Cedes Safe2+ User manual

Operation Manual

Safe2+

Safe4

Safety Light Curtain Systems

Active Optoelectronic Protective Device

Type 2 (Safe2+)

or Type 4 (Safe4)

based on IEC 61496-1, -2

English

IMPORTANT INFORMATION

FOLLOW THE INSTRUCTIONS GIVEN IN THIS MANUAL CAREFULLY. FAILURE TO DO

SO MAY CAUSE CUSTOMER COMPLAINTS AND SERIOUS CALL BACK. KEEP IN-

STRUCTION MANUAL ON SITE.

Serial Safety:

Safe4 / Safe2+ are extremely cost effective to purchase

and offer the user many technical advantages.

Safety light curtains for highest safety requirements!

Safe2+ / Safe4 Operation Manual

2 www.cedes.com © CEDES Safety & Automation AG / May 2008

Content

1. Approvals and Conformity.................... 2

2. Introduction........................................... 3

2.1. System design..........................................3

2.2. Special features .......................................3

3. Applications .......................................... 4

3.1. Typical applications .................................4

3.2. Applications restrictions............................4

3.3. Application conditions..............................5

3.3.1. Corner mirrors.................................5

4. Principles of operation.......................... 5

4.1. Mode of operation...................................5

4.2. Intelligent Laser Alignment System ILAS.....5

4.3. LED indicators .........................................5

4.4. Cascading...............................................6

4.5. Perimeter systems ....................................7

5. Installation............................................ 8

5.1. Regulations and standards .......................8

5.1.1. Safety distance to danger point .........8

5.1.2. Height of protective field...................8

5.1.3. Response time – light curtain.............8

5.1.4. Distance to reflective surfaces ...........8

5.1.5. Multiple light curtain arrangement ....9

5.2. Mechanical installation.............................9

5.2.1. Mounting brackets............................9

5.2.2. Intelligent Laser Alignment System ILAS

(Optional with Safe2+)...................10

5.2.3. Adjustment Procedure without ILAS..10

5.2.4. Adjustment Procedure with ILAS ......11

5.2.5. Remarks to ILAS .............................11

5.2.6. Testing the protection field..............11

5.3. Electrical Installation ..............................12

5.3.1. A connector cap.............................12

5.3.2. B connector cap .............................12

5.3.3. C connector cap.............................13

5.3.4. Test input to emitter........................13

5.3.5. Power supply..................................13

5.3.6. Bringing into operation...................13

5.3.7. Outputs .........................................13

5.3.8. Trouble shooting ............................14

5.3.9. OptiLink ........................................14

6. Interfacing to safety devices ............... 14

7. Dimensional drawings ........................ 16

7.1. System with integrated controller.............16

7.2. Systems with separated Controller...........17

8. Selection of a safety light curtain ....... 18

8.1. Check list ..............................................18

8.2. Selection table .......................................19

8.3. Special configuration .............................20

8.4. Accessories / Components .....................20

9. Inspection and service ........................ 20

9.1. Cleaning ...............................................20

9.2. Inspections ............................................21

9.3. Decommissioning ..................................21

10. Product labels ..................................... 21

11. Technical Data..................................... 22

12. Certificates .......................................... 23

12.1. TÜV certificate....................................... 23

12.2. CSA certificate....................................... 24

1. Approvals and Conformity

TÜV Rheinland Product Safety GmbH, performed

the CE - type examination according to the machin-

ery directive EC/98/37, appendix VI and the respec-

tive standards ICE 61496.

The CE - conformity declaration and the product ap-

proval certification (TÜV) is available at your nearest

CEDES dealer or on the homepage

www.cedes.com.

Warning

Safe2+ or Safe4 systems are only a safety protection

device if all instructions in this manual and in the

related documents are carefully followed and fully

complied with. In addition the installer is responsible

to comply with all local laws and standards.

If these instructions are not (or only partially) fol-

lowed, this may lead to serious injury or even death

and legal action against the responsible installer or

system integrator. In such a case claims against

CEDES are not valid.

This instruction manual is part of the light curtain

Safe2+ or Safe4. It must be kept accessible during

the whole life cycle for everybody who is in charge of

installation, operation, maintenance and safety con-

trol.

Operation Manual Safe2+ / Safe4

2. Introduction

Safe4 safety light curtains are active optoelectronic

protective equipments AOPE type 4 with object de-

tection capability of 14 mm or 30 mm. Safe4 has a

built-in fully redundant self-monitoring circuitry and

complies to annex VI of the European Machinery

Directive EC/98/37 and IEC 61496 as a safety com-

ponent. Safe4 is a control reliability device as well as

defined in ANSI B11.19-1990, 5.5 and OSHA 29

CFR 1910.212.

Safe2+ safety light curtains are active optoelectronic

protective equipments (AOPE) type 2 and comply to

annex IV of the European Machinery Directive

EC/98/37 and IEC 61496 as a safety component.

Moreover the systems comply as a control reliability

device as defined in ANSI B11.19-1990, 5.5 and

OSHA 29 CFR 1910.212.

A special feature of the Safe2+ system compared to

ordinary safety light curtains of type 2 is that the

controllers have a built-in fully redundant self-

monitoring circuitry. This feature makes the usual

implementation of a self test at the beginning of each

machine start unnecessary. The safety function of

each Safe2+ light curtain is never influenced in any

moment by the self test monitoring.

The big advantage for you as a user is that you can

run the Safe2+ system in the self test mode. So you

do not have to think about connecting and installing

an external test. You just have to wire a system cor-

responding to a type 4 system.

2.1. System design

Safe2+ or Safe4 light curtains consists of an emitter

and a receiver (Figure 1).

The emitter as well as the receiver of Safe 4 have a

standard built-in intelligent laser alignment system

ILAS.

By request the ILAS can be supplied in the Safe2+

safety light curtain.

This allows a much easier adjustment during installa-

tion and system testing compared to conventional

safety edges. The ILAS may also be used as a vibra-

tion indicator at the installation.

CEDES Safe4

Detection capability

(resolution)

Operating range

Protection height

Intelligent Laser Alignment System ILAS

Figure 1: Main system parameters

The products are a modular construction housed in a

very compact and sturdy extruded aluminium profile.

If space is limited, the controller may be separated

from the sensor by using an interconnection cable

(Figure 2).

Controller

separated

Standard

Protective field Controller

Figure 2: Integrated and separated Controller

2.2. Special features

The outstanding features of the safety light curtain

systems of Safe2+ or Safe4 are:

! Integrated self test mode, which make an ex-

ternal testing unnecessary

! Configuration with fitted intelligent laser

alignment ILAS (as an option for Safe2+)

! Finger (14 mm) and hand protection (30 mm)

available

! Wide dynamic range with a compact profile

type:

14 mm resolution: 0 m up to 9 m

30 mm resolution: 0 m up to 18 m, optional 6

or 5 up to 30 m

! Max. 256 beams per system

! Tolerant to dust, soiling, pollution

! Short circuit protected semiconductor outputs

! Electrical interface compatible to industry

standard

! Built-in diagnostic LED or optical interface

(OptiLink) for quick trouble shooting

! Very compact design: 30 x 40 mm (1.2" x 1.6")

! Very compact design for the whole dynamic

range

! Wide standard product range for resolution,

protective height, type of application

! Separate controller as an option

! Several protective fields by cascading

! Customer specific version on request

! Optical synchronisation, no electrical cable

needed between emitter and receiver

! Modern technology

! Insignificant power consumption

! Maintenance-free and cost effective

Safe2+ / Safe4 Operation Manual

4 www.cedes.com © CEDES Safety & Automation AG / June 2008

3. Applications

3.1. Typical applications

Depending on the risk analysis Safe2+ or Safe4

systems are used for (Figure 3):

! Entry / exit safeguarding

! Point-of-operation safeguarding

! Hazards area safeguarding

! Combination of entry and area safeguarding

! Combination of entry, area and point-of-

operation safeguarding

Typical areas of applications are:

! Robotic assembly line

! Welding robots

! Processing machinery

! Rotation machines

! Conveyor machines

! Automated paint shops

! Entry / exit of automatic storage facilities

Typical markets are:

! Automotive

! Apparatus

! Semi conductor industry

! Metal processing

! Paper processing

! Wood processing

! Glass manufacturing

! Textile industry

and at any place to protect working personnel from

dangerous machinery.

3.2. Applications restrictions

Safe2+ or Safe4 are is not designed and approved

for any application in explosive EX or radioactive

areas.

Safe2+ does not comply with the optical demands of

a type 4 light curtain according the international stan-

dard IEC 61496.

Exit / Entry Safeguarding

Point-of-Operation Safeguarding

Hazardous Zone Safeguarding

Figure 3: Typical applications

Operation Manual Safe2+ / Safe4

3.3. Application conditions

The safe application of the light curtain systems

Safe2+ or Safe4 needs certain precautions:

1. The control unit of the machine or system must

be able to be electrically stopped and the stop

time must be known.

2. The hazardous moving parts of the machine

must always be stoppable and must achieve a

safe position or complete standstill within the

specified stop time of the machine.

3. When installing Safe 2+ or Safe4, it has to be

ensured that overreach, under reach or unpro-

tected area situations are impossible by taking

all necessary steps.

Figure 4: Correct installation

Figure 5: Incorrect installation

For the professional installation and connection,

please consult the relevant laws and regulations.

The safety officer of the manufacturing facilities, the

local authorities (OSHA in USA, HSE in GB) or the

respective industry associations as well as the inten-

sively trained employees of CEDES are available for

any safety related queries.

3.3.1. Corner mirrors

The protective field between emitter and receiver can

be guided around a corner using a mirror to allow

safeguarding of two or three hazardous areas. Note

that using one mirror will reduce max. operating ran-

ge by approx. 20 %.

It is not recommended to use more than two mirrors

due to alignment difficulties that may occur.

As accessories two types of mirrors are available,

with different mounting plates and sizes. Detailed

information is available from CEDES.

4. Principles of operation

The emitter sends coded infrared light pulses to the

receiver, which evaluates them. If an object e.g. a

finger (14 mm) or a hand (30 mm) penetrates the

protective field, the fully redundant solid state Output

Signal Switching Devices OSSD of the receiver

switch off to stop the machine. As soon as the pro-

tective field is cleared, both outputs switch on again

(automatic restart).

4.1. Mode of operation

Safe2+ or Safe4 operates in the guard only mode

with automatic restart. Other modes of operation e.g.

PSDI mode (break mode), muting, external relay

monitoring can be realized using external safety

devices.

4.2. Intelligent Laser Alignment System

ILAS

The ILAS is a most convenient feature to make

alignment a pleasure. The ILAS can be activated at

any time during installation or operation. It provides

the possibility to check if the sensor is still perfectly

aligned. In addition it indicates any vibrations at the

mounting base.

4.3. LED indicators

POWER

Emitter

Power on

(orange) POWER

Receiver

Power on

(orange)

Output active

(green)

Output inactive

(red)

OK Normal operation

(green)

TEST Test input

(red)

OptiLink

(IR light) OptiLink

(IR light)

Figure 6: LED indicators

Safe2+ / Safe4 Operation Manual

6 www.cedes.com © CEDES Safety & Automation AG / June 2008

4.4. Cascading

Safe2+ or Safe4 allows one or several extension

modules to be connected by daisy-chaining to a

complete system (Figure 7). This can be used to

prevent someone from standing between the safety

device and the danger point (Figure 4). Any combi-

nations are possible, even mixed resolutions 14 / 30

mm. In every extension module an ILAS is integrated

for the simple and comfortable alignment depending

on the type (Safe2+ or Safe4) .

Following limitations shall be taken into considera-

tion:

• Maximum 256 light beams per controller

• The protective zone is made of units with

120 mm length

• 8 beams are used per unit with 30 mm resolution

• 16 beams are used per unit with 14 mm resolution

• 10 m maximum total length for light curtains, ex-

tension modules and connection cables combined

(Figure 8)

• Max. three ILAS may be operated simultaneously

• Only a CEDES prefabricated cable may be used

between the light curtains.

The extension modules are connected to the main

system via connection cables.

The customers defines:

• Main system (protective height, resolution, operat-

ing range)

• Length of connection cables

• Extension modules (protective height, resolution,

operating range)

• Accessories (mounting kit, electrical ports)

Due to safety reasons combined light curtain as de-

scribed above have to be configured and tested as

complete configuration by the manufacturer.

2 x entry safeguarding

2 x hazardous zone

safeguarding System length:

2 x length of hazardous zone safeguarding

+ 2 x length of entry safeguarding

+ 1 x length of connection cable

-----------------------------------------------

Total length (max. 10 m)

Figure 8: Connection of the back and the front side of a machine with only one Safe2+ / Safe4 cascading system. The total length of the

system is equal to the individual protective field lengths, plus connection cables added together.

Separated

Controller

2 protective

fields

3protective

fields

Figure 7: Possible configurations

Operation Manual Safe2+ / Safe4

4.5. Perimeter systems

Perimeter systems are usually produced by means

of several single beam light barriers. But the flexibil-

ity of the Safe2+ or Safe4 system allows also the

production of vertical entry safeguarding according to

the standard EN 999. Such systems are composed

of active and passive elements in one compact pro-

file. The element length of each is 120 mm.

The big advantage of Safe 2+ or Safe4 Perimeter

systems is the easy way of mounting and the un-

complicated way of starting up the operation. The

time needed to connect the wires and aligning the

optics is drastically reduced in comparison to stan-

dard Perimeter systems consisting of single beam

light barriers, where often mirrors are also included

which can only be positioned with difficulties.

The protective field and the active elements respec-

tively, are clearly recognized as black surfaces with

the integrated optical lenses. The not monitored

areas (passive elements) are also clearly indicated

as yellow surfaces.

400

900

Distance to reference plane [mm]

Reference plane (e.g. ground)

CEDES

300

1100

Distance to reference plane [mm]

Reference plane (e.g. ground)

700

CEDES

300

1200

Distance to reference plane [mm]

Reference plane (e.g. ground)

600

900

CEDES

Figure 9: Perimeter systems (2-, 3- and 4-beams), accord. to EN

999 [1998]

Safe2+ / Safe4 Operation Manual

8 www.cedes.com © CEDES Safety & Automation AG / June 2008

5. Installation

5.1. Regulations and standards

The compliance with the fundamental health & safety

requirements as detailed in the EU Machinery Direc-

tive EC/98/37 and control reliability according to

OSHA 29 CFR 1910.212, ANSI B11.19 and ANSI

B11.20 has to be achieved with the correct imple-

mentation of safety components. With the help of a

hazard analysis as laid out in EN 292 and EN 1050,

a comprehensive safety evaluation has to be made

when designing and planning machinery and ma-

chinery control equipment. If Active Optoelectronic

Protective Devices (AOPD) are used, the required

safety distances, sufficient protective height and all

application conditions must be considered during the

planning phase.

5.1.1. Safety distance to danger point

According to the standards, the Safe2+ or Safe4 light

curtain and the point of danger must be separated by

a defined safety distance. This minimum distance

safeguards that the danger point may only be

reached after the hazardous motion has stopped.

The safety distance (see also standards EN 294, EN

775, EN 811, EN 999) depends on

• Machine stop time

• Response time of the protective device (light

curtain + safety relays)

• Resolution of the protective device

• Approaching speed to the danger point

• Position of the AOPD

The approaching speed is dependent on safety dis-

tance Sas follows

S ≤500 mm, speed = 2 mm / ms

S > 500 mm, speed = 1.6 mm / ms

In cases of 'vertical' installation of the light curtains

within an industrial environment and a resolution of

the light curtain system d, (where 14 mm ≤d≤40

mm), the safety distance Sto the point of danger is

calculated according to the formula:

For 100 mm ≤S ≤500 mm:

S = 2 mm / ms x T + 8 x (d - 14)

For S > 500 mm

S = 1.6 mm / ms x T + 8 x (d - 14)

S = Safety distance in mm

T = Total response time in ms

(machine stop time + Safe2+ / Safe4 response

time + safety relay response time)

d = Resolution of Safe2+ or Safe4 in mm

In the case of perimeter systems (chapter 4.5) or

light curtains with a resolution d> 40 mm the safety

distance is calculated for vertical mounted light cur-

tains and horizontal approach, according to the for-

mula:

S = 1.6 mm / ms x T + 850 [mm]

More detailed information regarding safety distance

and safety height can be found in EN 999 or EN 294,

depending on mounting type of application.

5.1.2. Height of protective field

The protective field is clearly visible as the black

area with the optical lenses on the emitter and re-

ceiver.

In addition the height of the protective field Ais

found on the label of each system and in the selec-

tion tables, described in chapter 8.2 (resolution 14

and 30 mm).

Warning:

The laser beams of the ILAS are not part of to the

protective field.

Use only the protective field as mentioned on the

product label. Otherwise serious injury or death may

occur.

5.1.3. Response time – light curtain

The response time tRis found on the product label,

Configuration Tool or from the selection tables 8.2.

5.1.4. Distance to reflective surfaces

Reflective surfaces may cause specular reflections

within the emitter and receiver aperture angle, i.e. an

interruption of the protective field would not be recog-

nized (Figure 10).

dangerous point

reflective surface

optical axis

Figure 10: Distance to reflective surfaces

Should reflective surfaces arise, i.e. aluminium con-

tainer passing near the light curtain or if the danger

point itself is reflective, i.e. a steel blade, the safety

distance S2 must be increased, such that no reflec-

tive surface lies within the distance S2.

The increase of the safety distance is dependant of

the actual operation range R according to IEC 61496

and may be calculated as follows:

Safe4

S2= 72 mm für R < 3 m

S2= R x 0.0219 für R ≥3 m

Safe2+:

S2= 131 mm für R < 3 m

S2= R x 0.0437 für R ≥3 m

The safety distance may also be calculated with the

Configuration Tool.

Operation Manual Safe2+ / Safe4

5.1.5. Multiple light curtain arrangement

When using several optoelectronic safety devices in

the same application, the systems should be in-

stalled in such a way that they cannot interfere with

each other. Care must be taken that each receiver

only receives light from its own emitter (Figure 11).

Receiver Emitter

Emitter Receiver

Emitter Receiver EmitterReceiver

Figure 11: Multiple light curtain arrangement

The safety light curtain has been thoroughly tested

against light interferences according to the stringent

requirements of IEC 61496. Nevertheless any direct

interference into the receiver with other infrared

sources like through beam photoelectric sensors,

laser scanner, transmitters etc. should be avoided.

5.2. Mechanical installation

Be aware that a rigid, flat base, isolated against

shock and vibration should be selected to mount the

Safe2+ or Safe4. This in combination with the stan-

dard mounting brackets set will keep the initial

alignment during operation even in harsh industrial

environments.

5.2.1. Mounting brackets

The backside of the light curtain profile has continu-

ous grooves to fix the mounting brackets at any posi-

tion along the light curtain housing (Figure 22).

Edges up to a length of 1800mm are fixed using two

brackets. Longer edges with 3 brackets. Each sys-

tem includes necessary clamps (Standard 30mm

Mounting Kit, Part No. 106 500). They are adjustable

within ± 4º for a perfect alignment of the light curtain.

Optional available mounting brackets (Figure 12):

• Vertical mounting brackets for mounting the

light curtain in the vertical axis of the light cur-

tain. (± 4º adjustable)

• FGS mounting profiles (not adjustable)

• 180° Mounting, rotation ± 90°, for applications

where the mounting angle is not set using the

mounting frame.

• Damping kit helps to reduce vibration

Safe2+ / Safe4 Operation Manual

10 www.cedes.com © CEDES Safety & Automation AG / June 2008

The mounting brackets contain all necessary mount-

ing parts and an separate instruction sheet to en-

sure that the parts are assembled properly.

5.2.2. Intelligent Laser Alignment System

ILAS (Optional with Safe2+)

WARNING: Class 2 Laser

Do not expose your eyes to the laser to

prevent exposition to dangerous laser ra-

diation! Turn ILAS off if not used!

To switch on ILAS: Touch the hand symbol $

Operation: Laser beam is blinking

To switch off ILAS:

• Touch the hand symbol $again

• Automatically after 5 minutes

5.2.3. Adjustment Procedure without ILAS

1. Mount the emitter and the receiver with the ad-

justable mounting brackets. Make sure that the

longitudinal axis of both are oriented parallel. A

spirit level might help to find the correct posi-

tion.

29.5

M6 x 40

M4 x 16

Mounting kit 30mm (2 brackets)

Part No. 106 500

• For side mounting

• Adjustable by ± 4°

M4 x 12

M6 x 40

Mounting kit vertical 30mm (2 brackets)

Part No. 106 502

• For mounting in the vertical axis of the

light curtain

• Adjustable by ± 4°

FGS mounting profile

Part No. 106 503

• A special profile which is

compatible with existing

FGS-mountings.

• Adjustments has to be

made with the FGS-

mountings, if available.

47.5

Mounting kit 180° adj.

30mm (2 brackets)

Part No. 106 497

180° Mounting, rotation ±

90°, for applications where

the mounting angle is not set

using the mounting frame.

Figure 12: Different mounting brackets for a Safe2+ / Safe4

Operation Manual Safe2+ / Safe4

2. Take care that the receiver and emitter are ori-

ented in the same direction. This means, the

controllers of the emitter and receiver have to

be at the same end of the protective field.

It is not allowed to mount Safe2+ or Safe4 sys-

tems turned by 180° (Figure 13).

Sender

Empfänger

Sender

Empfänger

Incorrect

Correct

Figure 13: Layout of the emitter / receiver

3. After aligning the longitudinal axis of emitter

and receiver, rotate the receiver around the

longitudinal axis to find the receiving angle.

During rotation, the receiving angle is shown

when the green LED of the receiver controller

is on.

4. Adjust the receiver to the centre point of the

operating angle, and tighten.

5. After aligning the receiver rotate the emitter to

find the emitting angle. During rotation, the

emitting angle is shown when the green LED of

the emitter controller is on.

6. Adjust the emitter to the centre point of the op-

erating angle, and tighten.

7. Control the operation of the Safe2+ or Safe4

light curtain by using the test rod (Figure 15).

Introducing the test rod into the protective field

at any position must lead to a protective field

interruption (shining of the red LED on the re-

ceiver).

When mounting Perimeter Systems adjust the

heights according to the recommendations in the

standard EN 999.

5.2.4. Adjustment Procedure with ILAS

1. Mount the emitter and the receiver with the ad-

justable mounting brackets. Look for that the

longitudinal axis of both are oriented parallel.

Take care that receiver and emitter are ori-

ented in the same direction. This means, the

controllers of emitter and receiver have to be at

the same end of the protective field. It is not al-

lowed to mount Safe2+ or Safe4 systems

turned by 180° (Figure 13).

2. The ILAS is activated by touching the hand

symbol !at the emitter resp. at the receiver.

3. Adjust the emitter and receiver in a way that

both laser points hit the laser target on the op-

posite unit. Small deviations are harmless as

long as they are within the aperture angle.

4. Tighten all screws firmly.

5. Switch the ILAS off when aligned.

5.2.5. Remarks to ILAS

Due to dimensional tolerances the red ILAS light

spot deflects from the target center when the light

curtain is aligned optimal in the center of the operat-

ing range. The optimal operating point can be found

after alignment with ILAS (chapter 5.2.4) when mov-

ing the axis in X- (left, right) and Z- (up, down) direc-

tion. The optimal operating point is in the middle of

the two end points, where the receiver output

switches from active to inactive condition.

On optimal alignment of the light

curtain the ILAS light point can deflect

from the ILAS target point. The

maximum deflection adds up to the

following value due the operating

distance:

2 m R = 7 mm D = 7 mm

6 m R = 20 mm D = 21 mm

9 m R = 30 mm D = 32 mm

18 m R = 60 mm D = 63 mm

30 m R = 99 mm D = 105 mm

Figure 14: Adjustment with ILAS

5.2.6. Testing the protection field

After Installation and Alignment of the Safe2+/4

safety light curtain, the protection field has to be

tested with the test rod for the corresponding resolu-

tion (14 or 30 mm) according Figure 15. Introducing

the test rod into the protective field at any position

must lead to a protective field interruption (shining of

the red LED on the receiver).

When mounting Perimeter Systems adjust the

heights according to the recommendations in the

standard EN 999.

Emitter

Receiver

Figure 15: Correct testing of the protective field using a test

rod

Safe2+ / Safe4 Operation Manual

12 www.cedes.com © CEDES Safety & Automation AG / June 2008

5.3. Electrical Installation

The emitter and receiver are connected to the ma-

chine control using a 5-wire cable.

5.3.1. A connector cap

For the emitter and the receiver two M12 (for cable -

Ø 3 ... 6.5 mm) an two M16 cable glands (for cable -

Ø 3.5 ... 10 mm) are supplied.

Emitter Tx

Reveiver Rx

Figure 16: Terminal block connection

(see also Figure 22)

5.3.2. B connector cap

The B connector cap M12/5-pole plug connector

provides easy connection of a cable assembly. The

plug pin assignment is shown in Diagram 18.

Figure 17: M12/5 Pin connector

+24 VDC

0 V

OSSD 1

OSSD 2

+24 VDC

0 V

1) Operation with internal test

2) Test using a relay contact

3) Test using PNP output

Emitter

Lumberg 1 (brown)

Lumberg 3 (blue)

Lumberg 4 (black)

Lumberg 2 (white)

Lumberg 5 (grey)

Receiver

Lumberg 1 (brown)

Lumberg 3 (blue)

Lumberg 4 (black)

Lumberg 2 (white)

Lumberg 5 (grey)

Test 1

Test 2

Figure 18: Wiring of the connecting cables of the M12/5 Pin

Lumberg connector (Part no. cable: 301 347)

The wiring of such connecting plugs is given in fig-

ure 17 and figure 18.

24 VDC

0 VDC

Test 1

Test 2

Not connected

GND

24 VDC

0 VDC

Not connected

GND

1. Operation with internal test

2. Test using a relay contact

3. Test using a PNP output

24 VDC

0 VDC

Not connected

GND

OSSD 1

OSSD 2

24 VDC

0 VDC

OSSD 1

OSSD 2

Not connected

GND

Test 2

Test 1

+ 24 VDC

Emitter Tx

Reveiver Rx

OSSD1

+ 24 VDC OSSD2

GND

Operation Manual Safe2+ / Safe4

5.3.3. C connector cap

The receiver will be connected by a normal C con-

nector cap M12/5-pole connection cable to the T

connection of the emitter. The T connector A

(=Safety Relay) has a connection to the power sup-

ply and the OSSD output of the light curtain. The

test input is short-circuited.

+24 VDC

0 VDC

OSSD 1

OSSD 2

GND

(brown)

(blue)

(black)

(white)

(grey)

5.3.4. Test input to emitter

Normally the test input at the emitter is installed with

a short circuit jumper to activate the emitter. If an

external test is desired, a contact can be connected

to the test input).

The following points have to be considered:

• In case of operation in the modus "self moni-

toring" both OSSD outputs have to be con-

nected separately to the safety switching of

the machine.

Only with Safe2+:

• In case of connecting an external test it could

be that, depending on the test type, only one

OSSD output (OSSD1 or OSSD2) has to be

considered.

The timing of test input is as follows (Figure 19):

Time Value in ms

Response time on test signal t1≤tR+ 15

Time to test t2> t1

Restart time after test t3≤800

Test input

OSSD 1 / OSSD 2

t2t3

open

short circuited

Figure 19: Test timing diagram

tRmeans the response time of the respective

Safe2+ or Safe4 type (see product label).

Internal test Description Value

Continuous test current I 10 mA

Peak test current IP100 mA

Time of peak test current tP20 µs

Internal test Emitter Test LED

Emitter

Short circuited (closed) Active Green

Open Inactive Red

5.3.5. Power supply

Safe 2+ and Safe4 are devices of electrical safety

level III (extra low voltage). 24 VDC ± 20 % has to

be supplied by a power supply that complies with

IEC / EN 60204 and IEC / EN 60742. Such a power

supply meets the electrical safety requirements and

maintains the minimum power of 18 VDC during 20

ms even in the event of voltage dips

5.3.6. Bringing into operation

After the power supply has been applied to the

Safe2+ or Safe4 and the automatic power-up test is

successfully completed (power up test time < 3 s)

the green LED on the receiver and emitter will light

on. The system is now ready to operate.

The automatic power-up test will only be successful,

if the emitter and receiver are properly aligned, cor-

rectly connected and the protective field is not inter-

rupted.

Any intrusion of an object into the protective field will

switch the OSSD off within the specified response

time and the LED at the receiver toggles from green

to red.

5.3.7. Outputs

The two redundant Output Signal Switching De-

vices (OSSD) are fully monitored. Any short circuits

are detected. The maximum load is 0.4 A, higher

currents are limited through short circuit protection.

B= Receiver

C= Emitter

=Safety Relay

Tx Rx

=Safety Relay

OSSD 2+ 24 VDC

OSSD 1 0 VDC

GND

Safe2+ / Safe4 Operation Manual

14 www.cedes.com © CEDES Safety & Automation AG / June 2008

Increased output loads may be realized using exter-

nal safety interfaces.

Important information:

Safety devices for connection of Safe2+ or Safe4

the must be built with PNP logic. The outputs will be

periodically controlled for short-circuit and cross-

fault detection.

The output voltage at the solid-state outputs is de-

pendant on the power supply and the output load

(see chapter 11 Technical Data).

5.3.8. Trouble shooting

Possible errors and operation status are indicated

with the LED indicators on the emitter and receiver.

Also the OptiLink has an option that can be used for

the diagnostics (chapter 5.3.9).

Following combinations are relevant:

Table 1: Emitter

LED

Status Orange

(Power) Green

(ok) Red

(Test)

No power supply (external) off off on

Test input closed (external) on on off

Test input open (external) on off on

Controller error (internal) flashing off on

Protective field error (internal) flashing off flashing

Table 2: Receiver

LED

Status Orange

(Power)

Green

(Protective

field not

interrupted)

Red

(Protective

field

interrupted)

No power supply

(external) off off off

No sufficient power

(external) on off off

OSSD on (on-load operation,

protective field not inter-

rupted, normal)

on on off

OSSD off (off-load operation,

protective field interrupted or

insufficient alignment of the

system)

flashing off on

OSSD error (external, short

circuit between OSSD 1 and

OSSD 2, towards 0 V and 24

VDC)

all 3s

short time

off

off flashing

Controller error (internal) irregular

flashing off on

Protective field error (internal) flashing off flashing

External error: An external interface error can be

resolved by correcting the installation, due to

1. Receiver: short circuit of both OSSDs, of OSSD

to Usp, of OSSD to GND

2. Emitter: Test input open

3. No or too low power supply

4. Wrong configuration in case of cascading sys-

tems

5. Inadequate adjustment of emitter and receiver

Internal error (orange LED is irregularly flashing):

Please contact the nearest CEDES representative.

Normal operation

Emitter Receiver Operation status

Test input closed OSSD on Protective field free

Test input closed OSSD off Protective field interrupted

Test input open OSSD off Test active

5.3.9. OptiLink

As an accessory offers CEDES an infrared adapter

(OptiLink) including a software package for ex-

tended diagnostic purposes.

Figure 20: OptiLink

The adapter may be snapped on the controller dur-

ing normal operation and may be connected via the

interface to a MS-Windows personal computer for

diagnoses purposes. A detailed description about

extended diagnostic features is shipped with the

diagnostic package.

The OptiLink offers apart from the diagnosis of op-

erating conditions, the possibility to select and ana-

lyse the length of the interrupted protective field.

6. Interfacing to safety de-

vices

The interfacing of the light curtain with the machine

control has to be control reliability, i.e. a correct in-

terface with a safety PLC or safety relays with posi-

tive guided relay contacts.

Figure 21 - Diagram for automatic reset mode -

shows a diagram of a typical emergency stop relay

component.

Other applications are mentioned in the application

note "Safety Interfaces with Safe2+ / Safe4", on the

CEDES homepage or from safety relay manufactur-

ers.

Operation Manual Safe2+ / Safe4

Danger

The safety devices and the interconnection to

the machinery have to comply with the basic

safety requirements as mentioned in the cur-

rent regulations and standards.

Direct interfacing of a safety light curtain to

machine control that does not meet the neces-

sary safety integrity level, i.e. use of general

purpose PLCs or general purpose relays can

cause serious injury or death of persons.

Consult a professional safety engineer!

Danger

0 VDC

+24 VDC

Safe4

Sender/

Emitter

Safe4

Empfänger

Receiver

234567

245673

13 23 24

CEDES

SafeC S

14 S11 S12

A1 S33 S34

S21 S22 A2

Figure 21: Diagram for automatic reset mode with CEDES SafeC S (Part No: 103 105)

Safe2+ / Safe4 Operation Manual

7. Dimensional drawings

7.1. System with integrated controller

M16

M12

145

ILAS EmitterILAS target

25 A

ILAS targetILAS Emitter

Start of protective field

Pin 1

Pin 7

Figure 22: Dimensional drawing, cross Section with Pin-out of connector for systems with integrated controller

Emitter Receiver

Cross section with

connector pinning

Detail

mounting groove

Operation Manual Safe2+ / Safe4

7.2. Systems with separated Controller

min. 35

R min. 17

ca. 250

150

ø15

ontroller ext. = 176 22

16 125 35

15.5

Profile length B

Length of Protective field

Figure 23: Dimensional drawing, cross section with Pin-out of connector for systems with separated controller (dimensions emitter = dimen-

sions receiver)

Safe2+ / Safe4 Operation Manual

8. Selection of a safety light

curtain

8.1. Check list

In consideration of following points the selection of a

proper Safe2+ or Safe4 safety light curtain will be

simplified:

1. Regulations

Look up carefully the actual regulations and codes

applicable to the particular application in your coun-

try. Local authorities and professional organisations

as well as CEDES representatives will provide nec-

essary assistance.

USA: Occupation Safety and Health Administration

OSHA, others like ANSI, RIA and further pro-

fessional organisations

GB: Health and Safety Executive HSE, safety con-

sultants and professional organisations

2. Protective field

Determination of

• required operating range,

• protective height (available in increments of

120 mm),

• resolution (object detection capability: 14 mm

or 30 mm)

• and configuration of light curtain (special con-

figuration with extension modules)

Operating range, protective height and special con-

figuration must be chosen so that the danger points

are only accessible through the protective field.

3. Response time

The response time tR-BWS of Safe2+ or Safe4 can be

found on the product label and in the selection table

(next section). The response time can also be calcu-

late with the Configuration Tool.

The total response time of a system made of several

extension modules is the sum of the response time

of the single modules (sum of the protective heights

A). The total response time of the complete system

can be found on the product label.

Example:

You need a light curtain with 30 mm resolution made

of two segments to prevent someone from standing

between the light curtain and the danger point. The

vertical portion has a protective height of 960 mm,

the horizontal portion is 600 mm. The response time

of this configuration is identical with the response

time of a single light curtain with a protective height

of 1560 mm, which is the sum of 960 mm and 600

mm.

4. Corner mirrors

Using corner mirrors allows to safeguard two or

three protective fields with one light curtain.

Each corner mirror reduces the operating range by

appr. 20 % per mirror.

Operation Manual Safe2+ / Safe4

8.2. Selection table

Table 3: 14 mm Auflösung mit ILAS

Type Protective height A

(mm)

Total length B

(mm)

Response time tR

(ms)

Max. range

(m)

Resolution

(mm)

Weight per pair

(kg)

Part No.

System with

connector cap A

Part No.

Emitter Tx;

Receiver Rx

Tx: 106 430

Safe4-14-240 240 410 15.8 9 14 1.4 103 000 0002

Rx: 106 431

Tx: 106 432

Safe4-14-480 480 650 26.3 9 14 2.2 103 000 0004 Rx: 106 433

Tx: 106 434

Safe4-14-600 600 771 31.6 9 14 2.6 103 000 0005

Rx: 106 435

Tx: 106 436

Safe4-14-720 720 891 36.9 9 14 3.0 103 000 0006 Rx: 106 437

Tx: 106 438

Safe4-14-960 960 1'131 47.5 9 14 4.0 103 000 0008 Rx: 106 439

Tx: 106 440

Safe4-14-1200 1'200 1'372 58.1 9 14 4.5 103 000 0010 Rx: 106 441

Table 4: 30 mm Auflösung mit ILAS

Type Protective height A

(mm)

Total length B (mm) Response time tR

(ms)

Max. range

(m)

Resolution

(mm)

Weight per pair (kg) Part No.

System with

connector cap A

Part No.

Emitter Tx;

Receiver Rx

480 Tx: 106 442

Safe4-30-480 650 15.8 18 30 2.2 103 000 0014 Rx: 106 443

Tx: 106 444

Safe4-30-600 600 771 18.4 18 30 2.6 103 000 0015 Rx: 106 445

Tx: 106 446

Safe4-30-720 720 891 21.1 18 30 3.0 103 000 0016

Rx: 106 447

Tx: 106 448

Safe4-30-960 960 1'131 26.3 18 30 4.0 103 000 0018 Rx: 106 449

Tx: 106 450

Safe4-30-1200 1'200 1'372 31.6 18 30 4.5 103 000 0020

Rx: 106 451

Tx: 106 452

Safe4-30-1560 1'560 1'733 39.6 18 30 6.0 103 000 0023 Rx: 106 453

Tx: 106 454

Safe4-30-1800 1'800 1'973 44.9 18 30 7.0 103 000 0025

Rx: 106 455

The total length "B" (figure 21) of systems "with" or systems "without ILAS" differs by 50 mm. Detailed dimensional drawings are available on the CEDES Homepage under www.cedes.com.

Other protective heights up to 1'920 mm (resolution 14 mm) or up to 2'760 mm (resolution 30 mm) on request.

Safe2+ / Safe4 Operation Manual

8.3. Special configuration

All Safe2+ or Safe4 light curtains mentioned above

are also available with separated controllers or with

extension modules Naturally, all these versions are

provided with integrated self-monitoring and if re-

quired they also can be operate with external test,.

An extensive overview of all the possibilities that the

modularity of the Safe2+ or Safe4 systems offer are

shown in the "Configuration Tool" software. This

program can be obtained from any of your CEDES

partners and is also available from the CEDES

Homepage at www.cedes.com.

Your nearest CEDES sales office gives professional

support for the evaluation of a special configuration.

Due to safety reasons the special configuration has

to be assembled and tested at the manufacturing

site. You will receive a completed and tested system

with all safety relevant information on the type label

ready for installation.

Standard configuration

System with separated controller

Two separated protective fields with separated controller

Two separated protective fields by a passive zone

(Perimeter, static blanking)

Two separated protective fields

Three separated protective fields

Figure 24: Possible configurations

For further information, dimensional drawings in

different file formats are available on our CEDES

homepage.

An accessory which shows clearly the whole flexibil-

ity and great variety of the Safe2+ or Safe4 family is

a computer program named "Configuration Tool with

OptiLink".

The user defines with the help of an easy working

graphical editor the configuration:

1. Length and number of protective fields

2. Resolution

3. Connecting type (cable gland or M12/5 pin)

4. Length of the connection cables

5. System with or without ILAS

6. Safety category 2 or 4

The results given to the user are the

• exact designation of system for a clear identify-

ing of the customer design,

• response time and

• safety distance.

All data in the software "Configuration Tool" with

regards to safety, is checked and certified by TÜV

Rheinland. Calculations of the safety distances can

be printed out and become a part of the safety

evaluation documentation for the corresponding

application.

8.4. Accessories / Components

Table 5

CEDES

Part No. Description

106 427 Connection Cap A (Cable Gland) Tx / Rx

102 862 Connection Cap B (M12/5 Pin) Tx / Rx

106 429 Connection Cap C (Double M12/5 Pin) Tx

301 347 Cable, 5m, M12-M12, 5pol, M-F

102 792 Cable, 1m, MiniDin-MiniDin, 8pol, M-F

102 793 Cable, 3m, MiniDin-MiniDin, 8pol, M-F

106 500 Mounting kit 30mm (2 brackets)

106 502 Mounting kit vertical 30mm (2 brackets)

106 503 Mounting kit FGS 30mm (2 brackets)

106 497 Mounting kit 180° adj. 30mm (2 brackets)

106 501 Mounting kit silent block (2 pcs.)

103 006 Mirror 30

103 652 Mirror 60 with mounting column

102 965 ZCH Drawing opto edges Safe4/Safe2+

103 282 CD Configuration Tool / Optilink

104 565 OptiLink USB

103 105 Safety relay SafeC S

104 794 Safety relay SafeCIS3-2P-4IO

Edges up to a length of 1800mm are fixed using two

brackets. Longer edges with 3 brackets.

9. Inspection and service

All light curtains contain only electronics and there-

fore need no preventive maintenance.

9.1. Cleaning

The optical windows are to be cleaned with non-

aggressive materials only. The interval between

cleaning is dependant on the air pollution at the

installation.

Do not use aggressive solvents or abrasive sub-

stances. Otherwise range reduction and false

switching could arise

This manual suits for next models

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