Captron safeCAP SC4 User manual
safeCAP SC4
Original operating instructions
safeCAP SC4 with MCR-225
safeCAP SC4
Original operating instructions
safeCAP SC4 with MCR-225
Table of Contents
1 Foreword....................................................................................... 4
2 Safety.............................................................................................4
2.1 Notes and symbols used.......................................................... 4
2.2 General safety...........................................................................5
2.3 Personnel qualifications............................................................ 5
2.4 Intended use............................................................................. 6
2.5 Reasonably foreseeable misuse...............................................6
2.6 Determining the lifetime and validating the entire system.........6
2.7 Example calculation.................................................................. 6
2.8 Equivalent T-network................................................................ 7
3 General description..................................................................... 8
3.1 safeCAP SC4............................................................................ 8
3.2 Operating states........................................................................8
4 Storage.......................................................................................... 9
5 Assembly.......................................................................................9
5.1 Prepare SC4 for assembly......................................................10
5.2 Recommended screw types....................................................10
5.3 Maximum dimensions of the screws.......................................10
5.4 SC4 assembly without SCP4..................................................11
5.5 Connecting SC4 to the safety relay........................................12
5.5.1 MCR-225 connection plan................................................................... 12
5.5.2 Connecting SC4 to a spare safety relay..............................................12
5.6 Testing the safety function of the SC4....................................12
6 Maintenance................................................................................13
6.1 Maintenance operations..........................................................13
7 Disposal.......................................................................................14
8 Technical specifications............................................................ 14
8.1 Technical specifications, safety relay MCR-225......................15
2/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
8.2 Dimensional drawing...............................................................16
8.2.1 SC4A.................................................................................................... 16
8.2.2 SC4B.................................................................................................... 17
9 Declaration of conformity......................................................... 18
10 Imprint......................................................................................... 19
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 3/19
1 Foreword
These operating instructions are intended for installers and operators and
should be kept for future reference. Read these operating instructions carefully
and make sure that you have fully understood the contents before installing or
working with the safeCAP SC4. The operator is responsible for validating the
entire safety system.
2 Safety
2.1 Notes and symbols used
Warning notes in relation to personal injury / material damage are formulated
according to the "SAFE” principle. This means they contain information on the
type and source of the hazard, potential consequences as well as how to avoid
and avert danger. The following hazard classifications apply in the safety notes:
DANGER
Danger designates a hazardous situation, which, if ignored, will lead to
death or serious injury. The symbol next to the warning indicates the type
and source of the danger.
WARNING
Warning designates a hazardous situation, which, if ignored, may lead to
death or serious injury. The symbol next to the warning indicates the type
and source of the danger.
CAUTION
Caution designates a hazardous situation, which, if ignored, may lead to
injury. The symbol next to the warning indicates the type and source of the
danger.
NOTICE
Notice designates a situation, which may cause material damages and
impair the product’s function if attention is not paid.
4/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
TIP
Tip provides additional useful information about the handling of the product.
Symbol Meaning
4Avoiding and adverting danger in the warning note
►Instructions for action
All instructions to be followed within a procedure are always
listed in chronological order.
■List
2.2 General safety
All work on electrical systems or operating equipment may only be carried out
by a specially qualified electrician according to the applicable electrotechnical
regulations.
The safety of the system in which the SENSORswitch is integrated is the
responsibility of the operator.
2.3 Personnel qualifications
A qualified electrician is a person with suitable technical training, expertise and
experience as well as knowledge of relevant standards, who can evaluate the
work assigned to them correspondingly and recognize potential risks.
The following general safety notes for working with electrical energy must be
observed:
WARNING
Improper work on electrical systems!
Electric shock can result in death or life-threatening injuries.
4Before working on electrical systems, disconnect them from their
voltage supply and secure them against being switched on again.
4Wear appropriate personal protective equipment (PPE).
4Defects that are ascertained, such as damaged or loose cables, must
be remedied immediately.
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 5/19
2.4 Intended use
Combined with safety relay MCR-225, safeCAP SC4 ensures safety-
related release and interruption of a safety circuit. safeCAP SC4 is used to
protect people from work machines with dangerous closing movements. If
safeCAP SC4 is used without the aforementioned safety relay, the operator is
responsible for safety-related release and interruption of the safety circuit.
2.5 Reasonably foreseeable misuse
Any use other than as specified in the section Intended use or extending
beyond this is deemed to be improper.
The switch is not suitable for:
■use as a two-hand control without the aforementioned relay or independent
calculation of the performance level in accordance with ISO 13849.
■use as a two-hand control without validation of the entire system.
■use as an emergency stop command device.
■use in potentially explosive atmospheres.
■use outdoors.
2.6 Determining the lifetime and validating the
entire system
The following steps are mandatory.
■Determine the real parameters of the system.
4Required performance level
4dop
4hop
4tcycle
■The operator must verify that the lifetime TM is not exceeded.
■Validate the entire system.
■Observe the safety considerations in the operating instructions of the safety
relay.
2.7 Example calculation
The following values are only examples and must be replaced with your own
values.
6/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
■Performance level e must be achieved.
■dop = 250 d
■hop = 24 h
■tcycle = 10 s
nop [cycles / year]
nop = (dop * hop *3600 s) / tcycle
nop = 250 d / y * 24 h / d * 3600 s / h / 10 s / cycle = 2,160,000 cycles / year
According to the operating instructions, the relay has a lifetime of approximately
20 million cycles before a dangerous failure can occur.
TM = 20,000,000 / nop
TM = 20,000,000 / 2,160,000 = 9.3 years
According to this calculation, the relay has to be replaced after 9.3 years.
For other relays, values such as B10D or T10D can be specified. These values are
not considered here and can be requested from CAPTRON.
2.8 Equivalent T-network
If an equivalent T-network is used for the relay, the entire FIT value for the
equivalent T-network must be determined via an FMEDA or an equivalent
method.
The equivalent T-network must not exceed a FIT value of 45, and the MTTFd
should be more than 45 years to meet the following formula:
MTTFd (Equivalent t-network) = MTTFd (safeCAP) * 30 / ( MTTFd (safeCAP) -
30).
Exception: MTTFd (safeCAP) = 100;
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 7/19
3 General description
3.1 safeCAP SC4
1 Colored cover ring
2 LEDs
3 Button surface
3.2 Operating states
The LEDs indicate the different operating states of the SC4.
Green LEDs lit up. SC4 is ready for operation.
Red LEDs lit up. Button surface being actuated.
Green LEDs lit up.
Red LEDs flashing.
SC4 not working
■Insufficient actuation speed
■The button surface is excessively
dirty or wet
■There are objects on the button
surface
8/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
4 Storage
Component Conditions
safeCAP SC4 -25°C (-13°F) to 75°C (167°F)
Safety relay -40°C (-40°F) to 85°C (185°F)
Protector SCP-4 Protected against UV light for max. two years
20°C (68°F)
50% -70% relative air humidity
5 Assembly
WARNING
Improper work on electrical systems!
Electric shock can result in death or life-threatening injuries.
4Before working on electrical systems, disconnect them from their
voltage supply and secure them against being switched on again.
4Work on electrical installations should be carried out only by qualified
personnel in compliance with local and national electrical regulations
and specifications.
WARNING
Improper safeCAP SC4 assembly!
An improperly assembled two-hand control device can result in death or
life-threatening injuries.
4Select mounting surfaces for the safeCAP SC4 based on the
dimensions and spacing specified in DIN EN ISO 13851.
4Protect safeCAP SC4 against unintended actuation, for example SCP-4.
4Before working on the machine, check safeCAP SC4 for proper
function.
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 9/19
5.1 Prepare SC4 for assembly
Requirements: Mounting surface is
level and clean.
► Disconnect the system from its
voltage supply and secure it
against being switched on again.
► Set the desired position of the
SC4 and provide a center hole of
minimum Ø 45 mm to maximum
Ø 60 mm.
► Position the SC4 (B), lining up
the center and vertical axis, and
mark the holes (C).
► Select the diameter of the holes
according to the recommended
screw type and start drilling.
► Depending on the installation
position, you now need
to connect the SC4. see
"Connecting SC4 to the safety
relay"
5.2 Recommended screw types
■DIN EN ISO 1207 M4
■DIN EN ISO 7045 M4
■DIN EN ISO 1481 Ø3.9 mm
■DIN EN ISO 7049 Ø3.9 mm
5.3 Maximum dimensions of the screws
The drawing shows the maximum
dimensions of the screws.
10/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
5.4 SC4 assembly without SCP4
Requirements: Mounting surface is level and clean.
NOTICE
Risk of damage to the mounting flange!
Unsuitable screw heads or too great a tightening torque for the screws
can damage the mounting flange.
4Do not use countersunk screws.
4Tighten screws with a maximum torque of 1.1 Nm.
4The screw must not deform the mounting flange during tightening.
► Place and position the SC4 (B), then install it with the recommended
screws. The screw head must not deform the mounting flange (B).
► Place cover ring (A) with groove
(D) downward and press close
to the button surface. The cover
ring must be flush with the entire
button surface.
NOTICE
Mineral grease and oils can attack the plastic of the button!
4Do not use grease or oils to apply the cover ring (A).
NOTICE
The SC4 is not short circuit-proof and can be damaged if connected
incorrectly.
4Before applying the operating voltage, check to ensure correct
connection.
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 11/19
5.5 Connecting SC4 to the safety relay
1. Connect SC4A and the SC4B to the safety relay of the SC4A (M8).
2. Connect the SCA4A and SC4B to the safety relay based on the following
connection diagram.
5.5.1 MCR-225 connection plan
Black
NO
24 V
0 V
NO
NC
(5 m)
NC
Grey
Brown
Blue
White
Yellow
+
S1
1
S22S11 S12
S1
2 S21
A1
A2
S2
2 S21
-
(2m)
5m)
AABB
SCA4 SCB4
5.5.2 Connecting SC4 to a spare safety relay
The SC4 can also be connected to another safety relay or integrated in an
SRP/CS and must be coordinated with CAPTRON Electronic GmbH. The
safety of the system in which the SC4 is integrated is the responsibility of the
operator. For more information, please refer to [email protected].
5.6 Testing the safety function of the SC4
To ensure the safety function of the SC4, test the safety function as follows.
12/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
■During initial start-up
■Once the testing interval has expired
■After maintenance and repairs
Record the results.
► Disconnect SC4 from the machine.
► Connect a meter to the contacts of the safety relay that release the
machine function.
► Actuate the SC4s one after another.
aLEDs must be lit red.
aThe safety relay must not release N/O or N/C contacts.
Switching on must be verified at the output contacts of the safety relay
using the meter and must not exceed the safety times (0.5 s in this case).
► Disconnect the SC4 from the power supply.
► Actuate and continue actuating the SC4.
► Restore the power supply.
aLEDs must be lit red.
aThe safety relay must not release N/O or N/C contacts.
6 Maintenance
6.1 Maintenance operations
Carry out the following maintenance operations at the specified intervals.
Maintenance operation as
needed
annually Testing interval
Clean the button surface X
Test the safety function X
Check cables for intactness
and firm fit
X
Check screw connections
for tightness
X
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 13/19
7 Disposal
Different types of electrical and electronic components must be recycled
according to their type. All applicable statutory, state and local laws and
regulations must be complied with.
8 Technical specifications
General data SC4
Sensor principle capacitive static-dynamic
Temperature range 0°C to +55°C (+32°F to +131°F)
Rated insulation voltage 300 V
Degree of contamination 3
Degree of protection IP 67
Housing material safeCAP Polycarbonate (PC)
Static discharge 8 kV EN 61 000-4-2
High-frequency radiation 10 V/m EN 61 000-4-3
Fast transients 2 kV EN 61 000-4-4
HF conducted 10 V EN 61 000-4-6
Radio interference class B EN 55 011
Output SC4
Contact configuration 1 NO, 1 NC
Relay type Electronic PhotoMOS relay
Minimum current 10 mA per contact
Switching capacity at 24 V 200 mA per contact
Reliability Semi-conductor level
Input SC4
Operating voltage 24 V DC +/-10%
Ripple max. 10%
Power consumption < 65 mA
14/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
Input SC4
Switching frequency 1 Hz
Actuation speed > 50 mm/s
8.1 Technical specifications, safety relay
MCR-225
General data
Wire cross-section 0.2 - 2.5 mm2
Operating temperature - 25 to + 55°C
Storage temperature - 25 to + 85 °C
Switching capacity NO 3 A / 230 V AC (AC 15)
NC 1 A / 230 V AC (AC15)
NO 1 A / 24 V DC (DC 13)
NC 1 A / 24 V DC (DC 13)
Resistance to short circuit
Max. safety fuse
Circuit breaker
6 A gL
C 8 A
Safety figures Value Unit
Category 4
PL e
MTTFd90 a, years
DCavg 99.0 [%]
PFHd7.77 e-9 [1/h]
average usage dop 220 [days/year]
average usage hop 12 [hours/day]
tcycle 140 [s/cycle]
Lifetime 20 years
Test Time Interval 1 months
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 15/19
TIP
Refer to the safety relay instructions for more technical specifications.
8.2 Dimensional drawing
8.2.1 SC4A
16/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
8.2.2 SC4B
safeCAP SC4
safeCAP SC4 with
MCR-225
1.3 17/19
9 Declaration of conformity
18/19 1.3 safeCAP SC4
safeCAP SC4 with MCR-225
Table of contents
Other Captron Safety Equipment manuals
