Lasermet ICS-7-OEM User manual

ICS-7-OEM Instruction Manual
02058-53-000 Issue 3 19 January 2021
LASERMET ICS-7-OEM
INSTRUCTION MANUAL
FAIL SAFE LASER
INTERLOCK CONTROLLER

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LASERMET ICS-7-OEM
Instruction Manual
Contents
1 Declaration of Conformity .................................................................................................. 3
2 Safety Warnings .................................................................................................................. 4
3 Concept ............................................................................................................................... 5
3.1 Differences between ICS-7-OEM and ICS-6-OEM ....................................................... 6
4 Summary of Evaluation of Compliance to EN ISO 13849-1:2015 ....................................... 7
5 Installation .......................................................................................................................... 8
5.1 Positioning ................................................................................................................... 8
6 Wiring ............................................................................................................................... 10
6.1 ICS-7-OEM Inputs ...................................................................................................... 11
6.2 ICS-7-OEM Illuminated Sign Control Output ............................................................. 14
6.3 Interlock Operator Output Contacts ......................................................................... 15
7 Expansion Boards.............................................................................................................. 20
7.1 Installing Expansion Boards ....................................................................................... 21
7.2 Use with Active Guarding .......................................................................................... 21
7.3 Expansion Board Fault Output .................................................................................. 21
8 Mismatch Detector ........................................................................................................... 22
8.1 Configurable Options for Safety Circuit Mismatch Events ........................................ 22
8.2 Clearing a Mismatch Fault Indication ........................................................................ 23
8.3 Mismatch Detector Remote Test and Reset ............................................................. 24
9 LED Indicators ................................................................................................................... 24
10 Operation ...................................................................................................................... 26
10.1 Starting Up ............................................................................................................. 26
10.2 Resuming Operation after an Interlock Switch has been opened ........................ 27
11 Fuses ............................................................................................................................. 27
12 Specifications ................................................................................................................ 28
13 Warranty ....................................................................................................................... 28
14 Contact Details .............................................................................................................. 29

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1 Declaration of Conformity
LASERMET LIMITED
INTERLOCK CONTROL PANEL ICS-7-OEM
Drawing Number 02058-00-000
DECLARATION OF CONFORMITY
This is to certify that the ICS-7-OEM has been tested in accordance with the following
directives and standards and found to comply.
Lasermet certifies that this product complies with the basic requirements for health
and safety as provided by the following directives and standards:
Directives: Machinery Directive 2006/42/EC June 2010
Low Voltage Directive 2014/35/EU
EMC Directive 2014/30/EU
Standards: EN ISO 13849-1:2015
Safety of Machinery – Safety-related parts of Control Systems
EN 60947-1:2007 +A2:2014
Low Voltage Switchgear and Controlgear
EN 61010-1:2010 +A1:2016
Safety Requirements for Electrical Equipment
Supplier:
Lasermet Limited
Lasermet House
137 Hankinson Road
Bournemouth
BH9 1HR
Dorset
United Kingdom
Country of Origin: England
Date: 31 July 2018

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2 Safety Warnings
This device is intended to be used as part of a safety system which may be used to protect personnel
and equipment from possible injury, damage, or loss.
As such it must be installed and wired according to these instructions and tested by suitably qualified
persons. No attempt may be made to tamper with the parts, open them, or use them outside of the
parameters contained herein.
The units are only designed to be fixed to surfaces using their inbuilt fixing holes. They must not
come into contact with each other or any other moving part when in use. The parts should never be
subject to impact or mechanical strain.
Safety switches should never be defeated or bypassed. It is imperative that all steps are taken to
ensure that any spare actuators are made unavailable, such that they cannot be used to defeat the
switch or reduce the protection offered by the system in any way.
Glossary
EN European Normalised (Standard)
ICS Interlock Control System
ISO International Standards Organisation
LED Light-Emitting Diode
NC Normally Closed
NO Normally Open
OEM Other Equipment Manufacturer
PL Performance Level
PLC Programmable Logic Controller
SIL Safety Integrity Level
V Volts
VDC Volts (Direct Current)

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3 Concept
The ICS-7-OEM provides control of an interlock system primarily intended to protect persons from
accidental exposure to hazardous lasers. It is able to monitor several doors, windows, curtains etc.
fitted with safety interlock switches and disable the laser if any are open. In this manual the term
‘Door Switch’ refers to any interlock switch which may be fitted to a door, cover, window blind etc.
The versatile ICS-7-OEM system can be connected to any number of door switches and can indicate
the status of up to 6 switches or groups of switches.
Two external volt-free contacts are required to arm the system. These might be from a PLC, for
example. When these contacts are both closed, provided the necessary interlock input conditions
are met (e.g. doors closed), the Controller will arm and enable the laser. If the Arm contacts are then
opened the system will disarm.
If any interlock input (e.g. door) is open when the external Arm contacts are closed the controller
will not arm. If the interlock is then closed the controller will still not arm. This is to prevent an
unexpected start-up of the laser. If the system fails to arm because an interlock is open (e.g. door
open), the Arm request should be removed and the interlock closed (e.g. close the door).
The ICS-7-OEM has a fully dual channel cross-checked architecture and when correctly wired can
realise a system compliant with EN ISO 13849-1 up to performance level ‘e’.
Eight safety interlock outputs each rated at 4A resistive, 50VDC, are provided to enable the laser,
operate door locks, or provide signals to a PLC. The interlock outputs are volt-free contacts. Seven
outputs close when the system is armed. The other output is normally closed and opens when
armed. Each output actually comprises two contacts, one for each channel, operated by different
relays. In the event of one contact failing to open, the other contact will open and the system is
then disabled, preventing further use and maintaining safety. The contacts can be configured for a
variety of options.
The ICS-7-OEM is able to directly control and monitor safety-rated power contactors which may be
used to switch single or three-phase laser mains supplies.
The ICS-7-OEM is able to monitor output devices such as shutters with feedback (such as Lasermet’s
LS-20 and LS-200 beam shutters).
The controller has a pair of isolated volt-free contacts which close in the disarmed state provided all
monitored devices are proven to be in the safe condition. These contacts may be used to operate
the ‘system disarmed’ or ‘laser off’ section of a dual message illuminated sign. They are marked as
‘System Disarmed’ on the unit.
The controller also has a pair of contacts which close to indicate that all the interlock inputs are
closed. This may be used, for example, to signal to a PLC that all doors are closed and is marked as
‘Doors Closed’ on the unit label.
The ICS-7-OEM has a mismatch detector which when wired to a full dual-channel system disables the
system in the event of a mismatch between the two safety circuits. This provides protection against
the single failure of a door switch etc.

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The ICS-7-OEM can accommodate expansion modules externally, and Lasermet offer a range of
modules including:
 Uncommitted Relays
 Active Guarding
 Safety Logic Plus
 Network Interface
Lasermet provides a full range of equipment including interlock switches, illuminated warning signs,
laser shutters, entry keypads with built-in fail-safe override timer, door locks, external power
supplies etc. which can be connected to the ICS-7-OEM to provide a complete system. Full support,
design and installation is available from Lasermet, please contact us for any queries. Contact details
are given at the end of this manual.
3.1 Differences between ICS-7-OEM and ICS-6-OEM
 Power supply to expansion modules is now switched on in the disarmed state,
allowing visual checking of Active Guarding status before arming is attempted
 An extra normally closed interlock output has been added in addition to the 7
normally open outputs
 Fuses and option switches are now accessible without removing the top cover
 Electronic over-current trips are used instead of fuses for the A and B
interlock supplies
 The case has been expanded to allow single rows of 5mm terminals
 An input/button has been added to reset faults latched on the Active Guarding
expansion module
 An output has been added to indicate a fault on the expansion interface.
 All inputs and output connections are now in ABBA format

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4 Summary of Evaluation of Compliance to EN ISO 13849-1:2015
To achieve a complete system performance level ‘e’ the system must be wired as described in this
manual using suitably rated door sensors and measures taken to minimise the effects of common
cause failures in the sensors and wiring which may be connected to the unit.
Achieved Characteristics:
Architecture Category 4
Performance Level (PL) PL = e
MTTFd 381 years
PFH [1/h] 2.47 x 10-8
(Based on MTTFd being “capped” at 100 years)
Mission Time 20 years
Diagnostic Coverage (DC) 99% (HIGH)

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5 Installation
The ICS-7-OEM is designed to be attached to a 35mm ‘top-hat’ style DIN rail inside a control cabinet.
It should always be enclosed in a cabinet that requires use of a tool or key to open to prevent
tampering and risk of touching live connections.
Whilst the unit itself operates on 24V it is possible that higher voltages fed from other equipment
may be present on its output contacts.
5.1 Positioning
The ICS-7-OEM should be mounted in a convenient position for wiring. It should be inaccessible by
operators. It has indicator lights on its top surface which would normally only need to be observed
by installation and maintenance personnel.
Provision should be made to prevent the unit from sliding along the DIN rail after fitting, for example
by the use of end clamps or other equipment.
During installation, wired connections will need to be made from the ICS-7-OEM to all the
interlocked doors, warning signs, laser interlocks, shutters, PLC and other equipment as required by
the system. Allowance should be made for wire retention such as plastic slotted trunking running
alongside both long sides of the unit.
All of the terminals are identified on the label on the top of the unit, see next page.

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Figure 1: ICS-7-OEM Top Label showing terminal identification.
NOTE: Holes in the label are shown in yellow and windows for LEDs
are shown in red
The indicator LEDs show the position of the interlock and arm input
signals and the state of the controller.
All dual-channel inputs and outputs are wired ABBA, with one
channel connected A-A and the other channel B-B.
Input signals are connected on the right (bottom) of the controller
and are indicated by a green background.
All output signals are connected on the left (top) of the controller.
The normally open interlock operator outputs 2-8 are indicated by a
pink background. The normally closed output 1 is indicated by an
orange background.
Status outputs and status indications are indicated by an orange
background.

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6 Wiring
The ICS-7-OEM is a versatile interlock system and there are a variety of ways in which it can be used.
Be sure you know which configuration you require before you attempt to wire the unit. If you
require further assistance, please call Lasermet technical help. Contact details are at the end of this
manual.
Example overall wiring scheme

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6.1 ICS-7-OEM Inputs
Mechanical Interlock Switches
Up to six dual-channel door/cover interlock switches may be directly wired to the ICS-7-OEM. By
making external connections, more switches can be added and arranged in groups.
The interlock switches are wired to the terminals labelled Input 1 through to Input 6. Each interlock
switch should have two safety contacts which are closed when the door is closed. Some door
contacts such as Lasermet’s IS-MECH switches have an additional monitor contact which closes
when the door is opened. This is not used in ICS-7-OEM.
A 4-way terminal block is provided for each door interlock switch. One of the safety contacts which
are closed when the door is closed is wired to the ‘A’ terminals. The other safety contact is wired to
the ‘B’ terminals.
The example diagram below shows a system with two doors wired for ISO 13849 performance level
‘e’. Each door has two switches.
Wiring for two doors

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If the system is required to perform to ISO 13849 performance level ‘e’, two switches are usually
required to be fitted to each door, with the safety contact of one switch wired to the ‘A’ terminals
and the safety contact from the second switch wired in a separate cable to the ‘B’ terminals. If there
is any possibility of both cables being damaged for the same reason simultaneously it may also be
necessary to route the cables in different paths.
If an Interlock input is not used, one wire link should be fitted to connect the ‘A’ terminals together,
and a second wire link to connect the ‘B’ terminals on each unused input connector such as shown in
the above example for inputs 3-6.
If the laser hazard is considered low, it is possible to use switches with only one safety contact. In
this case connect the switch across the ‘A’ terminals. Fit a wire link across the ‘B’ terminals. The
Mismatch Detector cannot be used and must be disabled, see the Mismatch Detector section below.
It is usual to use low voltage 4-core flexible cable for these connections and Lasermet can supply
suitable cable in standard PVC or low smoke zero halogen (LSZH) types.
If there are more than six doors they can be wired in groups. A common situation is where there are
double doors. Interlock switches need to be fitted to both, and the two doors can then be wired
together so that a single pair of monitor indication lights will illuminate on the front panel of the ICS-
7-OEM if either of the doors is open. The switches in a group should be wired with their safety
contacts in series. Each group may have several switches. An example diagram for two door interlock
switches wired in a group is shown below.
Coded Magnetic Interlock Switches
Coded magnetic switches supplied by Lasermet cannot be overridden by the use of a magnet. Wire
the safety circuits in the same way as described in the 'Mechanical Interlock Switches section. The
monitor contacts should not be used.

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The Lasermet IS-MDC-12 is a dual channel magnetic door switch. If the mismatch detector is used in
the ICS-7-OEM, any single contact failure in the door switch will be detected and the laser inhibited.
In this switch the red and blue wires are taken to the ‘A’ terminals and the black and white wires to
the ‘B’ terminals. The green and yellow wires are not used.
For the highest level of safety two separate door switches may be used, one wired to the ‘A’
terminals and one to the ‘B’ terminals.
Emergency Stop and Break Glass Switches
The ICS-7-OEM treats Emergency Stop switches in the same way as Door Interlock switches. Ideally
the Emergency Stop switch should have two contacts which open when the button is pressed (2NC).
Connect one safety contact, which opens when the button is pressed, to the ‘A’ terminals of the E
STOP terminal block. Connect the other safety contact to the ‘B’ terminals.
If there are two or more switches, connect the contacts in series as shown below.
The Emergency Stop input may be driven by volt-free isolated contacts from a PLC or safety relay if
desired. The contacts must both be closed for the system to operate and they should be arranged to
operate simultaneously to avoid being detected as mismatched by the ICS-7-OEM.
If an emergency stop is not used, a wire link must be fitted between the two ‘A’ terminals on the E
STOP terminal block, and a second wire link across the ‘B’ terminals.
NOTE: The E-stop switch should be checked periodically.
ICS-LJM and ICS-LJM-SO
When the ICS-LJM or ICS-LJM-SO is used with the ICS-7-OEM, the output from the LJM must go into
the Emergency Stop input on the ICS-7-OEM.

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6.2 ICS-7-OEM Illuminated Sign Control Output
Low Voltage DC Warning Signs
The following options are for 24VDC warning signs such as Lasermet’s Miniature and Ultra Warning
Signs. These signs must not be connected to the mains supply.
Option 1: One Way Illuminated Sign
The warning sign will come on when the controller is armed. One of the seven normally open
outputs of the ICS-7-OEM is used to illuminate the sign. This output must not then be used to
operate a laser interlock as well.
Option 2: Two way Illuminated Warning Sign
The ‘Laser Off’ warning sign will come on when power is applied to the ICS-7-OEM. This will go off
and the ‘Laser On’ warning sign will come on when the controller is armed. Note that in the case of
the Lasermet Miniature Warning Sign, both indications are displayed in the same unit.
Note that the contacts inside the ICS-7-OEM are rated at 4A maximum and this rating must not be
exceeded.

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Note regarding Sign Operation
If output devices such as LS-20 shutters or contactors are fitted, or if the laser has feedback contacts
which close to prove that it is in a safe condition and the feedback signal from such devices is taken
to the ‘Output Monitor’ terminals of the ICS-7- OEM, the sign green ‘Laser Off’ indication will not be
given if these devices are not proven to be in the safe condition or if they are removed from the
system.
6.3 Interlock Operator Output Contacts
The ICS-7-OEM has seven dual-channel volt-free interlock operator output contacts (outputs 2-8)
which may be used for various purposes including:
 Operating warning signs as shown above
 Controlling beam shutters
 Operating the laser’s interlock input
 Controlling door locks
 Signalling the state of the controller to a PLC
There is also one normally closed output which opens when the laser is armed (output 1). This may
be used for signs or for signalling the output state.
Beam Shutters
The ICS-7-OEM may operate one or more beam shutters and one or more laser interlocks. For
permanent fixed installations these may be directly wired to the ICS-7-OEM. Where there is any
possibility of the equipment being changed or moved it is often most convenient to be able to
unplug the equipment.
Lasermet provide a range of small distribution boxes which allow for convenient positioning of wall
or surface-mounted plugs for laser interlocks and sockets for shutters. The boxes are available with
different combinations of plugs and sockets.
Modern industrial lasers are usually equipped with dual channel interlock inputs which may be
directly connected to one of the dual channel outputs of the ICS-7-OEM as described later in this
manual.
Many smaller lasers only have a single channel interlock input which can present problems if the
safety system has to comply with ISO 13849 performance level ‘e’ since two methods of control are
usually required. Some lasers have internal beam shutters which may be controlled by the ICS-7-
OEM. If the laser has two means of disabling, e.g. interlock and internal shutter, it is recommended
that both are used. Otherwise it may be necessary to consider having an external shutter in addition
to the laser’s own interlock if a high safety integrity is required.
Lasermet’s beam shutters are supplied with suitable leads to plug into the distribution boxes. Open-
ended leads are provided for laser interlocks allowing the customer to fit the correct plug for their
laser.

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LS-10 Shutter
Use the above circuit. Note that old versions of LS-10 will only work off 12VDC.
LS-20 and LS-200 Shutter
The LS-20 and LS-200 Shutters can use the above circuit; however, it is recommended that the
monitoring circuit shown below is included to allow the ICS-7-OEM to monitor the shutter and to
detect any faults.
If using the LS-20 SIL3 twin shutter the circuit below must be used to achieve the SIL3 / PL ‘e’ rating.

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The LS-20 Shutter has its own distribution socket. The wiring connections inside the distribution box
are shown below:
Shutter with own Power Supply
If your shutters have their own power supply or are to be run from an existing supply, you can use
one of the controller outputs to operate them. If the shutter requires a single contact to operate it,
connect the A and B contacts of the controller output in series as shown in the wiring diagrams
above for LS shutters, so that the shutter closes if either one or both output contacts open.
The connections should be arranged so that the shutter closes when the Interlock Operator contact
opens. Any ICS-7-OEM output used for shutters must not also be used for laser interlock control.
The contact is limited to 4A resistive load. If your shutter is solenoid-based it may need a protection
diode fitted to prevent possible damage to the ICS-7-OEM.
Interlock Connectors
Any of the ICS-7-OEM output contacts may be used to operate a laser’s interlock control, provided
they haven’t been used for any other purpose. The contacts are closed when the ICS-7-OEM is
armed. If there is more than one laser each must use its own output connector on the ICS-7-OEM.
Interlock sockets of several lasers must not be connected together.
Where the controller is part of a fixed laser system it is usual to directly connect the two devices. For
lasers with a single interlock channel use the following connections:

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For lasers with dual channel interlocks, use the following connections:
Where the laser may be removed from the system or exchanged a Lasermet Distribution Box may be
used to provide a connection point convenient to the laser. In this case for lasers with a single
channel interlock the A and B ICS-7-OEM output channels are connected in series to pins 1 and 2 of
the plug of the distribution box. See the diagram below.
Leads are available in various lengths to plug into the distribution box. The other end of the lead is
unconnected to allow fitting of a plug suitable for the laser.
Most industrial lasers are now designed to be compliant with EN 13849-1 and feature two interlock
input channels. This will require a distribution plug and socket with more connections. Furthermore,
some lasers also include one or two ‘laser safe’ contacts which can be monitored by the ICS-7-OEM.
In this instance if either or both ‘laser safe’ contacts are not closed the ICS-7-OEM will not illuminate
the ‘Laser Off’ section of any such warning sign and arming will be inhibited. Depending on the
safety performance of the laser itself such a system could meet EN 13849-1 performance level ‘e’.
The wiring of such a laser is shown below. Please contact Lasermet for assistance with distribution
boxes, connectors and leads if required.
If other devices are using the Output Monitor terminals, for example an LS-20 shutter, all the safe
proving contacts for each channel should be wired in series to the Output Monitor connector such
that the circuit is complete when all devices are in the safe condition.

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If the Output Monitor terminals are unused a wire link must be fitted between the ‘A’ terminals, and
a second link between the ‘B’ terminals.
Electro-magnetic Door Locks
Use only fail safe door locks provided by Lasermet (electric door strikes or maglocks). These will
prevent access to the room while the laser is on while always allowing people to enter or leave the
room in the event of a power loss. In order to ensure that people can always enter or leave the room
in the event of an emergency it will be necessary to put an emergency stop or break glass switch
near each door. If in doubt call Lasermet technical help.
The door should be fitted with interlock switches (see section 6.2) so that the laser is disabled if a
door is opened using the break glass switch.
Note that several maglocks can be wired in parallel from the same ICS-7-OEM output provided the
4A maximum rating of the contact is not exceeded.

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Some locks can be configured for 12V or 24V supply. They should be set for 24V operation and run
off the 24V supply to reduce the current consumption to 0.25A per lock. To set the Maglock for 24V
operation, open the terminal access cover on the lock. Remove the two black links from the circuit
board and refit one of them across the middle two pins. Park the spare link with one side on one of
the empty end pins so it is not lost. If in doubt, refer to the instructions supplied with the maglock.
In all cases a diode rated at 1A 50V or more must be wired directly across the terminals of each door
lock. Lasermet’s Maglocks usually have the diode fitted as standard, in which case it is essential that
the supply is connected the right way round.
7 Expansion Boards
The ICS-7-OEM can be connected to one or more Lasermet Interlock Expansion Boards which
provide extra functionality.
Boards which are currently available include:
 Active Guarding Interface
Lasermet’s Active Guarding system is intended to be used with lasers which are potentially capable
of damaging or burning through their enclosures. The enclosure is lined with replaceable active
detection panels. If the laser burns through the panel it is shut down before it burns through the
enclosure. The fail-safe Interface is available in the form of backplanes and plug-in interface boards
and is able to monitor large enclosures. The ICS-7-OEM is able to automatically test the operation of
the Active Guarding each time the system is armed.
 Safety Logic Plus Interface
Safety Logic Plus consists of a range of fail-safe logic function blocks which can be hardwired to
realise a complex safety interlock. Each block is dual-channel crosschecked and does not use
processors or software. Programming is achieved through hardwiring. This means obsolescence is
minimised and the system is maintainable for a long service life. The Interface Board allows ICS-7-
OEM to read the output of a Safety Logic Plus system whilst automatically testing it and providing
fault protection.
 Relay Expansion Card
This module contains a number of uncommitted relays which may be connected as required to
provide extra functionality or for interfacing to alarm, security or process control systems.
Other types of expansion boards are under development.