPE) such that persons can‐
not enter the hazardous area by moving past the material.
The distance to the opening should be a maximum of 200 mm on each side,
unle
ss otherwise determined in the risk assessment.
The height of the lowest beam of the Type 4 electro-sensitive protective device
(ESPE) must be ≤ 300 mm in order to prevent crawling beneath.
If the height of the AGV/AGC is lower than 300 mm, then the lowest beam of the
Type 4 electro-sensitive protective device (ESPE) must detect the material on the
vehicle.
If needed the operating entity of the machine must take additional security mea‐
sures, such as mounting electronically monitored swinging flaps.
The Type 4 electro-sensitive protective device (ESPE) must only be mounted with the
original accessories of the manufacturer and connected according to the instructions of
the manufacturer. For more notes, see the operating instructions for the Type 4 electro-
sensitive protective device (ESPE).
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If the Type 4 electro-sensitive protective device (ESPE) has additional functions that
af
fect the direct relationship between the status of the output signal switching devices
and the interruption of the protective field by the conveyed material, these must be
deactivated.
Such functions are, for example, integrated reset functions.
This does not apply to functions such as a blanking function that ignore continuously
interrupted signal pathways.
The following must also be taken into account:
•
The penetration distance required to calculate the minimum distance depends on
the resolution of the Type 4 electro-sensitive protective device (ESPE).
•
The approach speed of the material depends on the speed of the conveyor.
•
If it is possible to step onto the conveyor, the speed at which a person is moving
must be considered in the calculation.
NOTE
T
his safety systems only considers the positioning of a Type 4 electro-sensitive protec‐
tive device (ESPE) for monitoring of an opening for material transport. The positioning of
other equipment, such as safety fences, is not considered.
4.3.4 Pushbutton requirements
Requirements for the manual muting pushbutton
T
he pushbutton must be installed outside of the hazardous area. From the position of
the pushbutton, there must be a complete view of the hazardous area. It must not be
possible for a person to enter the hazardous area while activating the pushbutton.
Reset pushbutton requirements
The pushbutton must be installed outside of the hazardous area. From the position of
the pushbutton, there must be a complete view of the hazardous area. Activating the
pushbutton must not initiate any hazardous movement of the machine.
The reset pushbutton is intended to reset the Safe Entry Exit function. If the machine
should also be reset using the reset pushbutton, then after evaluating the risk assess‐
ment, it must be ensured that this cannot result in a hazard.
4.3.5 Process control
The controller must have the following information:
•
P
osition of the material on the conveyor
•
Speed of the material on the conveyor
If material of different sizes is transported, information about the size of the respective
material must also be available.
Recommended sources include:
•
Code reader
•
Process information
•
...
This information must be processed in such a way that the controller can chance the
signal status accordingly.
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NOTE
T
he process signal may originate from the following sources:
•
Safety-related part of an F-CPU
•
Standardized (not secure) logic component of an F-CPU
•
Standardized (not secure) logic component of another CPU
4.3.6 Conveyor speed
The safety controller defines the timing of the muting sequence based on a constant
con
veyor speed. In order to ensure the availability of the safety system, the speed of the
transported material must remain constant during the request, the muting function and
the end of the muting function.
If different conveyor speeds are used, up to four different timing sets can be set in the
safety controller. The currently valid timing set must be selected via signals from the
process controller, see "Interfaces", page 22.
The maximum possible speed of the conveyor depends on the drive as well as the mea‐
surement accuracy of the muting function request. The muting function request must
be sent when the material is a maximum of 200 mm from the Type 4 electro-sensitive
protective device. If the risk assessment concludes that persons in front of the material
definitely need more than 200 mm, the distance can be adjusted accordingly.
4.3.7 Height of the AGV/AGC
Only use AGVs/AGCs with a height over 300 mm if an individual risk assessment from
t
he manufacturer concludes that persons cannot climb onto the AGV/AGC, see EN
IEC 62046.
4.4 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.
4.4.1 Circuit diagram
The safety system with SIMATIC S7 F-CPU provides the safety-oriented application soft‐
w
are as a function block. Other suitable fail-safe modules of the SIMATIC S7-1500
series can also be used.
The components are connected according to the following diagram:
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SICK Safe Entry Exit – Function block for Siemens S7 Operating instructions

SICK
Brand
SICK
Model
Safe Entry Exit – Function block for Siemens S7
Type
Operating instructions
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