OPERATING INSTRUCTIONS mac4 - SICK

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

mac4Safety light curtain

Described product

mac4

Manufacturer

SICK AGErwin-Sick-Str. 179183 WaldkirchGermany

Legal information

This work is protected by copyright. Any rights derived from the copyright shall bereserved for SICK AG. Reproduction of this document or parts of this document is onlypermissible within the limits of the legal determination of Copyright Law. Any modifica‐tion, abridgment or translation of this document is prohibited without the express writ‐ten permission of SICK AG.

The trademarks stated in this document are the property of their respective owner.

© SICK AG. All rights reserved.

Original document

This document is an original document of SICK AG.

2 O P E R A T I N G I N S T R U C T I O N S | mac4 8014264/YUP1/2016-04-06 | SICKSubject to change without notice

Contents

1 About this document........................................................................ 61.1 Scope......................................................................................................... 61.2 Target groups and structure of these operating instructions................ 61.3 Additional information.............................................................................. 71.4 Symbols and document conventions...................................................... 7

2 Safety information............................................................................ 92.1 General safety notes................................................................................. 92.2 Correct use................................................................................................ 92.3 Requirements for the qualification of personnel.................................... 10

3 Product description........................................................................... 113.1 Setup and function................................................................................... 113.2 Product characteristics............................................................................. 12

3.2.1 Modular design........................................................................ 123.2.2 Absence of blind zones........................................................... 123.2.3 Automatic calibration of the protective field width................ 123.2.4 Status indicators...................................................................... 12

3.3 Example applications............................................................................... 14

4 Project planning................................................................................ 164.1 Manufacturer of the machine.................................................................. 164.2 Operator of the machine.......................................................................... 164.3 Assembly................................................................................................... 16

4.3.1 Scanning range and protective field width............................. 174.3.2 Minimum distance from the hazardous point....................... 174.3.3 Minimum distance to reflective surfaces............................... 204.3.4 Protection against interference from systems in close prox‐

imity to each other................................................................... 214.3.5 Mounting surface requirements............................................. 224.3.6 Fixing hole requirements......................................................... 23

4.4 Integration in the electrical control......................................................... 254.4.1 Restart interlock...................................................................... 274.4.2 External device monitoring (EDM).......................................... 284.4.3 Connection diagrams.............................................................. 29

5 Mounting............................................................................................. 305.1 Safety......................................................................................................... 305.2 Unpacking.................................................................................................. 315.3 Combine modules..................................................................................... 315.4 Installation................................................................................................ 32

5.4.1 Direct mounting....................................................................... 335.4.2 Mount optional alignment bracket......................................... 34

5.5 Attach information label........................................................................... 36

CONTENTS

8014264/YUP1/2016-04-06 | SICK O P E R A T I N G I N S T R U C T I O N S | mac4 3Subject to change without notice

6 Electrical installation........................................................................ 376.1 Safety......................................................................................................... 376.2 System connection (M12, 4-pin)............................................................. 386.3 Connect the sender and receiver............................................................ 39

7 Commissioning.................................................................................. 407.1 Safety......................................................................................................... 407.2 Align the sender and receiver.................................................................. 417.3 Switching on.............................................................................................. 427.4 Checks....................................................................................................... 42

8 Operation............................................................................................ 438.1 Safety......................................................................................................... 438.2 Regular test rod testing............................................................................ 43

9 Maintenance...................................................................................... 469.1 Safety......................................................................................................... 469.2 Regular cleaning....................................................................................... 469.3 Regular thorough check........................................................................... 47

10 Troubleshooting................................................................................. 4810.1 Safety......................................................................................................... 4810.2 Fault indicators......................................................................................... 48

11 Decommissioning............................................................................. 5011.1 Protection of the environment................................................................. 5011.2 Disposal..................................................................................................... 50

12 Technical data.................................................................................... 5112.1 Data sheet................................................................................................. 5112.2 Response time.......................................................................................... 5312.3 Table of weights........................................................................................ 5312.4 Dimensional drawings.............................................................................. 54

13 Ordering information........................................................................ 5513.1 Scope of delivery...................................................................................... 5513.2 Ordering information mac4...................................................................... 55

14 Accessories........................................................................................ 5714.1 Brackets.................................................................................................... 5714.2 Wiring technique....................................................................................... 5814.3 Alignment aid............................................................................................ 5914.4 Cleaning agent.......................................................................................... 5914.5 Test rods.................................................................................................... 5914.6 Additional accessories............................................................................. 59

15 Annex.................................................................................................. 60

CONTENTS


15.1 Compliance with EU directives................................................................. 6015.2 Checklist for initial commissioning and commissioning........................ 61

16 List of figures..................................................................................... 62

17 List of tables....................................................................................... 63

CONTENTS


1 About this document

These operating instructions contain information required during the life cycle of thesafety light curtain.

These operating instructions are available to all those who work with the safety lightcurtain.

Please read these operating instructions carefully and make sure that you understandthe content fully before working with the safety light curtain.

1.1 Scope

These operating instructions only apply to the mac4 safety light curtain with the follow‐ing type label entry in the operating instructions field: 8014262 or 8014262/YIQ6.

This document is included with the following SICK part numbers (this document in allavailable language versions):

8014262/YUP1

1.2 Target groups and structure of these operating instructions

These operating instructions are intended for the following target groups: Project devel‐opers (planners, developers, designers), installers, electricians, safety experts (e.g., CEauthorized representatives, compliance officers, persons who test and approve theapplication), operators, and maintenance personnel.

The structure of these operating instructions is based on the life cycle phases of thesafety light curtain: Project planning, mounting, electrical installation, commissioning,operation, and maintenance.

In many applications, the target groups are assigned as follows to the manufacturerand the organization operating the machine in which the safety light curtain is inte‐grated:

Area of responsibility Target group Special chapters of these operating instruc‐tions 1)

Manufacturer Project developers(planners, developers,designers)

Project planning, page 16Technical data, page 51Accessories, page 57

Installers Mounting, page 30

Electricians Electrical installation, page 37

Safety experts Project planning, page 16Commissioning, page 40Technical data, page 51Checklist for initial commissioning and com‐missioning, page 61

Users Operator Operation, page 43Troubleshooting, page 48

Maintenance person‐nel

Maintenance, page 46Troubleshooting, page 48Ordering information, page 55

1) Chapters not listed here are intended for all target groups. All target groups must take into account thesafety and warning instructions of the complete operating instructions!

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

1 ABOUT THIS DOCUMENT


1.3 Additional information

www.sick.com

The following information is available on the Internet:

• versions in other languages• data sheets and application examples• CAD data of drawings and dimensional drawings• certificates (e.g. EU declaration of conformity)• Guide for Safe Machinery (Six steps to a safe machine)

1.4 Symbols and document conventions

The following symbols and conventions are used in this document:

Safety notes and other notes

DANGERIndicates a situation presenting imminent danger, which will lead to death or seriousinjuries if not prevented.

WARNINGIndicates a situation presenting possible danger, which may lead to death or seriousinjuries if not prevented.

CAUTIONIndicates a situation presenting possible danger, which may lead to moderate or minorinjuries if not prevented.

NOTICEIndicates a situation presenting possible danger, which may lead to property damage ifnot prevented.

NOTEIndicates 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.

LED symbols

These symbols indicate the status of an LED:

The LED is off. The LED is flashing. The LED is illuminated continuously.

Sender and receiver

These symbols indicate the sender and receiver of the safety light curtain:

The symbol indicates the sender. The symbol indicates the receiver.

ABOUT THIS DOCUMENT 1


http://www.sick.com

When using these symbols in this document, the arrow direction is purely symbolic andmakes no statement about the actual beam direction shown in the figures. Arrows onthe level of the light beams are used to indicate direction (from sender to receiver).

1 ABOUT THIS DOCUMENT


2 Safety information

This chapter contains information on general safety for the safety light curtain.

More safety information about specific usage situations of the safety light curtain isavailable in the respective chapters.

2.1 General safety notes

DANGERHazard due to lack of effectiveness of the protective deviceIn the case of non-compliance, it is possible that the dangerous state of the machinemay not be stopped or not stopped in a timely manner.

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

b Pay particular attention to all safety notes in this document.

2.2 Correct use

The mac4 safety light curtain is an electro-sensitive protective device (ESPE) and is suit‐able for the following applications:

• Hazardous point protection• Access protection

The mac4 safety light curtain must be only used within the limits of the prescribed andspecified technical data and operating conditions at all times.

Any instance of improper use, incorrect modification, or manipulation of the mac4safety light curtain shall void any warranty provided by SICK AG; furthermore, SICK AGshall not accept any responsibility or liability for any resulting damage and consequen‐tial damage.

Foreseeable misuse

DANGERHazard due to lack of effectiveness of the protective devicePersons and parts of the body to be protected may not be recognized in case of non-observance.The safety light curtain works as an indirect protective measure and cannot provide pro‐tection from parts thrown out nor from emitted radiation. Transparent objects are notdetected.

b Only use the safety light curtain as an indirect protective measure.

Among others, the mac4 safety light curtain is not suitable for the following applica‐tions:

• Outdoors• Under water• In explosive environments• In areas with flying sparks

SAFETY INFORMATION 2


2.3 Requirements for the qualification of personnel

The safety light curtain must be configured, installed, connected, commissioned andserviced only by qualified safety personnel.

Project planning

For project planning, a person is considered competent when he/she has expertise andexperience in the selection and use of protective devices on machines and is familiarwith the relevant technical rules and national work safety regulations.

Mechanical mounting

For mechanical mounting, a person is considered competent when he/she has theexpertise and experience in the relevant field and is sufficiently familiar with the appli‐cation of the protective device on the machine that he/she can assess its operationalsafety status.

Electrical installation

For electrical installation, a person is considered competent when he/she has theexpertise and experience in the relevant field and is sufficiently familiar with the appli‐cation of the protective device on the machine that he/she can assess its operationalsafety status.

Commissioning

For commissioning, a person is considered competent when he/she has the expertiseand experience in the relevant field and is sufficiently familiar with the application ofthe protective device on the machine that he/she can assess its operational safety sta‐tus.

Operation and maintenance

For operation and maintenance, a person is considered competent when he/she hasthe expertise and experience in the relevant field and is sufficiently familiar with theapplication of the protective device on the machine and has been instructed by themachine operator in its operation.

An operator must clean the safety light curtain and carry out specific checks asinstructed. More information for the operator of the machine: see "Operation",page 43, see "Regular cleaning", page 46.

2 SAFETY INFORMATION


3 Product description

This chapter provides information on the operation of the safety light curtain and showsexamples of its range of use.

3.1 Setup and function

The mac4 safety light curtain is an electro-sensitive protective device (ESPE) consistingof a sender and a receiver.

A series of parallel infrared light beams form a protective field between sender andreceiver that protects the hazardous area (hazardous point and access protection).When one or more beams are completely interrupted, the safety light curtain reportsthe interruption in the light path to the secure output signal switching devices (OSSDs)by a signal change. The machine or its control must safely analyze the signals (e.g., viaa safety controller or via safety relays) and stop the dangerous state.

Sender and receiver automatically synchronize themselves electrically. An electricalconnection between both components is, therefore, required.

Sender

Receiver

Figure 1: Sender and receiver

Protective field height

The protective field height indicates the range in which the test rod belonging to thesafety light curtain is detected. The size of the safety light curtain determines the pro‐tective field height. The design and construction of the mac4 safety light curtainextends the protective function of a device to the end of the housing without any blindzones.

Protective field width

The protective field width is the dimension of the light path between sender andreceiver. The maximum protective field width is limited by the scanning range.

PRODUCT DESCRIPTION 3


Resolution

The resolution describes the size of the smallest object detected by the safety light cur‐tain in the protective field. The resolution corresponds to the diameter of the test rodbelonging to the safety light curtain, which is reliably detected when in the protectivefield.

With the available resolution options of 17 mm and 30 mm, the safety light curtainallows detection of different sized objects and specific adaptation of the minimum dis‐tances to the hazardous point. More information about the minimum distance: see"Minimum distance from the hazardous point", page 17.

Information on protective field height, resolution and protective field range: see "Datasheet", page 51.

Scanning range

The scanning range limits the maximum protective field width, see "Technical data",page 51. The scanning range is reduced by using deflector mirrors.

3.2 Product characteristics

3.2.1 Modular design

The safety light curtain is modular. The base modules of the sender and receiver can beextended with extension modules to increase the protective field height. For intermedi‐ate sizes, an end module can be used instead of the last extension module, whichmeans that the system can be flexibly adapted to the requirements defined by theapplication.

An extension module or an end module is simply attached to a base module or to anextension module that has already been attached. If the base module only is used oran extension module is used as the last module, an end cap is attached. The tightnessrequired by the enclosure rating and the electrical connection of the modules are onlyestablished by putting them together – no additional cabling between the modules isrequired. The system is thus easily and quickly installed and put into operation.

3.2.2 Absence of blind zones

The design and construction of the safety light curtain extends the protective functionof a device to the end of the housing without any blind spots. The absence of blindzones reduces the space requirement when integrated in the machine.

3.2.3 Automatic calibration of the protective field width

When switched on, the safety light curtain automatically calibrates to the protectivefield width.

Automatic adjustment of the signal level to the distance between sender and receiverallows the safety light curtain to operate without fault in many cases, even when sev‐eral systems are operated in close proximity.

3.2.4 Status indicators

The sender and receiver LEDs indicate the operational status of the safety light curtain.

3 PRODUCT DESCRIPTION


Base module indicators

Figure 2: Module indicators

The base modules each have three LEDs that indicate the operational status:

No LED color Indicator Labeling

1 Red/green OSSD status indicator OSSD

2 White Communication COM

3 Red Fault indicator ERR

Table 1: Base module indicators

The white LED (COM) is only active when switching on, see "Switching on", page 42.For a complete overview of the fault indications: see "Fault indicators", page 48.



OSSDLED

COM LED(white)

ERR LED(red)

Status indicator Meaning

(red) Automatic calibration ofthe protective field rangewhen switching on

The COM LED goes out after afew seconds, the OSSD LEDswitches to green and the safetylight curtain is ready for opera‐tion. If the COM LED does not goout after a few seconds, auto‐matic calibration of the protec‐tive field range cannot be com‐pleted. For troubleshooting, see"table 5: Fault indicators",page 48.

(green) No errors are found. The safety light curtain is readyfor operation.

Table 2: Status displays

3.3 Example applications

Figure 3: Hazardous point protection

3 PRODUCT DESCRIPTION


Figure 4: Access protection



4 Project planning

This chapter includes important information about the proper integration of the safetylight curtain in machines for planners, developers and designers.

4.1 Manufacturer of the machine

DANGERHazard due to lack of effectiveness of the protective devicePersons and parts of the body to be protected may not be recognized in case of non-observance.

b Use of the safety light curtain requires a risk assessment. Check whether addi‐tional protective measures are required.

b Observe the relevant national standards and guidelines, as well as relevantmachine-specific standards and guidelines. Also comply with the applicablenational regulations derived from the application (e.g., work safety regulations,safety rules, or other relevant safety guidelines).

b Do not combine the components of the safety light curtain with components fromother safety light curtains.

b Apart from for the procedures described in this document, the components of thesafety light curtain must not be opened.

b The components of the safety light curtain must not be tampered with or changed.b Improper repair of the protective device can lead to a loss of the protective func‐

tion. Do not carry out any repairs on the device components.

4.2 Operator of the machine


b Changes to the electrical integration of the safety light curtain in the machine con‐trol and changes to the mechanical installation of the safety light curtain requireanother risk assessment. The results of this risk assessment may require the oper‐ator of the machine to meet the obligations of a manufacturer.

b Apart from the procedures described in this document, the components of thesafety light curtain must not be opened.

b The components of the safety light curtain must not be tampered with or changed.b Improper repair of the protective device can lead to a loss of the protective func‐

tion. Do not carry out any repairs on the device components.

4.3 Assembly

This chapter contains important information about the design.

Information on the individual steps for mounting the device: see "Mounting", page 30.

4 PROJECT PLANNING



b Make sure that the following design requirements are met such that the safetylight curtain can fulfill its protective function.

° Sender and receiver must be arranged such that persons or parts of the bodyare reliably detected when they enter the hazardous area.

° Reaching under, over, and around as well as moving the safety light curtainmust be prevented.

° If people can stop between the protective device and the hazardous pointwithout being detected, check if additional protective measures (e.g., restartinterlock) are required.

4.3.1 Scanning range and protective field width

Scanning range

The scanning range limits the maximum protective field width, see "Technical data",page 51. The protective field width cannot change during operation.

The scanning range is reduced by using deflector mirrors.

Protective field width

The protective field width is the dimension of the light path between sender andreceiver.

The protective field width is automatically calibrated when the safety light curtain isswitched on during initialization and must not be changed during operation.


b The safety light curtain can only be mounted on machines on which the protectivefield width does not change when the safety light curtain is switched on.

4.3.2 Minimum distance from the hazardous point

A minimum distance must be maintained between the safety light curtain and the haz‐ardous point. This distance is required to prevent a person or part of the body fromreaching the hazardous area before the end of the dangerous state of the machine.


b Calculate the required minimum distance for your machine.b Mount the safety light curtain taking this calculation into account.

Position of the protective field in relation to the housing

The optical axis (position of the protective field) is not in the center of the housing,rather offset by 7 mm to the housing edge.

PROJECT PLANNING 4


Figure 5: Position of the protective field in relation to the housing

figure 5 shows a standard mounting situation. As viewed by the operator, the sender ison the right and the receiver on the left with the direction of the cable outlet pointingdownwards. In this mounting situation, the optical axis is on the operator side. The dis‐tances to the hazardous point is increased. The fulfillment by design of the requiredminimum distances is facilitated.

If a different mounting situation is selected, where the optical axis is located on theside of the hazardous point, the reduced distance to the hazardous point must betaken into account when maintaining the minimum distance.

Calculate minimum distance

The calculation of the minimum distance is based on international and national stand‐ards and statutory requirements applicable at the place of installation of the machine.

If the minimum distance is calculated according to ISO 13855, then it depends on thefollowing points:

• Machine stopping time (time interval between triggering the sensor function andthe end of the dangerous state of the machine)

• Response time of the protective device see "Response time", page 53• Reach or approach speed of the person• Resolution (detection capability) of the mac4 safety light curtain• Type of approach: orthogonal or parallel• Parameters specified based on the application

For the USA (scope of OSHA and ANSI), the following regulations apply among others:

a) Laws: Code of Federal Regulations, Title 29 (CFR29) Part 1910.217

b) Standards: ANSI B11.19

4 PROJECT PLANNING


NOTEAdditional information is available in the ISO 13855 standard and in the Guide for SafeMachinery.

NOTESICK offers a stopping/run-down time measurement service in many countries.

3

4

1

2

Figure 6: Minimum distance to hazardous point for orthogonal approach to protective field

1 Minimum distance S2 Protective field height3 Hazardous point4 Depending on the application and distance, persons must be prevented from standing

behind the protective device.

Calculation example of the minimum distance S according to ISO 13855

The example shows the calculation of the minimum distance for orthogonal approachto the protective field. Depending on the application and the ambient conditions (e.g., aprotective field parallel or at an arbitrary angle to the direction of approach or an indi‐rect approach), a different calculation may be required.

1. First, calculate S using the following formula:S = 2,000 mm/s × T + 8 × (d – 14 mm)Where:

° S = minimum distance in millimeters (mm)

° T = machine stopping time + response time of the protective device afterinterruption in the light path in seconds (s)

° d = resolution of the safety light curtain in millimeters (mm)The reach/approach speed is already included in the formula.

2. If the result S is ≤ 500 mm, then use the determined value as the minimum dis‐tance.

PROJECT PLANNING 4


3. If the result S is > 500 mm, then recalculate S as follows:S = 1,600 mm/s × T + 8 × (d – 14 mm)

4. If the new value S is > 500 mm, then use the newly determined value as the mini‐mum distance.

5. If the new value S is ≤ 500 mm, then use 500 mm.

Example calculation

Machine stopping time = 290 ms

Response time after interruption of the light path = 30 ms

Resolution of the safety light curtain = 30 mm

T = 290 ms + 30 ms = 320 ms = 0.32 s

S = 2000 × 0.32 + 8 × (30 – 14) = 768 mm

S > 500 mm, therefore:

S = 1600 × 0.32 + 8 × (30 – 14) = 640 mm

Taking reaching over into account

If access to the hazardous area cannot be ruled out by reaching over a vertical protec‐tive field, the height of the protective field and minimum distance of the electro-sensi‐tive protective device must be determined. This is done by comparing the calculatedvalues based on the possible detection of limbs or body parts with the values resultingfrom reaching over the protective field. The greater value resulting from this comparisonmust be used.

Figure 7: Representation of the accessibility of electro-sensitive protective device by reachingover. Left: Protective field that cannot be reached over. Right: Protective field that can bereached over.

4.3.3 Minimum distance to reflective surfaces

DANGERHazard due to lack of effectiveness of the protective deviceReflective surfaces and dispersive media can prevent persons or parts of the body tobe protected from being properly reflected and, therefore, remain undetected.

b Make sure that all reflective surfaces and objects maintain a minimum distancefrom the protective field.

b Make sure that no dispersive media (e.g., dust, fog, or smoke) are within the calcu‐lated minimum distance from the protective field.

The light beams from the sender may be deflected by reflective surfaces and dispersivemedia. This may prevent an object from being detected.

4 PROJECT PLANNING


All reflective surfaces and objects (e.g., material bins, machine table, etc.) must there‐fore maintain a minimum distance (a) from the protective field. This minimum distance(a) must be maintained on all sides of the protective field. This applies in horizontal,vertical, and diagonal directions, as well as at the end of the safety light curtain. Thesame area must be free from dispersive media (e.g., dust, fog, or smoke).

The minimum distance (a) depends on the distance (D) between sender and receiver(protective field width).

a

D

Figure 8: Minimum distance to reflective surfaces

How to determine the minimum distance from reflective surfaces:

b Determine the distance between sender and receiver D in meters (m).b Read the minimum distance a in millimeters (mm) in the graph or calculate it

based on the respective formula from table 3:

a/mm

D/m

Figure 9: Graph, minimum distance from reflective surfaces

Distance between sender andreceiver D in m

Calculating the minimum distance for reflective surfa‐ces a in mm

D ≤ 3 m a = 131 mm

D > 3 m a = tan (2.5°) × 1,000 mm/m × D = 43.66 × 1 mm/m ×D

Table 3: Formula for calculating the minimum distance from reflective surfaces

4.3.4 Protection against interference from systems in close proximity to each other

DANGERHazard due to lack of effectiveness of the protective deviceSystems of safety light curtains that operate in close proximity to each other can inter‐fere with each other.

b Use appropriate measures to prevent systems in close proximity from interferingwith each other.

PROJECT PLANNING 4


1

2

Figure 10: Preventing mutual interference from system 1 and system 2

The infrared light beams of the sender of system 1 can interfere with the receiver ofsystem 2. This can disrupt the protective function of system 2. This would mean thatthe operator is at risk.

The mac4 safety light curtain has automatic signal level adjustment that allows fault-free operation of adjacent systems in many cases.

If fault-free operation is still not possible, take appropriate action, e.g., mount opticallyopaque partitions or reverse the direction of transmission of a system.

1

2

Figure 11: Trouble-free operation due to reversed direction of transmission of system 1 and sys‐tem 2

In the figure, the direction of transmission of systems in close proximity to each other isreversed. System 2 is not affected by the beams of system 1.

4.3.5 Mounting surface requirements

In the case of direct mounting, the modules are not aligned after mounting.

In the case of direct mounting, the mounting surfaces must be sufficiently flat and par‐allel so that the sender and receiver are in alignment with each other after mountingwithout any further adjustment. The angular displacement should not exceed 1°, seefigure 12.

4 PROJECT PLANNING


A II B

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Figure 12: Maximum offset between sender and receiver.

The alignment bracket makes it possible to rotate the sender and receiver around theaxis of the device and to align them precisely with each other, see "Mount optionalalignment bracket", page 34.

4.3.6 Fixing hole requirements

In the case of direct mounting, the fixing holes must meet the following requirements.

The module housings are designed so that senders and receivers can be mounted tothe side or back of the mounting surface. The distances between the fixing holes mustmaintain the specified tolerances, see figure 13. Elongated holes in the longitudinaldirection can simplify installation of the modules.

Profile rails can also be used to simplify mounting. Instead of fixing holes, sliding nutscan be used that can be moved in a longitudinal direction when mounting.

PROJECT PLANNING 4


Dimensions in mm

Figure 13: Distance of the fixing holes for rear or side mounting

The fixing holes for sender and receiver must be placed so that a vertical and horizontaloffset is avoided, see figure 14.

horizontal

vertical

Figure 14: Avoid offset between sender and receiver

This requirement for mounting position or mounting levels must also be observed forside mounting, see figure 15.

4 PROJECT PLANNING


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Figure 15: Avoid offset for side mounting

After mounting, the entire length of the modules must rest on the mounting surface. Itis recommended that two screws are used for mounting each base and extension mod‐ule, and that each end module is secured with one screw.

4.4 Integration in the electrical control

This chapter contains important information about integration in the electrical control.Information about the individual steps for electrical installation of the device: see "Elec‐trical installation", page 37.

Requirements for use

The output signals of the protective device must be evaluated by downstream control‐lers such that the dangerous state of the machine can be reliably brought to an end.Depending on the safety concept, the signals are evaluated either with a safety relay ora safety controller, for example.


b Make sure that the following control and electrical requirements are met such thatthe safety light curtain can fulfill its protective function.

• The control of the machine must allow electrical interference.• The electrical control of the machine must meet the requirements of IEC 60204-1.• A restart interlock must be implemented depending on applicable national regula‐

tions or required reliability of the safety function. Because the safety light curtaindoes not have this function, it must be implemented in the external control ifrequired.

• When using a safety controller, different signal levels of both OSSDs must bedetected depending on applicable national regulations or required reliability of thesafety function. The maximum time discrepancy time tolerated by the controllermust be selected according to the application.

• The OSSD1 and OSSD2 output signals must not be connected to each other.• In the machine controller, the signals of both OSSDs must be processed sepa‐

rately.

PROJECT PLANNING 4


F-In 1 F-In 2 F-In 1 F-In 2

Figure 16: Dual-channel and isolated connection of OSSD1 and OSSD2

• The machine must switch to the safe state at any time if at least one of the twoOSSDs switches to the OFF state.

• Prevent the formation of a potential difference between the load and the protec‐tive device. If you connect loads to the OSSDs (safety outputs) that then alsoswitch if controlled with negative voltage, you must connect the 0 V connections ofthese loads and those of the corresponding protective device individually anddirectly to the same 0 V terminal strip. In the event of a fault, this is the only way toensure that there can be no potential difference between the 0 V connections ofthe loads and those of the corresponding protective device.

R R R R R R R R

Figure 17: No potential difference between load and protective device

• For compatibility with safety controllers or relays, note the requirements for loadcapacity and inductance, see "Data sheet", page 51 For example, the FlexiSoftFX3-XTDI80002 and FlexiSoft FX3-XTIO84002 safety controllers andUE48-2OS2D2, UE48-2OS3D2, UE48-3OS2D2, and UE48-3OS3D2 safety relayseach with a connecting cable up to 10 m in length are suitable.

4 PROJECT PLANNING


DANGERHazard due to lack of effectiveness of the protective deviceIn the case of non-compliance, it is possible that the dangerous state of the machinemay not be stopped or not stopped in a timely manner.Downstream contactors must be positively guided and monitored depending on appli‐cable national regulations or required reliability of the safety function.

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

b Because the safety light curtain does not have external device monitoring, it mustbe implemented in the external control if required.

Requirements for the electrical control of the machine

The two outputs are short-circuit protected against 24 V DC and 0 V. When the protec‐tive field is clear, the OSSDs are in the on state and the signal level is HIGH (non-iso‐lated). In the event of an interruption to the light path or a device error, the OSSDs arein the off state, the signal level is LOW (over 2 kΩ against 0 V).

The safety light curtain complies with the rules for electromagnetic compatibility (EMC)for the industrial sector (Radio Safety Class A). Radio interference cannot be ruled outwhen used in residential areas.


b Make sure that the following control and electrical requirements are met such thatthe safety light curtain can fulfill its protective function.

• The external voltage supply of the safety light curtain must be capable of bufferingbrief power failures of 20 ms as specified in IEC 60204-1.

• The power supply unit must ensure safe isolation according to IEC 61140(SELV/PELV). Suitable power supply units are available as accessories from SICK,see "Accessories", page 57.

4.4.1 Restart interlock

A restart interlock must be implemented depending on applicable national regulationsor required reliability of the safety function.

The restart interlock prevents the machine from automatically starting up, for exampleafter a protective device has responded while the machine is operating or after chang‐ing the machine’s operating mode.

Before the machine can be restarted, the operator must reset the restart interlock.

PROJECT PLANNING 4


Figure 18: Schematic representation of operation with restart interlock

The dangerous state of the machine 1 is brought to an end if the light path is inter‐rupted 2 and is not re-enabled 3 until the operator presses the reset pushbuttonlocated outside the hazardous area 4. The machine can then be restarted.

Depending on the applicable national regulations, there must be a restart interlock if aperson can stand behind the protective field. Observe IEC 60204-1.

The safety light curtain does not have an internal restart interlock. If required, a restartinterlock must therefore be implemented externally via the circuitry or the control, e.g.,in connection with the SICK switching amplifier UE48-2OS/UE48-3OS.

4.4.2 External device monitoring (EDM)

Verification of the external switching elements (external device monitoring, EDM) mustbe implemented depending on applicable national regulations or required reliability ofthe safety function.

The external device monitoring (EDM) monitors the status of downstream contactors.

In order to use the external device monitoring, positively guided contactors must beused to switch off the machine. If the auxiliary contacts of the positively guided contac‐tors are connected to the external device monitoring, the external device monitoringchecks whether the contactors drop off when the OSSDs are switched off.

NOTEBecause the safety light curtain does not have integrated external device monitoring,this must be implemented in the external control, if required.

4 PROJECT PLANNING


4.4.3 Connection diagrams

Connection diagram for UE48-2OS with restart interlock and external device monitor‐ing

24 VDC

0 VDV

UE48-2OS2D2S34 S21S35 S22

S33 S12S11 S31

14A2 24 32

13A1 23 31

K1

K1

K2

S1

OSSD1

OSSD2

0 V DC

24 V DC 1

2

3

4

5

K2

Figure 19: Connection diagram for UE48-2OS with restart interlock and external device monitor‐ing

The mac4 safety light curtain can be connected to the UE48-2OS switching amplifiers.It is operated with restart interlock and external device monitoring.

Functionality

When the protective field is clear, the OSSD1 and OSSD2 outputs carry voltage. Thesystem can be switched on when K1 and K2 are in the de-energized position. Pressingthe S1 button switches on the UE48 switching amplifier. Contacts 13-14 and 23-24 ofthe UE48 activate the K1 and K2 contactors.

When the protective field is interrupted, the OSSD1 and OSSD2 outputs carry no volt‐age. The UE48 switches off and K1, K2 are deactivated.

Fault analysis

Failure of K1 and K2 does not cause the loss of the shut-down function. Cross-circuitsand short-circuits of the OSSD1 and OSSD2 outputs are recognized and lead to thelocking state. It is recognized if the K1 or K2 contactors do not de-energize.

PROJECT PLANNING 4


5 Mounting

This chapter describes the mounting of the safety light curtain.

The following steps are necessary after mounting and installation:

– "Electrical installation", page 37– "Commissioning", page 40

NOTEMount the safety light curtain in the following order.

5.1 Safety

For information on the requirements for properly mounting the safety light curtain, see"Assembly", page 16.

DANGERDangerous state of the machine

b Make sure that the dangerous state of the machine is (and remains) switched offduring mounting, electrical installation, and commissioning.

b Make sure that the outputs of the safety light curtain have no effect on themachine during mounting, electrical installation, and commissioning.


b Take appropriate measures for vibration dampening if the vibration and shockrequirements are above the values and test conditions specified in the data sheet,see "Technical data", page 51.


b Do not carry out any repairs to the device components.b Do not make any changes to or tamper with the device components.b With the exception of the procedures described in this document, the device com‐

ponents must not be opened.

NOTICERisk of damage to the systemThe modules achieve the tightness required by the enclosure rating only by connectingthem or by putting on the end cap. Dust or other contamination in the housing candamage the modules.

b Make sure that open modules are not contaminated by dust or similar.b If necessary, first connect the modules in a clean environment and put an end cap

or an end module on before bringing the system to the installation site.b Do not use compressed air to clean open modules.

5 MOUNTING


NOTICERisk of damage to the systemThe modules have exposed electrical contact surfaces in the area of the interfaces.Electrostatic discharge can damage the contact surfaces of the modules. ESD protec‐tion exists only after connecting or putting on the end cap.

b Make sure that modules are not touched in the area of the electrical contact sur‐faces.

5.2 Unpacking

b Check the components for completeness and the integrity of all parts, see "Scopeof delivery", page 55.

b Sender modules are labeled on the packaging with "Sender" and receiver moduleswith "Receiver". Base modules are labeled with "Base", extension modules with"Extension". The resolution is specified as "17 mm" or "30 mm".

b Please contact your respective SICK subsidiary should you have any complaints.

5.3 Combine modules

Connect modules

DANGERHazard due to lack of effectiveness of the protective devicePersons and parts of the body to be protected may not be recognized in case of non-observance.If the modules are connected improperly, detection gaps occur at the transition pointsthat exceed the specified detection capability (resolution).

b Follow the instructions in this chapter exactly when combining modules.

1. Make sure that you only connect sender or receiver modules. The modules arelabeled on the front with 'Sender" or "Receiver".

2. Make sure that you only connect modules of the same resolution. The resolution isspecified on the front of the modules.

3. Push the modules together until the interlock audibly (click) engages. Note the per‐mitted number of extension modules, see "Technical data", page 51.

4. Skip this step if you have used an end module as the last module:When the required protective field height is achieved, put the end cap includedwith the base module on the last module.

Figure 20: Connect modules

MOUNTING 5


Release modules

NOTICEThe modules may only be released up to a maximum of 5 times per interface.

b Only release modules in important service cases.

1. Disassemble the complete sender or receiver unit (base and additional modules)from the machine.

2. Put the sender or receiver unit on a clean flat surface.3. Put the unlocking tool with the pin down into the recess of the snap connection.4. Press down on the tool until it is flush with the bottom of the unit.5. Hold down and turn the tool approx. 1/4 turn in any direction. The snap connec‐

tion is released.6. Pull both released modules apart.7. The end cap is removed from the module in the same manner.

1.

2.

3.

3.

Figure 21: Releasing modules

5.4 Installation

The sender and receiver are mounted either directly or using the optional alignmentbracket. The alignment bracket makes it possible to rotate the sender and receiveraround the axis of the device and to align them precisely with each other.

DANGERHazard due to lack of effectiveness of the protective devicePersons or parts of the body to be protected may not be recognized or not recognized intime in case of non-observance.

b It is vital that you observe the minimum distances calculated for your machine:see "Minimum distance from the hazardous point", page 17 and see "Minimumdistance to reflective surfaces", page 20.

b Mount the safety light curtain such that the hazardous point cannot be reachedfrom below, above, or behind the safety light curtain and that the light curtain can‐not be repositioned.

5 MOUNTING



b The safety light curtain can only be mounted on machines on which the protectivefield width does not change when the safety light curtain is switched on.

NOTE

b Read this section completely before installing the modules.

Mounting instructions

b Assemble the modules in a clean environment, see "Combine modules", page 31.b The end with the cable connection must point in the same direction for the sender

and receiver.

Figure 22: Sender and receiver must not be installed at 180° rotated relative to each other.

b Mount the sender and receiver with the prepared mounting hardware. Tighten thescrews to a torque of 1.3 Nm ± 0.2 Nm. Higher torques can damage the modulehousing while lower torques do not provide adequate fixation to prevent the safetylight curtain from moving in the event of vibrations. It is recommended that twoscrews per module be used to secure the mounting.

b When mounting, make sure that sender and receiver are aligned correctly. Theoptical lens systems of sender and receiver must be located opposite one another.

b Check the parallelism of the components using a water level or a straight edge, forexample.

5.4.1 Direct mounting

No special brackets are required to mount the sender and receiver. The modules canbe mounted directly on the machine frame. The modules can also be mounted on adevice column or profile frame.

The module housings are designed so that senders and receivers can be mounted withthe side or back to the mounting surface.

MOUNTING 5


Mounting the safety light curtain directly

Choose mounting hardware such as screws and sliding nuts or nuts based on theoptions specific to the machine. The following table provides an overview of some screwtypes, whose shaft and head diameter fit the fixing holes of the device housing. Therecesses for the screw heads in the housing have a depth of 5 mm. When choosingscrews, make sure that they do not exceed this depth.

Screw type Standard Thread diame‐ter

Screw head diame‐ter

Cheese head cap screw with hexa‐gon socket

DIN EN ISO 4762 M4 6.8 mm ... 7 mm

Cheese head cap screw with hexa‐gon socket with low profile head

DIN 7984 M4 6.8 mm ... 7 mm

Cheese head cap screw with hexa‐gon socket, low head, with keyguide

DIN 6912 M4 6.8 mm ... 7 mm

Cheese head cap screw with hexa‐gon socket ("Torx"), low profilehead

DIN EN ISO 14580 M4 6.8 mm ... 7 mm

Slotted cheese head screws DIN EN ISO 1207 M4 6.8 mm ... 7 mm

Hexagon screws with thread tohead

DIN EN ISO 4017 M4 7 mm(width across flats)

Hexagon screws with shafts DIN EN ISO 4014 M4 7 mm(width across flats)

b Make sure that the requirements for mounting surfaces are observed, see "Mount‐ing surface requirements", page 22.

CAUTIONRisk of injury from protruding screws threadWhen mounting through the machine or profile frame, the screws can present an injuryrisk if too long.

b Select the appropriate screw lengths to prevent any risk of injury from an over‐hang.

5.4.2 Mount optional alignment bracket

The alignment bracket makes it possible to rotate the sender and receiver around theaxis of the device and to align them precisely with each other.

5 MOUNTING


Figure 23: Mount optional alignment bracket

1. Screw assembled modules to the profile rails with the screws and nuts provided.Tightening torque: 1.3 Nm ± 0.2 Nm.

2. Screw a swivel block to each of the upper and lower ends of the profile rails usingthe countersunk screws provided. Tightening torque: 1.2 Nm ± 0.2 Nm.

3. Mount the lower swivel mount bracket on the mounting surface.4. Place the safety light curtain with the lower swivel mount block in the lower swivel

mount bracket.5. Push the upper swivel mount bracket onto the upper swivel mount block.6. Mount the upper swivel mount bracket on the mounting surface.7. Align devices, see "Align the sender and receiver", page 41.8. Fix devices to the swivel mount brackets with clamping connections.

MOUNTING 5


5.5 Attach information label

b Affix “Important Information” label to the machine in close proximity to sender andreceiver. The information label is self-adhesive. Please note the following:

° Use the “Important Information” label in the language of the operator of themachine. Use several information labels if additional languages are requiredfor other operators.

° Affix the information label such that it is easily visible by each operator duringoperation of the machine. After attaching additional objects and equipment,the information label must not be concealed from view.

5 MOUNTING


6 Electrical installation

6.1 Safety

Information on the requirements that must be met for safe integration of the safetylight curtain in the control and electronics of the machine: see "Integration in the elec‐trical control", page 25.

Mounting should be completed before electrical installation.

DANGERHazard due to electrical voltageHazard due to unexpected starting of the machine

b Make sure that the machine is (and remains) disconnected from the power supplyduring the electrical installation.

b Make sure that the dangerous state of the machine is (and remains) switched offduring electrical installation.

b Make sure that the outputs of the safety light curtain have no effect on themachine during electrical installation.

b Only use an appropriate power supply, see "Technical data", page 51.

DANGERHazard due to lack of effectiveness of the protective deviceThe dangerous state may not be stopped in the event of non-compliance.

b Always connect the two OSSDs separately. The two OSSDs must not be connectedto each other.

b Connect the OSSDs such that the machine controller processes both signals sepa‐rately.

F-In 1 F-In 2 F-In 1 F-In 2

Figure 24: Dual-channel and isolated connection of OSSD1 and OSSD2

ELECTRICAL INSTALLATION 6


DANGERHazard due to lack of effectiveness of the protective deviceThe dangerous state may not be stopped in the event of non-compliance.

b Prevent the formation of a potential difference between the load and the protec‐tive device.

• If you connect loads to the OSSDs (safety outputs) that then also switch if control‐led with negative voltage, you must connect the 0 V connections of these loadsand those of the corresponding protective device individually and directly to thesame 0 V terminal strip. In the event of a fault, this is the only way to ensure thatthere can be no potential difference between the 0 V connections of the loads andthose of the corresponding protective device.

R R R R R R R R

Figure 25: No potential difference between load and protective device

• For compatibility with safety controllers or relays, note the requirements for loadcapacity and inductance, see "Data sheet", page 51 For example, the FlexiSoftFX3-XTDI80002 and FlexiSoft FX3-XTIO84002 safety controllers andUE48-2OS2D2, UE48-2OS3D2, UE48-3OS2D2, and UE48-3OS3D2 safety relayseach with a connecting cable up to 10 m in length are suitable.

6.2 System connection (M12, 4-pin)

12

3 4

Figure 26: System connection pin assignment (male connector)

Pin Wire color Receiver

1 Brown 24 V DC input (power supply)

2 White OSSD1 (output signal switching device 1)

3 Blue 0 V DC input (power supply)

4 Black OSSD2 (output signal switching device 2)

Table 4: mac4 system connection pin assignment (M12, 4-pin)

Connection diagrams for the electrical installation: see "Integration in the electrical con‐trol", page 25.

6 ELECTRICAL INSTALLATION


6.3 Connect the sender and receiver

Sender and receiver automatically synchronize themselves electrically. An electricalconnection between both components is, therefore, required. Therefore, for the mac4safety light curtain, only the receiver should be connected to the control.

Overview of the cables available from SICK: see "Accessories", page 57.

Figure 27: Connect the sender and receiver

b Connect the sender and receiver. Connect the 5-pin connection cable 1 betweenboth ends of the cable to the yellow plug inserts.

b Connect the receiver to the electrical control. Connect the 4-pin connecting cable2 between the end of the cable to the black plug insert and control.

ELECTRICAL INSTALLATION 6


7 Commissioning

The mounting and electrical installation must be completed before commissioning asdescribed in the following chapters:

• "Assembly", page 16• "Integration in the electrical control", page 25• "Mounting", page 30• "Electrical installation", page 37

7.1 Safety

DANGERHazard due to lack of effectiveness of the protective deviceWhen changes are made to the machine, the effectiveness of the protective device maybe affected unintentionally.

b After every change to the machine and changes to the integration or operationaland secondary conditions of the safety light curtain, check the protective devicefor effectiveness and recommission as specified in this chapter.


b Make sure that the dangerous state of the machine is (and remains) switched offduring mounting, electrical installation, and commissioning.

b Make sure that the outputs of the safety light curtain have no effect on themachine during mounting, electrical installation, and commissioning.

DANGERHazard due to lack of effectiveness of the protective device

b Before operating the protected machine for the first time, make sure that themachine is first checked and released by qualified safety personnel.

b Only operate the machine when the protective device is functioning properly.


b Make sure that the optical properties of the front screens of the sender andreceiver are not changed, e.g., by:

° beading water, mist, frost, or ice formation. If necessary, remove any residuesof this type or any other form of contamination and restart the receiver.

° Scratches or damage. If necessary, replace the respective sender or receiverif its front screen is scratched or damaged.

b Make sure that all reflective surfaces and objects maintain a minimum distancefrom the protective field, see "Minimum distance to reflective surfaces", page 20.


7 COMMISSIONING


7.2 Align the sender and receiver

If you use the alignment bracket, you must align the sender and receiver with eachother after mounting and electrical installation.

In the case of direct mounting, the modules are not aligned after mounting.


b Make sure that the dangerous state of the machine is (and remains) switched offduring the alignment process.

b Make sure that the outputs of the safety light curtain have no effect on themachine during the alignment process.

The alignment bracket makes it possible to rotate the sender and receiver around theaxis of the device, and tilt and shift vertically, in order to align the devices precisely.

You can align the sender and receiver to each other either before or after switching onthe safety light curtain. We recommend aligning the devices before switching on, asseveral set-up procedures run directly after switching on (see "Switching on",page 42).

Figure 28: Align the sender and receiver

Align before switching on

Check the alignment of sender and receiver before switching on using one of the follow‐ing procedures:

b Use the laser alignment aid AR60 with the appropriate adapter.b Use a folding ruler or a tape measure and a water level.

Then switch the safety light curtain on, see "Switching on", page 42.

Align after switching on

If alignment is not possible before switching on, we recommend the following proce‐dure:

1. Loosen the clamping connections that fix the safety light curtain in place.2. Align sender and receiver in relation to each other by eye.3. Turn the receiver clockwise at least 10° away from the sender.4. Switch on the safety light curtain. The white COM LED flashes.5. Turn the receiver slowly in the direction of the sender.

COMMISSIONING 7


6. As soon as the white COM LED lights up continuously, maintain the position andmark the position of the receiver.

7. Switch off the safety light curtain.8. Repeat steps 3 to 7. First, turn the receiver 10° anti-clockwise. In step 6, re-mark

the position of the receiver at which the COM LED stops flashing and lights up con‐tinuously.

9. Turn the receiver to the mid-point between the two marks.10. Repeat steps 1 to 9 with the sender. Finally, turn the sender to the mid-point

between the two marks.11. Switch off the safety light curtain at the end of the alignment process.12. Re-tighten the clamping connections.13. Then switch the safety light curtain on, see "Switching on", page 42.

7.3 Switching on

When powering up, several automatic adjustment procedures run within a few secondsto establish the operational readiness of the safety light curtain. After switching on, syn‐chronization begins indicated by the flashing COM LED. After synchronization is com‐pleted successfully and signal strength is adequate (mounting surfaces or mechanicalalignment in allowable tolerance range), the COM LED lights up solid white. The dis‐tance (protective field range) is then calibrated and the signal level automaticallyadjusted for this status. When this process is completed successfully, the COM LEDgoes out. The OSSD LEDs from the sender and receiver switch to green, signaling theoperational readiness of the system.

If the OSSD LEDs do not switch to green, there is an error, see "Troubleshooting",page 48.

7.4 Checks

Check the protective device as described below and in accordance with the applicablestandards and regulations.

Checks before initial commissioning/commissioning

b The checks must be carried out by qualified safety personnel or specially qualifiedand authorized personnel, and must be recorded and documented to ensure thatthe tests can be reconstructed and retraced.

b Check the effectiveness of the protective device for all operating modes selectableon the machine according to the checklist in the appendix (see "Checklist for initialcommissioning and commissioning", page 61).

b Make sure that the operating personnel have been instructed in the function ofthe protective device before being allowed to operate the machine. The instructionis the responsibility of the machine operator and must be carried out by qualifiedpersonnel.

b Use the test rod to check the effectiveness of the protective device, see "Opera‐tion", page 43.

7 COMMISSIONING


8 Operation

8.1 Safety

DANGERRisk of ineffectiveness of the protective device after changesPersons and parts of the body to be protected may not be recognized in case of non-observance.

b Maintenance work, alignment work, fault diagnoses, and any changes to the inte‐gration of the safety light curtain in the machine must only be carried out by quali‐fied personnel.

b Then check the effectiveness of the protective device and recommission it, see"Commissioning", page 40.


b Make sure that the optical properties of the front screen of the sender andreceiver are not changed by beading water, mist, frost, or ice formation.


b Make sure that no dispersive media are found within the calculated minimum dis‐tance from the protective field.

b After initialization of the system, the sender and receiver can no longer be movedrelative to each other. Make sure that the system is reinitialized if the sender orreceiver moves or is moved.

NOTEThis document does not provide information on operating the machine in which thesafety light curtain is integrated.

8.2 Regular test rod testing

Checking the effectiveness with the test rod

The effectiveness of the protective device must be checked daily using the test rod pro‐vided. The diameter of the test rod corresponds to the resolution of the light curtain.

Before introducing the test rod, check if the OSSD LED illuminates green. If not, thenyou must first change this status. The check is otherwise meaningless.

NOTEThe OSSD LEDs of the sender and receiver display the same OSSD status. For the test‐ing steps described below, you must always pay attention to one of the two OSSD LEDs.

OPERATION 8



b Only use the included test rod with the diameter specified on the type label of thesafety light curtain.

b Do not use any test rods with a similar or the same diameter of other safety lightcurtains.

DANGERHazard due to unexpected starting of the machine

b Make sure that the dangerous state of the machine is (and remains) switched offduring the check.

b Make sure that the outputs of the safety light curtain have no effect on themachine while checking the components.

1. Move the test rod slowly through the protective field to be protected (e.g., machineopening) as indicated by the arrow, see figure 29.

2. Watch the OSSD LED on the sender or receiver during the check. The OSSD LEDshould continuously light up red. The OSSD LED must not light up green.

Figure 29: Test rod check: Step 1

3. Then, guide the test rod along the edges of the area to be protected as indicatedby the arrow, see figure 30.


8 OPERATION


Figure 30: Test rod check: Step 2

5. If you use one or more deflector mirrors, then also guide the test rod slowlythrough the area to be protected directly in front of the deflector mirrors.


DANGERHazard due to lack of effectiveness of the protective devicePersons and parts of the body to be protected may not be recognized in case of non-observance.Do not operate the machine if the OSSD LED lights up green during the test!

b If the OSSD LED lights up green during the test even if only briefly, work must stopat the machine.

b In this case, the mounting and electrical installation of the safety light curtainmust be checked by qualified safety personnel.

OPERATION 8


9 Maintenance

The safety light curtain is maintenance-free. Depending on the ambient conditions, reg‐ular cleaning is required.

9.1 Safety




9.2 Regular cleaning


b Regularly check the degree of contamination on all components based on theapplication conditions.

b Observe note on regular test rod test, see "Operation", page 43.

Depending on the ambient conditions of the safety light curtain, the front screens mustbe cleaned regularly and in the event of contamination. Static charges can cause dustparticles to be attracted to the front screen. The deflector mirrors must be cleaned reg‐ularly and in the event of contamination.


b Make sure that the optical properties of the front screens of the sender andreceiver are not changed, e.g., by:

° beading water, mist, frost, or ice formation. If necessary, remove any residuesof this type or any other form of contamination and restart the receiver.

° Scratches or damage. If necessary, replace the respective sender or receiverif its front screen is scratched or damaged.



9 MAINTENANCE



b Make sure that the dangerous state of the machine is (and remains) switched offwhile cleaning.

b Make sure that the outputs of the safety light curtain have no effect on themachine during cleaning.

NOTICE

b Do not use aggressive cleaning agents.b Do not use abrasive cleaning agents.b We recommend anti-static cleaning agents.b We recommend the use of anti-static plastic cleaner (SICK part number 5600006)

and the SICK lens cloth (SICK part number 4003353).

Clean the front screen

1. Use a clean, soft brush to remove dust from the front screen.2. Then wipe the front screen with a clean, damp cloth.3. Check the position of the sender and receiver after cleaning.4. Check the effectiveness of the protective device. Information on the procedure for

thorough checking, see "Operation", page 43.

9.3 Regular thorough check


b The checks must be carried out by qualified safety personnel or specially qualifiedand authorized personnel and must be recorded and documented to ensure thatthe tests can be reconstructed and retraced at any time.

b Check the machine following the inspection intervals specified in the nationalrules and regulations. This procedure ensures that any changes to the machine ormanipulations of the protective device are detected after initial commissioning.

b Check the machine again in the following cases according to the checklist in theappendix, see "Checklist for initial commissioning and commissioning", page 61:

° If changes are made to the machine or to protective devices (e. g., changes tothe mechanical, electrical, or optical connection).

° If sender or receiver or individual modules have been replaced.

Safety signs, information labels

b Regularly check the information labels for the following points:

° Presence

° Readabilityb Replace the information labels if missing, damaged, or illegible.

b Please observe the notes on the information labels, see "Attach information label",page 36.

MAINTENANCE 9


10 Troubleshooting

This chapter describes how you identify and remedy faults that interrupt the function ofthe safety light curtain.

10.1 Safety


b Immediately put the machine out of operation if the behavior of the machine can‐not be clearly identified.

b Immediately put the machine out of operation if you cannot clearly identify or allo‐cate the fault, or if you cannot safely remedy the fault.

b Secure the machine such that it cannot be switched on unintentionally.


b When any work is taking place, use the protective device to secure the machine orto ensure that the machine is not switched on unintentionally.




NOTEIf you cannot remedy the fault with the help of the information provided in this chapter,please contact your respective SICK subsidiary.

10.2 Fault indicators

By electrical synchronization between sender and receiver, the same LED information isdisplayed on each device. Only in case of fault is different information displayedbetween sender and receiver. Therefore, the ERR LED flashing on the device concernedcan be used to quickly analyze the cause of the fault.

OSSDLED (red)

COMLED(white)

ERR LED(red)

Status or possible causeof the fault

Rectification

No operating voltage b Check the power supply, see"Technical data", page 51.

Table 5: Fault indicators

10 TROUBLESHOOTING


OSSDLED (red)

COMLED(white)

ERR LED(red)

Status or possible causeof the fault

Rectification

Tolerance requirementsfor the mounting surfa‐ces not complied with,optical synchronizationcannot be set up.

b Check the parallelism andflatness of the mounting sur‐faces, as well as the positionof the mounting points forpossible offset.

b Switch the power supply offand then on again.

Automatic calibration ofthe protective field rangewhen switching on.If the COM LED does notgo out after a few sec‐onds, automatic calibra‐tion of the protective fieldrange cannot be com‐pleted. It is possible thatthe sender or receiverwere moved when theprotective field range wasautomatically calibrated.

With adequate tolerance of themounting surfaces and mountingpoints, the COM LED goes out aftera few seconds. The OSSD LEDswitches to green and the safetylight curtain is ready for operation.

b Check the parallelism of themounting surfaces, as well asthe position of the mountingpoints for possible offset.


/ Operating voltage too lowor too high or ...

b Check the power supply, see"Technical data", page 51.


A fault or unexpectedstate was identified onthe OSSDs of the systemconnection (e.g., overvolt‐age, short-circuit to HIGHor short-circuit to LOW,cross-circuit) or ...

b Check the system wiring for afault. Make sure that theOSSDs have been wired cor‐rectly, see "Integration in theelectrical control", page 25.


Error in the module con‐nection was detectedor ...

b Check that sender andreceiver modules are notmixed.

b Check that the end cap andall module connections arelocked in place correctly.

An internal fault hasbeen detected.


b If the fault persists, replacethe defective device, see"Ordering information",page 55.

Table 5: Fault indicators

NOTEb If a fault cannot be resolved with the above measures, send the devices to the fac‐

tory for analysis.

TROUBLESHOOTING 10


11 Decommissioning

11.1 Protection of the environment

The safety light curtain has been designed to minimize its impact on the environment. Ituses only minimum of power and natural resources.

b At work, always act in an environmentally responsible manner. For this reason,please note the following information on disposal.

11.2 Disposal

Always dispose of serviceableness devices in compliance with local/national rules andregulations with respect to waste disposal.

NOTEWe would be pleased to be of assistance on the disposal of this device. Contact us.

11 DECOMMISSIONING


12 Technical data

12.1 Data sheet

General system data

Minimum Typical Maximum

Protective field height (rounded) 210 mm to 1050 mm in 105 mm increments

Max. allowed modules 1 base module, 4 extension modules and end capOR1 base module, 3 extension modules and 1 end module

Resolution (detection capability),depending on the type

17 mm or 30 mm

Protective field range 1) 0.4 m ... 3.2 m

Protection class (EN 50178) 2) III

Enclosure rating (EN 60529) IP 65

Supply voltage Uv

on the device 3) 4)

21 V 24 V 27 V

Residual ripple 5) ±10%

Power consumption 6) 2 W 4.8 W

Synchronization Electrical

Type (EN 61496-1) Type 4

Category (EN ISO 13849-1) Category 4

Performance level 7)

(EN ISO 13849-1)PL e

Safety integrity level 7) SIL3 (IEC 61508)

SIL claim limit 7) SILCL3 (EN 62061)

PFHd (mean probability of a danger‐ous failure per hour)

< 1 × 10-8

TM (mission time) 20 years (EN ISO 13849-1)

Safe state when a fault occurs At least one OSSD is in the off state.

Power-up delay of sender andreceiver after applying supply voltage

3 s

Connection M12, 4-pin

Length of connecting cable and con‐nection cable:

Wire cross-section > 0.25 mm²(AWG 24), copper cable

10 m ea.

Permissible conductor resistance

Connecting cable 8) 9) (M12, 4-pin) 1.1 Ω

Connection cable (M12, 5-pin) 1.1 Ω

Table 6: General system data

1) The protective field range is automatically calibrated with switching on the safety light curtain during initi‐alization and must not be changed during operation.

2) Safety extra-low voltage SELV/PELV3) The external power supply must be capable of buffering brief power failures of 20 ms as specified in

EN 60204-1. Suitable power supplies are available as accessories from SICK.4) Operation in short-circuit protected network max. 2 A. UV connections reverse polarity protected.5) Within the limits of UV.6) The values for power consumption are largely independent of protective field height and resolution.

TECHNICAL DATA 12


7) For more detailed information on the exact configuration of your machine, please consult your respectiveSICK subsidiary.

8) Make sure to limit the individual conductor resistance to the downstream controller to this value toensure that a cross-circuit between the outputs is safely detected. (Also note EN 60 204 ElectricalMachine Equipment, Part 1: General Requirements.)

9) The connecting cable must not be used to connect other loads.

Sender


Wavelength of sender Near-infrared(NIR) - invisible

Weight Depending on the protective field height, see "Table ofweights", page 53

Table 7: Technical specifications, sender

Receiver


Output signal switching devices(OSSDs)

2 PNP semiconductors, short-circuit protected 1), cross-circuit monitored

Response time see "Response time", page 53

Power-down time 100 ms

ON state, switching voltage HIGH(Urms) 2)

UV –3 V 22.5 V UV

OFF state, switching voltage LOW 2) 3) 0 V 0 V 2.0 V

Current-carrying capacity of theOSSDs

300 mA each 4)

Leakage current of the OSSDs 250 µA ea.

Load capacity 2.2 µF 5)

Load inductance 2 H 6)

Test pulse data 4)

Test pulse range 350 μs 400 μs

Test pulse rate 1 s–1 8) 5 s–1 10 s–1

Connection M12, 4-pin

Table 8: Technical specifications, receiver

1) Applies to voltages between -30 V and +30 V.2) According to IEC 61131-23) The specified values are the switching voltage passed to the safety light curtain. If higher voltages are

impressed from the outside, the maximum value of 2.0 V can be exceeded.4) Applies to devices (base module receiver) marked “(Rev. 1)” on the “Ident No.” type label entry. For devi‐

ces not marked “(Rev. 1)”, the following applies: Current-carrying capacity of the OSSDs (maximum) =100 mA each.

5) Applies to devices (base module receiver) marked “(Rev. 1)” on the “Ident No.” type label entry. For devi‐ces not marked “(Rev. 1)”, the following applies: Load capacity (maximum) = 15 nF.

6) Applies to devices (base module receiver) marked “(Rev. 1)” on the “Ident No.” type label entry. For devi‐ces not marked “(Rev. 1)”, the following applies: Load inductance (maximum) = 2.2 mH.

7) When active, the outputs are tested cyclically (brief LOW). When selecting the downstream controllers,make sure that the test signals do not result in deactivation when using the specified parameters.

8) Applies to devices (base module receiver) marked “(Rev. 1)” on the “Ident No.” type label entry. For devi‐ces not marked “(Rev. 1)”, the following applies: Test pulse rate (minimum) = 3 s–1.

12 TECHNICAL DATA


Operating Data


Ambient operating temperature 1) 0°C +50°C

Air humidity (non-condensing) 15% 95%

Storage temperature −30°C +70 °C

Housing cross section 25 mm × 30 mm, see "Dimensional drawings",page 54

Vibration resistance 2) 5 g, 10 Hz to 55 Hz (EN 60068-2-6)

Shock resistance 3) 10 g, 16 ms (EN 60068-229)

Table 9: Operating Data

1) The temperature difference between sender and receiver must not exceed 25 K.2) Test conditions per axis: 1 octave/minute, amplitude: 0.35 mm, 20 sweeps.3) Test conditions per axis: 500 shocks.

12.2 Response time

The response time depends on the resolution and protective field height of the system.The safety light curtain is available with a resolution of 17 mm or 30 mm.

Protective field height, rounded[mm]

Response time [ms]

Resolution 17 mm Resolution 30 mm

210 12 12

315 13 12

420 14 13

525 15 13

630 16 14

735 17 14

840 18 15

945 19 15

1050 20 16

Table 10: Response time dependent on the protective field height

12.3 Table of weights

Module Weight

Base module (sender) 123 g ± 10 g

Base module (receiver) 150 g ± 10 g

Extension module 114 g ± 5 g

End module 60 g ± 5 g

End cap 10 g ± 2 g

Table 11: Module weight

TECHNICAL DATA 12


12.4 Dimensional drawings

Dimensions in mm

Figure 31: Dimensional drawing, sender and receiver

1 Base module2 Extension module3 Connection M12, 4-pin, black4 Connection M12, 5-pin, yellow Connection M12, 5-pin, yellow Optical axis, sender Optical axis, receiver Status indicators Mounting holes End module

Protective field height, rounded [mm] Protective field height (housing length L),exact value [mm]

210 223

315 327

420 431

525 535

630 639

735 743

840 847

945 951

1050 1055

Table 12: Dimensions based on the protective field height, sender and receiver

12 TECHNICAL DATA


13 Ordering information

13.1 Scope of delivery

Scope of delivery, base module sender

• Base module sender• End cap

Scope of delivery, base module receiver

• Base module receiver• End cap• Unlocking tool 4075862• Test rod with diameter corresponding to the resolution of the safety light curtain• Label "Important Information"• Safety note• Mounting Instructions• Operating instructions for download: www.sick.com

Scope of delivery, extension module sender

• Extension module sender

Scope of delivery, extension module receiver

• Extension module receiver

Scope of delivery, end module sender

• End module sender

Scope of delivery, end module receiver

• End module receiver

13.2 Ordering information mac4

Ordering information

Sender Receiver

Resolution Module Part num‐ber

Type Part num‐ber

Type

17 mm Base module 1060617 C4M-SB0221A1BA0 1060618 C4M-EB0221A1BB0

17 mm Extensionmodule

1060619 C4M-SE0211A1AA0 1060620 C4M-EE0211A1AA0

17 mm End module 1070089 C4M-SX0101A1AA0 1070090 C4M-EX0101A1AA0

30 mm Base module 1060621 C4M-SB0223A1BA0 1060622 C4M-EB0223A1BB0

30 mm Extensionmodule

1060623 C4M-SE0213A1AA0 1060624 C4M-EE0213A1AA0

30 mm End module 1070091 C4M-SX0103A1AA0 1070092 C4M-EX0103A1AA0

Table 13: Ordering information mac4

ORDERING INFORMATION 13


http://www.sick.com

Module selection

Protective fieldheight, rounded [mm]

Part numbers and order quantities

Sender Receiver

Base module Extension mod‐ule

End module Base module Extension mod‐ule

End module

210 1 × 1060617 – – 1 × 1060618 – –

315 1 × 1060617 – 1 × 1070089 1 × 1060618 – 1 × 1070090

420 1 × 1060617 1 × 1060619 – 1 × 1060618 1 × 1060620 –

525 1 × 1060617 1 × 1060619 1 × 1070089 1 × 1060618 1 × 1060620 1 × 1070090

630 1 × 1060617 2 × 1060619 – 1 × 1060618 2 × 1060620 –

735 1 × 1060617 2 × 1060619 1 × 1070089 1 × 1060618 2 × 1060620 1 × 1070090

840 1 × 1060617 3 × 1060619 – 1 × 1060618 3 × 1060620 –

945 1 × 1060617 3 × 1060619 1 × 1070089 1 × 1060618 3 × 1060620 1 × 1070090

1050 1 × 1060617 4 × 1060619 – 1 × 1060618 4 × 1060620 –

Table 14: Selection table mac4, resolution 17 mm

Protective fieldheight, rounded [mm]

Part numbers and order quantities

Sender Receiver

Base module Extension mod‐ule

End module Base module Extension mod‐ule

End module

210 1 × 1060621 – – 1 × 1060622 – –

315 1 × 1060621 – 1 × 1070091 1 × 1060622 – 1 × 1070092

420 1 × 1060621 1 × 1060623 – 1 × 1060622 1 × 1060624 –

525 1 × 1060621 1 × 1060623 1 × 1070091 1 × 1060622 1 × 1060624 1 × 1070092

630 1 × 1060621 2 × 1060623 – 1 × 1060622 2 × 1060624 –

735 1 × 1060621 2 × 1060623 1 × 1070091 1 × 1060622 2 × 1060624 1 × 1070092

840 1 × 1060621 3 × 1060623 – 1 × 1060622 3 × 1060624 –

945 1 × 1060621 3 × 1060623 1 × 1070091 1 × 1060622 3 × 1060624 1 × 1070092

1050 1 × 1060621 4 × 1060623 – 1 × 1060622 4 × 1060624 –

Table 15: Selection table mac4, resolution 30 mm

13 ORDERING INFORMATION


14 Accessories

14.1 Brackets

Type Part Part number

BEF-2021GT002 2 × profile rails, L-shaped, 210 mm, 4 ×swivel blocks, incl. screws

2079610


2079611


2079612


2079613


2079614


2079615


2079616


2079617


2079618

BEF-2SMKEAKU4 4 × swivel mount brackets 2019649

Profile rails, L-shaped

1 Profile rails, L-shaped2 Swivel block3 Countersunk screw, tightening torque 1.2 Nm ± 0.2 Nm.

Protective field height, rounded [mm] Bracket length L [mm]

210 286

315 390

420 494

Table 16: Bracket length

ACCESSORIES 14


Protective field height, rounded [mm] Bracket length L [mm]

525 598

630 702

735 806

840 910

945 1014

1050 1118

Table 16: Bracket length

Swivel mount bracket

3,8

34,3

8

13

44

62

36

Ø 24

14.2 Wiring technique

Type Design Part number

Connecting cables M12, 4-pin

DOL-1204G02M025KM0 Female connector straight with 2 m cable,open end

2077084

DOL-1204G05M025KM0 Female connector straight with 5 m cable,open end

2077085

DOL-1204G10M025KM0 Female connector straight with 10 mcable, open end

2077087

Connection cables M12, 5-pin

DSL-1205G01M025KM0 Female connector and male connectorstraight with 1 m cable

2077088


2077089


2077090

Power supplies

Part Part number

Output 24 V DC, 50 W (2.1 A), power supply NEC Class 2, SELV, PELV,input 120–240 V AC (PS50WE24V)

7028789

Output 24 V DC, 95 W (3.9 A), power supply NEC Class 2, SELV, PELV,input 100–120/220–240 V AC (PS95WE24V)

7028790

14 ACCESSORIES


14.3 Alignment aid

Part Part number

Laser alignment aid AR60 1015741

Adapter 4083046

14.4 Cleaning agent

Part Part number

Anti-static plastic cleaner 5600006

Lens cloth 4003353

14.5 Test rods

Part Part number

Test rod 17 mm 2066238

Test rod 30 mm 2069275

Test rod holder 2052249

Table 17: Ordering information, test rods

14.6 Additional accessories

Tools

Part Part number

Unlocking tool 4075862

ACCESSORIES 14


15 Annex

15.1 Compliance with EU directives

EU declaration of conformity (excerpt)

The undersigned, representing the following manufacturer herewith declares that theproduct is in conformity with the provisions of the following EU directive(s) (including allapplicable amendments), and that the respective standards and/or technical specifica‐tions are taken as the basis.

Complete EU declaration of conformity for download

You can call up the EU declaration of conformity and the current operating instructionsfor the protective device by entering the part number in the search field atwww.sick.com (part number: see the type label entry in the “Ident. no.” field).

15 ANNEX


http://www.sick.com

15.2 Checklist for initial commissioning and commissioning

Checklist for manufacturers/installers installing electro-sensitive protective devices(ESPE)

The details on the items listed below must be available at the latest when the system iscommissioned for the first time, depending, however, on the various applications therequirements of which must be reviewed by the manufacturer/installer.

This checklist should be retained and kept with the machine documentation to serve asreference during recurring tests.

This checklist does not replace the initial commissioning, nor the regular inspection byqualified safety personnel.

Have the safety rules and regulations been observed in compliance with thedirectives/standards applicable to the machine?

Yes ⃞ No ⃞

Are the applied directives and standards listed in the declaration of conformity? Yes ⃞ No ⃞Does the protective device comply with the required PL/SIL claim limit and PFHdin accordance with EN ISO 13849-1/EN 62061 and the required type in accord‐ance with EN 61496-1?

Yes ⃞ No ⃞

Is the access to the hazardous area/hazardous point only possible through theprotective field of the ESPE?

Yes ⃞ No ⃞

Have appropriate measures been taken to protect (mechanical protection) ormonitor (protective devices) any persons or objects in the hazardous area whenprotecting a hazardous area or hazardous point, and have these devices beensecured or locked to prevent their removal?

Yes ⃞ No ⃞

Are additional mechanical protective measures fitted and secured againstmanipulation which prevent reaching below, above or around the ESPE?

Yes ⃞ No ⃞

Has the maximum shutdown and/or stopping time of the machine been meas‐ured, specified and documented (at the machine and/or in the machine docu‐mentation)?

Yes ⃞ No ⃞

Has the ESPE been mounted such that the required minimum distance from thenearest hazardous point has been achieved?

Yes ⃞ No ⃞

Are the ESPE devices properly mounted and secured against manipulation afteradjustment?

Yes ⃞ No ⃞

Are the required protective measures against electric shock in effect (protectionclass)?

Yes ⃞ No ⃞

Is the control switch for resetting the protective devices (ESPE) or restarting themachine present and correctly installed?

Yes ⃞ No ⃞

Are the outputs of the ESPE (OSSD) integrated according to required PL/SILCLcompliant with EN ISO 13849-1/EN 62061 and does the integration correspondto the comply with the circuit diagrams?

Yes ⃞ No ⃞

Has the protective function been checked in compliance with the test notes ofthis documentation?

Yes ⃞ No ⃞

Are the specified protective functions effective at every operating mode that canbe set?

Yes ⃞ No ⃞

Are the switching elements activated by the ESPE, e.g. contactors, valves, moni‐tored?

Yes ⃞ No ⃞

Is the ESPE effective over the entire period of the dangerous state? Yes ⃞ No ⃞Once initiated, will a dangerous state be stopped when switching the ESPE on oroff and when changing the operating mode, or when switching to another pro‐tective device?

Yes ⃞ No ⃞

Has the ”Important Information” label for the daily check been attached suchthat it is well visible for the operator?

Yes ⃞ No ⃞

ANNEX 15


16 List of figures

1. Sender and receiver................................................................................................... 112. Module indicators.......................................................................................................133. Hazardous point protection........................................................................................144. Access protection........................................................................................................155. Position of the protective field in relation to the housing........................................ 186. Minimum distance to hazardous point for orthogonal approach to protective field

..................................................................................................................................... 197. Representation of the accessibility of electro-sensitive protective device by reach‐

ing over. Left: Protective field that cannot be reached over. Right: Protective fieldthat can be reached over........................................................................................... 20

8. Minimum distance to reflective surfaces..................................................................219. Graph, minimum distance from reflective surfaces.................................................2110. Preventing mutual interference from system 1 and system 2............................. 2211. Trouble-free operation due to reversed direction of transmission of system 1 and

system 2.................................................................................................................... 2212. Maximum offset between sender and receiver........................................................ 2313. Distance of the fixing holes for rear or side mounting.............................................2414. Avoid offset between sender and receiver................................................................2415. Avoid offset for side mounting...................................................................................2516. Dual-channel and isolated connection of OSSD1 and OSSD2................................2617. No potential difference between load and protective device.................................. 2618. Schematic representation of operation with restart interlock.................................2819. Connection diagram for UE48-2OS with restart interlock and external device moni‐

toring............................................................................................................................2920. Connect modules........................................................................................................3121. Releasing modules..................................................................................................... 3222. Sender and receiver must not be installed at 180° rotated relative to each other.

..................................................................................................................................... 3323. Mount optional alignment bracket............................................................................ 3524. Dual-channel and isolated connection of OSSD1 and OSSD2................................3725. No potential difference between load and protective device.................................. 3826. System connection pin assignment (male connector).............................................3827. Connect the sender and receiver.............................................................................. 3928. Align the sender and receiver.................................................................................... 4129. Test rod check: Step 1................................................................................................4430. Test rod check: Step 2................................................................................................4531. Dimensional drawing, sender and receiver.............................................................. 54

16 LIST OF FIGURES


17 List of tables

1. Base module indicators............................................................................................. 132. Status displays............................................................................................................143. Formula for calculating the minimum distance from reflective surfaces...............214. mac4 system connection pin assignment (M12, 4-pin).......................................... 385. Fault indicators........................................................................................................... 486. General system data.................................................................................................. 517. Technical specifications, sender................................................................................528. Technical specifications, receiver..............................................................................529. Operating Data............................................................................................................5310. Response time dependent on the protective field height........................................5311. Module weight.............................................................................................................5312. Dimensions based on the protective field height, sender and receiver................. 5413. Ordering information mac4........................................................................................5514. Selection table mac4, resolution 17 mm................................................................. 5615. Selection table mac4, resolution 30 mm................................................................. 5616. Bracket length.............................................................................................................5717. Ordering information, test rods..................................................................................59

LIST OF TABLES 17


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