C 4000 Palletizer Standard/Advanced Safety Light Curtain

O P E R A T I N G I N S T R U C T I O N S Standard/Advanced Safety Light Curtain

Operating Instructions This document is protected by the law of copyright, whereby all rights established therein remain with the company SICK AG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without the explicit written approval of the company SICK AG. 2 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Contents Contents 1 About this document... 5 1.1 Function of this document...5 1.2 Target group...5 1.3 Scope...5 1.4 Depth of information...5 1.5 Abbreviations...6 1.6 Symbols used...6 2 On safety... 8 2.1 Specialist personnel...8 2.2 Applications of the device...8 2.3 Correct use...9 2.4 General safety notes and protective measures...9 2.5 Environmental protection... 10 3 Product description...11 3.1 Special features... 11 3.2 Operating principle of the device... 12 3.2.1 Device components... 12 3.2.2 The light curtain principle... 12 3.3 Application examples... 13 3.4 Status indicators... 13 3.4.1 Status indicators of the sender... 14 3.4.2 Status indicators of the receiver... 15 4 Configurable functions...16 4.1 Restart interlock... 16 4.2 External device monitoring (EDM)... 17 4.3 Emergency stop... 17 4.4 Bypass... 18 4.5 Signal output (ADO)... 19 4.6 Conveyor-belt signal... 20 4.7 Beam coding... 20 4.8 Scanning range... 21 4.9 Self-teach dynamic blanking... 21 4.9.1 Function... 21 4.9.2 Object size... 22 4.9.3 Deactivating the output switching signal devices... 24 4.10 Sender test... 24 5 Installation and mounting...25 5.1 Additional measures against bypassing the protection... 25 5.2 Determining the safety distance... 25 5.2.1 Safety distance from the hazardous point... 26 5.2.2 Minimum distance to reflective surfaces... 28 5.3 Mounting the device... 29 5.3.1 Mounting with swivel mount bracket... 30 5.3.2 Mounting with side bracket... 32 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 3

Contents Operating Instructions 6 Electrical installation...34 6.1 System connection M26 11 + FE...35 6.2 Configuration connection M8 4 (serial interface)...36 6.3 Extension connection M26 11 + FE...37 6.4 External device monitoring (EDM)...38 6.5 Reset button...39 6.6 Conveyor-belt signal...40 6.7 Emergency stop...40 6.8 Key-operated switch for bypass...41 6.9 Signal output (ADO)...41 6.10 Test input (sender test)...42 7 Commissioning...43 7.1 Display sequence during start-up...43 7.2 Aligning sender and receiver...43 7.3 Test notes...44 7.3.1 Tests before the first commissioning...44 7.3.2 Regular inspection of the protective device by qualified personnel...45 7.3.3 Daily functional checks of the protective device...45 8 Configuration...46 8.1 Default delivery status...46 8.2 Preparing the configuration...46 9 Care and maintenance...47 10 Fault diagnosis...48 10.1 In the event of faults or errors...48 10.2 SICK support...48 10.3 Error displays of the diagnostics LEDs...48 10.4 Error displays of the 7-segment display...49 10.5 Extended diagnostics...51 11 Technical specifications...52 11.1 Data sheet...52 11.2 Response time...55 11.3 Table of weights...56 11.3.1...56 11.4 Dimensional drawings...57 11.4.1 without extension connection...57 11.4.2 with extension connection...58 11.4.3 Swivel mount bracket...59 11.4.4 Side bracket...59 12 Ordering information...60 12.1 Delivery...60 12.2...60 12.3 Additional front screen (weld spark guard)...61 12.4 Accessories...61 13 Annex...63 13.1 Declaration of conformity...63 13.2 Manufacturer s checklist...64 13.3 List of tables...65 13.4 List of illustrations...66 4 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 1 About this document 1 About this document Please read this chapter carefully before working with the documentation and the C 4000 Palletizer, also referred to in the following as C 4000 for short. 1.1 Function of this document These operating instructions are designed to address the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting, installation, configuration, electrical installation, commissioning, operation and maintenance of the safety light curtain C 4000. These operating instructions do not provide instructions for operating machines on which the safety light curtain is, or will be, integrated. Information on this is to be found in the appropriate operating instructions for the machine. 1.2 Target group These operating instructions are addressed to planning engineers, developers and operators of plants and systems which are to be protected by one or several C 4000 safety light curtains. It also addresses people who integrate the C 4000 into a machine, initialise its use, or who are in charge of servicing and maintaining the device. 1.3 Scope Note These operating instructions apply to the safety light curtain with the following entry on the type label in the field Operating Instructions: 8 010 835. This document is part of SICK part number 8 010 835 (operating instructions Safety Light Curtain in all available languages). For the configuration and diagnostics of these devices you require CDS (Configuration & Diagnostic Software) version 2.30 or higher. To check the version of the software, on the? menu select Info... 1.4 Depth of information These operating instructions contain information on: installation and mounting fault, error diagnosis and troubleshooting electrical installation commissioning and configuration part numbers care and maintenance conformity and approval of the safety light curtain C 4000. Planning and using protective devices such as the C 4000 also require specific technical skills which are not detailed in this documentation. When operating the C 4000, the national, local and statutory rules and regulations must be observed. General information on accident prevention using opto-electronic protective devices can be found in the brochure Safe Machines with opto-electronic protective devices. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 5

Chapter 1 About this document Operating Instructions Note We also refer you to the SICK homepage on the Internet at www.sick.com Here you will find information on: sample applications a list of frequently asked questions regarding the C 4000 these operating instructions in different languages for viewing and printing certificates on the prototype test, the EC declaration of conformity and other documents 1.5 Abbreviations ADO ESPE CDS EDM EFI OSSD Application diagnostic output = configurable signal output that indicates a specific status of the protective device Electro-sensitive protective equipment (e.g. C 4000) SICK Configuration & Diagnostic Software External device monitoring Enhanced function interface = safe SICK device communication Output signal switching device 1.6 Symbols used Recommendation Note, Red, Yellow, Green Take action WARNING Recommendations are designed to give you some assistance in your decision-making process with respect to a certain function or a technical measure. Refer to notes for special features of the device. Display indicators show the status of the 7-segment display of sender or receiver: Constant indication of characters, e.g. U Flashing indication of characters, e.g. 8 Alternating indication of characters, e.g. L and 2 The depiction of numbers on the 7-segment display can be rotated by 180 with the aid of the CDS. In this document the depiction of the numbers on the 7-segment display is however always in the normal, non-rotated position. LED symbols describe the state of a diagnostics LED. Examples: Red The red LED is illuminated constantly. Yellow The yellow LED is flashing. Green The green LED is off. Instructions for taking action are shown by an arrow. Read carefully and follow the instructions for action. Warning! A warning indicates an actual or potential risk or health hazard. They are designed to help you to prevent accidents. Read carefully and follow the warning notices! 6 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 1 About this document Software notes show the location in the CDS (Configuration & Diagnostic Software) where you can make the appropriate settings and adjustments. In the CDS open the menu View, Dialog box and select the item File cards to go straight to the above dialog fields. Alternatively, the software wizard will guide you through the appropriate setting. If you use the SICK switching amplifier UE 402, you will find the functions under the same names, however to some extent in different places in the CDS Configuration dialog box. This is dependent on the scope of the related function. The operating instructions for the UE 402 contain detailed information. Sender and receiver In drawings and diagrams, the symbol denotes the sender and the symbol denotes the receiver. The term dangerous state The dangerous state (standard term) of the machine is always shown in the drawings and diagrams of this document as a movement of a machine part. In practical operation, there may be a number of different dangerous states: machine movements electrical conductors visible or invisible radiation a combination of several risks and hazards 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 7

Chapter 2 On safety Operating Instructions 2 On safety This chapter deals with your own safety and the safety of the equipment operators. Please read this chapter carefully before working with the C 4000 or with the machine protected by the C 4000. 2.1 Specialist personnel The safety light curtain C 4000 must be installed, commissioned and serviced only by specialist personnel. Specialist personnel are defined as persons who have undergone the appropriate technical training and who have been instructed by the responsible machine operator in the operation of the machine and the current valid safety guidelines and who have access to these operating instructions. 2.2 Applications of the device The safety light curtain C 4000 is an electro-sensitive protective equipment (ESPE). The physical resolution is 30 or 40 mm with a maximum protective field width of 19 metres. The realisable protective field length is between 750 and 1,800 mm. The device is a Type 4 ESPE as defined by IEC 61496-1 and -2 and is therefore allowed for use with controls in control category 4 in compliance with EN 954-1. The device is suitable for hazardous area protection access protection Access to the hazardous point must be allowed only through the protective field. The plant/ system is not allowed to start as long as personnel are within the hazardous area. Refer to chapter 3.3 Application examples on page 13 for an illustration of the protection modes. WARNING Only use the safety light curtain as an indirect protective measure! An opto-electronic protective device provides indirect protection, e.g., by switching off the power at the source of the hazard. It cannot provide protection from parts thrown out, nor from emitted radiation. Transparent objects are not detected. Depending on the application, mechanical protective devices may be required in addition to the safety light curtain. Note The safety light curtain cannot be cascaded. 8 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 2 On safety 2.3 Correct use The safety light curtain C 4000 must be used only as defined in chapter 2.2 Applications of the device. It must be used only by qualified personnel and only on the machine where it has been installed and initialised by qualified personnel in accordance with these operating instructions. If the device is used for any other purposes or modified in any way also during mounting and installation any warranty claim against SICK AG shall become void. 2.4 General safety notes and protective measures WARNING Safety notes Please observe the following procedures in order to ensure the correct and safe use of the safety light curtain C 4000. The national/international rules and regulations apply to the installation, commissioning, use and periodic technical inspections of the safety light curtain, in particular: Machine Directive 98/37/EEC Work Equipment Directive 89/655/EEC the work safety regulations/safety rules other relevant health and safety regulations Manufacturers and operators of the machine on which the safety light curtain is used are responsible for obtaining and observing all applicable safety regulations and rules. The notices, in particular the test regulations (see Test notes on page 44) of these operating instructions (e.g. on use, mounting, installation or integration into the existing machine controller) must be observed. The operator of the machine on which the safety light curtain is used, must prevent bypassing of the protective field with appropriate additional measures (see "Additional measures against bypassing the protection" on page 25). Changes to the configuration of the devices can degrade the protective function. After every change to the configuration you must therefore check the effectiveness of the protective device. The person who makes the change is also responsible for the correct protective function of the device. When making configuration changes, please always use the password hierarchy provided by SICK to ensure that only authorised persons make changes to the configuration. The SICK service team is available to provide assistance if required. The tests must be carried out by specialist personnel or specially qualified and authorised personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time. The operating instructions must be made available to the operator of the machine where the safety light curtain C 4000 is fitted. The machine operator is to be instructed in the use of the device by specialist personnel and must be instructed to read the operating instructions. The external voltage supply of the device must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204-1. Suitable power supplies are available as accessories from SICK (Siemens type series 6 EP 1). 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 9

Chapter 2 On safety 2.5 Environmental protection Operating Instructions The safety light curtain C 4000 has been designed to minimise environmental impact. It uses only a minimum of power and natural resources. At work, always act in an environmentally responsible manner. For this reason please note the following information on disposal. Note Disposal Always dispose of unserviceable or irreparable devices in compliance with local/national rules and regulations on waste disposal. We would be pleased to be of assistance on the disposal of this device. Contact your local SICK representative. 10 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 3 3 Product description Product description Note This chapter provides information on the special features and properties of the safety light curtain. It describes the construction and the operating principle of the device, in particular the different operating modes. Please read this chapter before mounting, installing and commissioning the device. The descriptions of functions in this chapter only apply to the safety light curtain C 4000 Palletizer with the following entry on the type label in the Operating Instructions field: 8 010 835. 3.1 Special features The safety light curtain has the following characteristics: protective operation with either internal or external (realised on the machine) restart interlock connection for the reset button either in the control cabinet or directly to the device external device monitoring (EDM) bypass for safe operational statuses 2 beam codings possible in addition to non-coded operation configurable signal output (ADO) for improved availability status display with 7-segment display range of functions can be expanded using switching amplifiers in the SICK Intelliface product family connection option on device for an emergency stop button or a key-operated pushbutton for bypass self-teach dynamic blanking and direction detection of moving objects in the protective field operating mode switching (only in conjunction with SICK switching amplifier, e.g. UE 402) link to conveyor-belt signal 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 11

Chapter 3 Product description 3.2 Operating principle of the device Operating Instructions Fig. 1: Components of the 3.2.1 Device components Receiver Sender Please refer to chapter 11 Technical specifications on page 52 for the data sheet. Please refer to pages 57ff. for the dimensional drawings. 3.2.2 The light curtain principle The safety light curtain C 4000 consists of a sender and a receiver (Fig. 1). Between these two units is the protective field, defined as the protective field length and the protective field width. The construction height determines the protective field length of the appropriate system. For the exact protective field length, please see Tab. 18ff. in chapter 11.4 Dimensional drawings on page 57. The protective field width is derived from the dimension of the light path between sender and receiver and must not exceed the maximum rated protective field width (see Technical specifications on page 52). Sender and receiver automatically synchronise themselves optically. An electrical connection between both components is not required. The C 4000 is modular in structure. All optical and electronic components and assemblies are housed in a slim and torsionally rigid housing. 12 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 3 Fig. 2: Access protection with self-teach dynamic blanking Product description 3.3 Application examples The safety light curtain C 4000 operates correctly as a protective device only if the following conditions are met: The control of the machine must be electrical. It must be possible to achieve a safe state on the machine at any time. Sender and receiver unit must be so mounted that objects penetrating the hazardous area are safely identified by the C 4000. The restart button must be fitted outside the hazardous area such that it cannot be operated by a person working inside the hazardous area. When operating the reset button, the operator must have full visual command of the hazardous area. The statutory and local rules and regulations must be observed when installing and using the device. 3.4 Status indicators Note The LEDs and the 7-segment displays of the sender and the receiver signal the operating status of the C 4000. The depiction of numbers on the 7-segment display can be rotated by 180 with the aid of the CDS (Configuration & Diagnostic Software). If you rotate the numbers of the 7-segment display, the point on the 7-segment display goes out: Point visible: The bottom edge of the numbers on the 7-segment display is pointing towards the configuration connection. Point not visible: The bottom edge of the numbers on the 7-segment display is pointing towards the LED display. Device symbol (receiver) or (sender), context menu Configuration draft, Edit, option 7-segment display of the related device. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 13

Chapter 3 Fig. 3: Status indicators of the sender Product description 3.4.1 Status indicators of the sender Yellow Operating Instructions 7-segment display Tab. 1: Status indicators of the sender Display Yellow Other displays Meaning Power supply OK System error. The device is defective. Replace the sender. The device is in the test mode. Non-coded operation (only after switching on) Operation with code 1 (only after switching on) Operation with code 2 (only after switching on) All other displays are error messages. Please refer to chapter Fault diagnosis on page 48. 14 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 3 Fig. 4: Status indicators of the receiver Product description 3.4.2 Status indicators of the receiver Orange Red Yellow Green 7-segment display Tab. 2: Status indicators of the receiver Display Orange Yellow Red Green Other displays Meaning Cleaning or realignment required Reset required System providing signals for shutting down the machine (output signal switching devices off) System enabled (output signal switching devices on) Bypass active System error. The device is defective. Replace the receiver. Poor alignment to sender. Please refer to chapter 7.2 Aligning sender and receiver on page 43. Operation with large protective field width (only after switching on) Self-teach dynamic blanking active Object in the protective field with activated self-teach dynamic blanking Non-coded operation (only after switching on) Operation with code 1 (only after switching on) Operation with code 2 (only after switching on) Emergency stop active All other displays are error messages. Please refer to chapter Fault diagnosis on page 48. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 15

Chapter 4 Configurable functions Operating Instructions 4 Configurable functions This chapter describes the functions of the safety light curtain which are selectable via software. WARNING Test the protective device after any changes! The entire protective device must be tested for correct operation after each change of the configuration (see chapter 7.3 Test notes on page 44). When starting to configure the device, you may save an application name with a maximum of 22 characters. Use this function as a memory jog, e.g. to describe the application of the current device configuration. Device symbol (receiver) or C 4000 Palletizer (sender), context menu Configuration draft, Edit, file card General, option Application name. 4.1 Restart interlock WARNING Always configure the application with restart interlock! Ensure that there is always a restart interlock. The C 4000 is unable to verify if the restart interlock of the machine is operable. If you deactivate both the internal and the machine s restart interlock, the operators of the machine will be at an acute risk of injury. Note Tab. 3: Permissible configuration of the restart interlock Recommendation The dangerous state of the machine is interrupted if the light path is broken, and is not reenabled until the operator presses the reset button. Do not confuse the restart interlock with the starting interlock on the machine. The start interlock prevents the machine starting after switching on. The restart interlock prevents the machine starting again after an error or an interruption in the light path. The possible combinations are shown in the following table: Restart interlock of the C 4000 Restart interlock of the machine Permissible application Deactivated Activated All Activated Activated All. Restart interlock of the C 4000 handles the reset function (see Reset below). Activated Deactivated Not permitted Deactivated Deactivated Not permitted The electrical connection of the reset button is described in chapter Reset button on page 39. Device symbol (receiver), context menu Configuration draft, Edit, file card General, option Restart interlock. You can indicate the status Reset required using a signal lamp. The C 4000 has a dedicated output for this purpose. The electrical connection of the signal lamp is described in chapter Connection of a signal lamp to the output Reset required on page 39. 16 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 4 Recommendation Configurable functions Reset If you want to activate the restart interlock on the C 4000 (internal) and also a restart interlock on the machine (external), then each restart interlock has its own button. When actuating the reset button for the internal restart interlock the C 4000 activates the output signal switching devices. the safety light curtain changes from red to green. Only the external restart interlock prevents the machine from restarting. After pressing the reset button for the C 4000, the operator must also press the restart button for the machine. If the reset button and the restart button are not pressed in the specified sequence, the dangerous state remains disrupted. The reset button prevents the accidental and inadvertent operation of the external restart button. The operator must first acknowledge the dangerous state with the reset button. 4.2 External device monitoring (EDM) Note The external device monitoring (EDM) checks if the contactors actually de-energise when the protective device responds. If you activate external device monitoring, then the C 4000 checks the contactors after each interruption to the light path and prior to machine restart. The EDM can so identify if one of the contacts has fused, for instance. In this case the error message appears in the 7-segment display. the safety light curtain remains red. with the internal restart interlock activated, the safety light curtain uses the flashing LED Yellow to signal Reset required. If the system is unable to change to a safe operational state (e.g. after contactor failure), the system locks and shuts down completely (lock-out). The 7-segment display will then show the error message. The electrical connection for the external device monitoring is described in chapter 6.4 External device monitoring (EDM) on page 38. Device symbol (receiver), context menu Configuration draft, Edit, file card General, option EDM. 4.3 Emergency stop Notes The C 4000 has an input for a two-channel emergency stop button. The emergency stop monitoring in the device corresponds to stop category 0 in accordance with EN 418. You can connect e.g. a door contact or an emergency stop button to the emergency stop input. The operation of the emergency stop button has the following effect: The safety light curtain deactivates the OSSDs. The switches to red. The 7-segment display on the indicates. The emergency stop function deactivates the OSSDs even if the bypass function is activated. Take into account the response time of the emergency stop function! The response time of the safety light curtain on interruption via the emergency stop input is up to 200 ms. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 17

Chapter 4 Configurable functions Operating Instructions WARNING Notes Pay attention to the way in which the emergency stop function works! The emergency stop button connected to the extension connection on the C 4000 affects only the output signal switching devices (OSSDs) on the C 4000. The C 4000 checks after switch on whether an emergency stop function has been configured and whether a door switch or similar switch is connected. If the configuration and the electrical connection do not match, the system locks completely (lock-out). The 7-segment display will then show the error message. The safety light curtain has a signal output (ADO) at which the status of the emergency stop input can be signalled. For details refer to the next section. WARNING Regularly check the connected emergency stop button or door contact! By means of organisational measures ensure that the emergency stop button or door contact is operated once at a specified interval. This is necessary so that the C 4000 can detect any fault that has occurred on the emergency stop button or door switch. The interval is to be defined to suit the specific case dependant on the application. Always check whether the output signal switching devices on the light curtain are deactivated on the operation of the emergency stop button or door switch. The electrical connection of the emergency stop is described in chapter 6.7 Emergency stop on page 40. Device symbol (receiver), context menu Configuration draft, Edit, file card General, option Emergency stop active. Fig. 5: Schematic layout of the bypass function 4.4 Bypass Bypass inactive Bypass active In some applications it is, at times, necessary to mute the protective evaluation field of the safety light curtain. For example, for continued transport of a pallet with shifted cargo. When the bypass is active, the safety light curtain displays Green and the 7-segment display of the receiver displays. WARNING Switch on the machine safely when using the bypass function! As long as the bypass function is active, the safety light curtain does not detect any movements in the protective field. You must ensure that other protective measures are activated during the bypass, e.g. the safe set-up mode of the machine in order that there is no danger to persons or parts of the machine during the bypass. 18 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 4 Notes Configurable functions The bypass function may only be activated as follows: by a key-operated pushbutton with an automatic reset and two levels by two input signals that are independent of each other, e.g. two position pushbuttons or two secure PLC signals It must be possible to view the entire hazardous point when operating the key-operated switch. It is not possible to combine the bypass and PSDI mode functions. 200 ms after switching off the bypass, the system is again in a safe status (latency time). Device symbol C 4000 Host (receiver), context menu Configuration draft, Edit, selection of the operating mode, General tab, option Bypass. The connection of the key-operated switch for bypass is described in Section 6.8 "Keyoperated switch for bypass" on Page 41. 4.5 Signal output (ADO) The C 4000 has a signal output (ADO) that can be configured. With the aid of the signal output, the safety light curtain can signal specific states. You can use this output for a relay or a FPLC. WARNING You must not use the signal output for safety-relevant functions! You are only allowed to use the signal output for signalling. You must never use the signal output for controlling the application or with safety-relevant functions. Tab. 4: Possible configuration for the signal output The connection can signal one of the following states: Assignment Contamination OSSD status with delay of [s] Status of the emergency stop Object in the protective field Possible uses Eases diagnostics in case of contaminated front screen. Signals the status of the output signal switching devices. If the safety light curtain switches to red, then it signals the status immediately. If it switches to green, then it signals the status only after an adjustable delay in the range from 0.1 to 3.1 seconds. Signal is present if the button connected to the emergency stop input on the C 4000 has been pressed. Signal is present if a valid object is in the protective field while the function "Multi Mode", "Single Mode" or "Self-Teach Dynamic Blanking" is selected. Device symbol (receiver), context menu Configuration draft, Edit, file card General, option Assignment of the signal output. The electrical connection of a PLC/controller to the signal output is described in chapter 6.9 Signal output (ADO) on page 41. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 19

Chapter 4 Configurable functions 4.6 Conveyor-belt signal Operating Instructions The self-teach dynamic blanking can be coupled to a conveyor-belt signal. By coupling to a conveyor-belt signal, blanking is only active if a signal is present from a transport conveyor belt. If the conveyor belt is not moving, the entire protective field is active. Device symbol (receiver), context menu Configuration draft, Edit, file card Self-teach dynamic blanking, option Conveyor-belt signal. The electrical connection to a conveyor-belt signal is described in section 6.6 "Conveyorbelt signal" on page 40. 4.7 Beam coding If several safety light curtains operate in close proximity to each other, the sender beams of one system may interfere with the receiver of another system. With code 1 or 2 activated, the receiver can distinguish the beams designated for it from other beams. The following settings are available: non-coded, code 1 and code 2. WARNING Use different beam codings if the systems are mounted in close proximity! Systems mounted in close proximity to each other must be operated with different beam codings (code 1 or code 2). If this precaution is neglected, the system may be impaired in its protective function by the beams from the neighbouring system and so change to the unsafe state. This would mean that the operator is at risk. Fig. 6: Schematic layout of the beam coding Code 1 Code 2 Notes Beam coding increases the availability of the protected machine. Beam coding also enhances the resistance to optical interference such as weld sparks or similar. Beam coding will increase the response time of the system. This may also change the required safety distance. Instructions can be found in chapter 5.2 Determining the safety distance on page 25. After activating the system, sender and receiver will briefly display the coding. Device symbol (receiver) or (sender), context menu Configuration draft, Edit, file card General, option Beam coding. 20 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 4 Configurable functions 4.8 Scanning range WARNING Match the scanning range with the protective field width! The scanning range of the system must be adapted to the protective field width. If the scanning range is set too low, the light curtain may not switch to green. If the scanning range is too great, the light curtain may malfunction. This would mean that the operator is at risk. The available settings depend on the physical resolution of the system: Tab. 5: Physical resolution and scanning range Physical resolution Selectable scanning ranges Scanning range with 1 additional front screen Scanning range with 2 additional front screens 30 mm 40 mm 0.5 6 m 5 19 m 0.5 5.5 m 4.6 17.4 m 0.5 5 m 4.2 16 m Note Device symbol (receiver), context menu Configuration draft, Edit, file card Standalone, option Scanning range [m]. If you are using the additional front screen (see page 61) available as an accessory, the overall scanning range will be reduced by 8% for each additional front screen. 4.9 Self-teach dynamic blanking 4.9.1 Function On the you configure self-teach dynamic blanking. The self-teaching dynamic blanking provides access protection in which precisely defined objects (e.g. pallets) have access to a system or machine (see Fig. 7, ). However, if other objects, particularly people, enter the protective field, the C 4000 shuts down the output signal switching devices (see Fig. 7, ). Fig. 7: Schematic diagram of the self-teach dynamic blanking The direction of movement may not change during entry. During this process, the C 4000 dynamically teaches itself the distance between objects. The C 4000 monitors this distance until the objects leave the beam path. The direction of entry into the beam path can be configured: 1. coming from the display 2. going towards the display 3. coming from both sides 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 21

Chapter 4 Notes Configurable functions Operating Instructions Devices with a protective field of 750mm can only be used in combination with the direction of object entry monitoring activated. Notes While the objects pass through the protective field, the C 4000 monitors the speed at which objects move. This must not exceed 2 m/s. Differences between Standard and Advanced: The Standard model (resolution 40 mm) can only blank single objects (e.g.: packages). The Advanced model (resolution 30 mm) can also blank compound objects, which move up to three objects in the beam path (e.g. three supports of a pallet). Compound-object blanking is only available with the Advanced. In this way, in many applications a higher level of safety and availability can be assured than would be possible without compound-object blanking. This requires the careful analysis of the usage of compound-object blanking as part of a risk analysis for these applications. The usage of this function is only recommended if the analysis produces advantages in reliability and thus advantages in safety. The person responsible for the machine has the responsibility to decide whether or not to use this function and, if compound-object blanking is used, to undertake the installation, mounting and configuration of the light curtain such that the necessary safety is achieved at the machine and access to the hazardous area through the light curtain in conjunction with compoundobject blanking is prevented by other safeguards. Safety can be improved further by connection of a conveyor-belt signal. Thus, if the conveyor belt is not moving, the entire protective field is active without blanking (see section 4.6 "Conveyor-belt signal" on page 20). Note 4.9.2 Object size You configure the maximum permissible object size for the number of moving objects. This can be up to 240 mm for compound objects (Multi Mode) (only possible with a resolution of 30 mm). For single objects (Single Mode), the maximum object size is calculated by the protective field length minus 100 mm. For example, protective field 1500 mm 100 mm = a maximum object size of 1400 mm. The minimum object size for single objects (Single Mode) is 500 mm. The Light curtain switches to red after recognizing a new object size (object is completely in the protective field and both synchronization beams are free). The new object will be taught in via the connected reset button with implicated Teach-in functionality. At the same time the restart interlock will be reset at the C4000. Objects up to this size are not detected. Safe shut down requires larger objects (see Tab. 6 on page 23). 22 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 4 Configurable functions WARNING Prevent objects that are too small entering the protective field! The safety light curtain does not switch to red when the object is smaller than the configured maximum permissible object size. The safety light curtain only safely switches to red when the object is sufficiently larger than the configured maximum permissible object size. Exactly how large an object must be to cause a safe shut down depends on two factors: the physical resolution of the safety light curtain on whether the object is moving through the protective field or is stationary in the protective field (e.g. when the machine is being restarted) Based on Tab. 6 on page 23. If you allow a maximum permissible object size bigger than 70 mm, then you must take organisational measures to ensure that people (or other objects that are not allowed) are detected, e.g. appropriate safety clothing or industrial clothing. A person is only detected when he/she is larger than the object size necessary for safe shut down or when the distance between his/her legs changes when walking. During the object entry (while single mode is activated) the conveyor with its load is blocking access to the hazardous area. Tab. 6: Object size from which the C 4000 safely shuts down the OSSDs in Multi Mode (compound objects). Example (*): At a physical resolution of 30 mm and a maximum permissible object size of 40 mm, a moving object with a size of 50 mm or larger results in safe shut down. Object size for safe shut down in Multi Mode Necessary object size [mm] from which the C 4000 Configured maximum permissible object size safely shuts down the OSSDs Physical resolution [mm] 30 mm 40 mm Floating Stationary Floating Stationary 40 50* 70 60 70 90 70 100 80 90 110 90 100 130 100 110 130 120 130 150 130 160 140 150 170 150 160 190 160 170 190 180 190 210 190 220 200 210 230 210 220 250 220 230 250 240 250 270 250 280 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 23

Chapter 4 Configurable functions Operating Instructions Object size for safe shut down in Single Mode The object size, from which the C 4000 safely shuts down the OSSDs in Single Mode (single objects), can be calculated using the following formulas: For moving objects: configured maximum permissible object size + configured tolerance + 10 mm Example: configured maximum permissible object size (120 mm) + configured tolerance (60 mm) + 10 mm = required object size of 190 mm For stationary objects: configured maximum permissible object size + configured tolerance + 10 mm + resolution Example: configured maximum permissible object size (120 mm) + configured tolerance (60 mm) + 10 mm + resolution (30 mm) = required object size of 220 mm Device symbol (receiver), context menu Configuration draft, Edit, file card Self-teach dynamic blanking, option Compound object. 4.9.3 Deactivating the output switching signal devices The deactivates its OSSDs for at least 1 second if there are more objects in the protective field than configured. when the size of an object exceeds the object size necessary for safe shut down. if the distance between two objects in the protective field changes. if an object enters the protective field other than at the start. if an object enters the protective field other than at the end. if the speed of an object exceeds 2.5 m/s. if the object number has been configured for multiple objects but only one object passed through the light grid. Note 4.10 Sender test The C 4000 sender has a test input on pin 3 for checking the sender and the related receiver. During the test, the sender no longer emits light beams. Thus, it simulates for the receiver an interruption of the protective field. During the test the sender indicates. The test is successful, if the C 4000 receiver switches to red, i.e. the output signal switching devices (OSSDs) are deactivated. C 4000-sender and receiver are self-testing. You only need to configure the function of the sender test if this is necessary for an older existing application. To be able to perform a sender test the option Enable sender test must be active. (Deactivated in its default delivery status). a means of controlling the test input must be available. Device symbol (sender), context menu Configuration draft, Edit, option Enable sender test. The electrical connection at the test input is described in chapter 6.10 Test input (sender test) on page 42. 24 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 5 Installation and mounting 5 Installation and mounting This chapter describes the preparation and completion of the installation of the safety light curtain C 4000. The installation and mounting requires two steps: determining the necessary safety distance installation with swivel mount or side brackets additional measures against bypassing the protection The following steps are necessary after mounting and installation: completing the electrical connections (chapter 6) aligning sender and receiver (chapter 7.2) testing the installation (chapter 7.3) 5.1 Additional measures against bypassing the protection In order for the protective field not to be bypassed (intentionally/unintentionally), the following additional measures may become necessary: Bypass attempts Jumping across the protective field Crawling underneath the protective field Balancing across the protective field Walking in the shadow of an object Teach-in of persons with a solid object (cardboard box, briefcase) Measures Select a sufficient light-curtain length Mount the light curtain higher Mount fixed barriers Observe a maximum mounting height of 400 mm or choose additional barriers Mount additional light curtains Mount fixed barriers Minimize the distance between C4000 and pallet to prevent a foot being placed in between 5.2 Determining the safety distance The light curtain must be mounted with the correct safety distance from the hazardous point from reflective surfaces WARNING No protective function without sufficient safety distance! The reliable protective effect of the light curtain depends on the system being mounted with the correct safety distance from the hazardous point. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 25

Chapter 5 Fig. 8: Safety distance from the hazardous point Installation and mounting 5.2.1 Safety distance from the hazardous point Operating Instructions A safety distance must be maintained between the light curtain and the hazardous point. This safety distance ensures that the hazardous point can only be reached after the dangerous state of the machine has been completely stopped. The safety distance as defined in EN 999 and EN 294 depends on: stopping/run-down time of the machine or system (The stopping/run-down time is shown in the machine documentation or must be determined by taking a measurement.) response time of the protective device (response times see chapter 11.2 Response time on page 55) approach speed resolution of the light curtain and/or beam separation other parameters that are stipulated by the standard depending on the application Hazardous area Safety distance S ESPE Mounting height H Note How to calculate the safety distance S according to EN 999 and EN 294: The safety distance is in respect to the first beam in the direction of the approach to the hazardous point (cf. Fig. 8). The following calculations show an example calculation of the safety distance. Depending on the application and the ambient conditions, a different calculation may be necessary. Safety distance for single objects (Single Mode): Calculate the safety distance for single objects (Single Mode) using the following formula: S = k T + 850 + penetration depth [mm] Where... S = Safety distance [mm] k = Approach speed [1600 mm/s] T = Stopping/run-down time of the machine + response time of the protective device after light path interruption [s] 850 = Arm length according to EN 999 [mm] The penetration depth is calculated by object size + tolerance. In the worst case, it corresponds to the length of the protective field 100 mm. 26 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 5 Installation and mounting Example: Stopping/run-down time of the machine = 290 ms Response time after light path interruption = 30 ms T = 290 ms + 30 ms = 320 ms = 0.32 s Object size = 700 mm Tolerance = 90 mm Penetration depth = 790 mm S = 1600 0.32 + 850 + 790 = 2152 mm Safety distance for compound objects (Multi Mode): Calculate the safety distance for compound objects (Multi Mode) using the following formula: S = SW + ½ SW + A + EB - (0,4 H) + k T Where... S = Safety distance [mm] SW = Step length according to EN 999 [700 mm] A = Arm length according to EN 999 [850 mm] EB = Entry area of the ESPE [60 mm] k = Approach speed [1600 mm/s] T = Stopping/run-down time of the machine + response time of the protective device after light path interruption [s] H = Mounting height for the light curtain [mm] Example: Stopping/run-down time of the machine = 290 ms Response time after light path interruption = 30 ms Mounting height for the light curtain = 300 mm T = 290 ms + 30 ms = 320 ms = 0.32 s H = 300 mm S = 700 mm +350 mm + 850 mm + 60 mm - (300 mm 0,4) + (0,32 s 1600 mm/s) = 2352 mm While having objects < 70mm reduced safety distances can be applied other than stated in the above mentioned formula. 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 27

Chapter 5 Installation and mounting 5.2.2 Minimum distance to reflective surfaces Operating Instructions Fig. 9: Minimum distance to reflective surfaces The light beams from the sender may be deflected by reflective surfaces. This can result in failure to identify an object. All reflective surfaces and objects (e.g. material bins) must therefore be located at a minimum distance a from the protective field of the system. The minimum distance a depends on the distance D between sender and receiver. Reflective surface Field of view Minimum distance a Distance D sender-receiver Fig. 10: Graph, minimum distance from reflective surfaces Note The field of view of the sender and receiver optics is identical. How to determine the minimum distance from reflective surfaces: Determine the distance D [m] sender-receiver. Read the minimum distance a [mm] from the graph: 28 SICK AG Industrial Safety Systems Germany All rights reserved 8 010 838/23-03-05

Operating Instructions Chapter 5 Installation and mounting 5.3 Mounting the device WARNING Special features to note during mounting: Always mount the sender and receiver parallel to one another. Only mount the sender and receiver horizontally. During mounting, ensure that sender and receiver are aligned correctly. The optical lens systems of sender and receiver must be located in exact opposition to each other. The system plugs of both devices must point in the same direction. The minimum distance between sender and receiver is 500 mm. Take suitable measures to attenuate vibration if the shock requirements are above the values given in chapter 11.1 Data sheet on page 55. Observe the safety distance of the system during mounting. On this subject read the chapter Determining the safety distance on page 25. Mount the safety light curtain such that it is not possible to climb over, crawl underneath or stand behind the safety light curtain and such that the light curtain cannot be repositioned. A mounting height of 400 mm is considered to be a non-critical value with regards to crawling. Access to the hazardous area is only to be via the protective field. Once the system is mounted, one or several of the enclosed self-adhesive safety information labels must be affixed. Use only information labels in the language which the operators of the machine understand. Affix the information labels such that they are easily visible by the operators during operation. After attaching additional objects and equipment, the information labels must not be concealed from view. Affix the information label Important Notices to the system in close proximity to sender and receiver. Fig. 11: Diagonal mounting The sender and receiver can also be mounted diagonally to one another to make packages, which are stacked cardboard boxes, appear as a single, solid object for the light curtain. This arrangement must be especially protected against crawling. The senders and receivers can be mounted in two different ways: mounting with swivel mount bracket mounting with side bracket 8 010 838/23-03-05 SICK AG Industrial Safety Systems Germany All rights reserved 29