Leuze electronic MC3x Series User manual

SAFE IMPLEMENTATION AND OPERATION
Original operating instructions
EN 2012/10 - 700021 We reserve the right to make technical changes

Leuze electronic MC3x 2
© 2012
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]

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1.1 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Approved purpose and foreseeable improper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Device overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Automatic start/restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Contactor monitoring (EDM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Selecting the position and arrangement of sensor and actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2 Mounting and aligning sensor and actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.1 Checklist - correct mounting of sensor and actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3 Mounting the Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.1 Terminal assignments of the Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1.1 MSI-MC310 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.2 Sensor pin assignment (1NC/1NO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1.3 MSI-MC311 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2 Sensor pin assignment (2NO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.3 Connection examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3.1 Connection examples with MC3xS1x sensors and MSI-MC310 Safety Relay . . . . . . . . . . . . . . . . 31
7.3.2 Connection examples with MC3xS2x sensors and MSI-MC311 Safety Relay . . . . . . . . . . . . . . . . 33
7.4 Connecting to the machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.5 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.6 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.7 Unlocking start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.1 Before the initial start-up and following modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1.1 Checklist  before the initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.2 To be performed periodically by competent persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.3 To be performed daily by the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.3.1 Check list  daily or at change of shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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10.1 What to do in case of failure? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.2 Rectifying the fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
13.1 Magnetically Coded Sensors, actuator, contact set 1NC/1NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
13.2 Magnetically Coded Sensors, actuator, contact set 2NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
13.3 MSI-MC310 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13.4 MSI-MC311 Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Leuze electronic MC3x 5
The information on the MC3x Magnetically Coded Sensor is divided into two documents. Document MC3x
Application information contains only the most important safety notices.
For safe implementation, testing and operation, you must download document MC3x Magnetically Coded
Sensors with MSI-MC3x Safety Relay, safe implementation and operation from
 http://www.leuze.com/
or request it from
 [email protected] or
 Tel. [phone]
Table 1.1: Documents on the MC3x Magnetically Coded Sensors with Safety Relay
Table 1.2: Warning symbols and signal words
Table 1.3: Other symbols
Detailed information for all
users
MC3x Magnetically Coded Sensors
with MSI-MC3x Safety Relay
Safe implementation and operation
On the Internet, download from:
http://www.leuze.com/
Basic information for techni-
cians and operating com-
pany
MC3x Magnetically Coded Sensors
with MSI-MC3x Safety Relay
Application information
Print document part no. 70002
included in the delivery contents
of the Magnetically Coded Sensor
Symbol indicating dangers to persons
NOTICE Signal word for property damage
Indicates dangers that may result in property damage if the measures for danger
avoidance are not followed.
CAUTION Signal word for minor injury
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in serious or fatal injury if the measures for
danger avoidance are not followed.
DANGER Signal word for life-threatening danger
Indicates dangers with which serious or fatal injury is imminent if the measures
for danger avoidance are not followed.
Symbol for tips
Text passages with this symbol provide you with further information.
Symbols for action steps
Text passages with this symbol instruct you to perform actions.

Leuze electronic MC3x 6
Table 1.4: Terms and abbreviations
The checklists (see chapter 8 Testing) serve as a reference for the machine manufacturer or supplier.
They replace neither testing of the complete machine or system prior to the initial start-up nor their periodic
testing by a competent person. The checklists contain minimum testing requirements. Depending on the
application, other tests may be necessary.
EDM External Device Monitoring
OSSD Output Signal Switching Device
RES Start/ tart interlock
PDF-M Magnetically Coded Sensors (Proximity Devices with defined behavior under
Fault conditions) with automatic monitoring (Self-Monitoring)
PDF-S Magnetically Coded Sensors (Proximity Devices with defined behavior under
Fault conditions) with Single fault tolerance
PFHdProbability of a dangerous Failure per Hour
Probability of dangerous Failure per Hour
MTTF Mean time to a dangerous failure
Mean Time To Failure
PL Performance Level
2NO Two contacts in "open" state without the presence of an actuator
xxx Placeholder for version

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Before using the MC3x Series, a risk evaluation must be performed according to valid standards (e.g.
EN ISO 12100-1, EN ISO 13849-1, EN ISO 14121). The result of the risk assessment determines the
required safety level of the Safety Relay, sensor and actuator.
The realizable category of integration in control circuits acc. to EN ISO 13849-1 is dependent on the used
contact block, wiring and evaluation.
For mounting, operation and testing, document MC3x Magnetically Coded Sensors with MSI-MC3x
Safety Relay, the application information as well as all relevant national and international standards, regu-
lations, rules and directives must be observed. Relevant and supplied documents must be observed,
printed and handed to the affected personnel.
Before working with Safety Relay, sensor and actuator completely read and understand the documents
applicable to your task.
In particular, the following national and international legal regulations apply for the start-up, technical
inspections and work with safety components:
 Machinery directive 2006/42/EC
 Electromagnetic compatibility directive 2004/108/EC
 EN 1088, Interlocking devices associated with guards
 EN 60204-1, Electrical equipment of machines
 EN 60947-5-3, Requirements for proximity switches
 Use of Work Equipment Directive 89/655/EEC supplemented by Directive 95/63 EC
 OSHA 1910 Subpart 0
 Safety regulations
 Accident-prevention regulations and safety rules
 Ordinance on Industrial Safety and Health and Labor Protection Act
 Device Safety Act
For safety-related information you may also contact the local authorities (e.g., industrial inspec-
torate, employer's liability insurance association, labor inspectorate, occupational safety and
health authority).
Make certain that, during all conversions, maintenance work and inspections, the system is securely
shut down and protected against being restarted.

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 Safety Relay, sensor and actuator are intended for use in protective door monitoring in accordance
with EN 1088 and EN 60947-5-3.
 They are used for the safety-related monitoring of moveable guards and, thus, for the protection of
persons at entry or access areas of points of operation on machines and systems (e.g., protective
door, sliding gate, protective hoods).
 Safety Relay, sensor and actuator must only be used after they have been selected in accordance
with the respectively applicable instructions and relevant rules, standards and regulations regarding
labor protection and safety at work, and after they have been mounted on the machine, connected,
commissioned, and checked by a competent person.
 When selecting the Safety Relay, sensor and actuator, it must be ensured that their safety-related
capability meets or exceeds the required Performance Level ascertained in the risk assessment. For
the table of safety-related characteristic parameters, see chapter 13 Technical data.
 The MC3x sensors may only be operated with the approved MC3x actuators and MSI-MC3x Safety
Relays. Proper function with respect to safety can be ensured only if compatible components are
used.
 Safety Relay, sensor and actuator must be in perfect condition and periodically inspected by compe-
tent persons.
 If the point of operation can be reached within the stopping time of the dangerous process, a Safety
Locking Device must be used instead of the Magnetically Coded Sensor.
 The guard must be dimensioned and mounted in such a way that reaching or stepping around is not
possible.
 MC3x only reports persons upon opening of the guard, not whether persons are located in the dan-
ger zone. For this reason, a start/restart interlock in the safety chain is essential for access safe-
guarding.
 Sensor and actuator must be connected to the fixed or moveable guard in a permanent and tamper-
proof manner. The mounting conditions must be observed (see chapter 6 Mounting).
 The sensors and their actuators are to be protected against strong physical shocks and vibrations.
Observe the permissible environmental conditions for storage and operation (see chapter 13
Technical data).
 Sensor and actuator must be protected against foreign bodies (e.g., iron filings and blasting agents).
 The normally closed contacts of the MSI-MC310 are used to signal the state. Use as safety-related
contacts is not permitted.
 Sensor and actuator must be connected in such a way that a dangerous process can only be acti-
vated while the guard is closed and so that a stop command that ends the dangerous process is trig-
gered upon opening of the guard.
 Cable gland, insulation materials and connecting wires of the appropriate protection rating are to be
used.
 Safety Relay, sensor and actuator must be replaced after a maximum of 20 years (see chapter 13
Technical data). Repairs or the exchange of parts subject to wear and tear do not extend the ser-
vice life.
 Damaged components must be replaced immediately.
 Sensor or actuator must neither be tampered with nor may their correct position be changed.
 External magnets must not be used nor may the contacts be bridged.
 No structural changes may be made to Safety Relay, sensor or actuator. When manipulating, the
protective function is no longer guaranteed. In addition, all guarantee claims against the manufac-
turer shall no longer apply.
Any use other than that defined under the approved purpose or which goes beyond that use of the Safety
Relay, sensor and actuator is considered improper use!

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Safety Relay, sensor and actuator must be used under the following conditions, .e.g.:
 The safety of multiple persons is dependent on the function of Safety Relay, sensor and actuator
(e.g. nuclear power plants, trains, aircraft, motor vehicles, incinerators, medical devices)
 Where subjected to strong physical shocks or in potentially explosive or easily flammable atmo-
spheres
 Danger posed by ejected objects or the spraying of hot or hazardous liquids from within the danger
zone
 Presence detection of persons in danger zones
 Looping into the safety circuit parts that are not relevant to safety
 The combination of non-approved parts with Safety Relay, sensor or actuator
 Combination with non-compatible controls (current limiting, logic)
 Mounting positions that enable reaching or stepping around
 Using the sensor or actuator as limit stop
 Insufficiently stable mounting locations or unsecured mounting of sensor or actuator
 Mounting on ferromagnetic materials.
Prerequisites for competent persons:
 They have a suitable technical education.
 They know the rules and regulations for occupational safety, safety at work and safety technology
and can assess the safety of the machine.
 They know the instructions for the safety components and the machine.
 They have been instructed by the responsible person on the mounting and operation of the machine,
the Safety Relay and the sensor with actuator.
Manufacturer and operating company must ensure that the machine and Safety Relay, sensor and actu-
ator used function properly and that all affected persons are adequately informed and trained.
The type and content of all imparted information must not lead to unsafe actions by users.
The manufacturer of the machine is responsible for:
 safe machine construction
 safe implementation of Safety Relay, sensor and actuator
 imparting all relevant information to the operating company
 adhering to all regulations and directives for the safe starting-up of the machine
The operating company is responsible for:
 instructing the operator
 maintaining the safe operation of the machine
 adhering to all regulations and directives for occupational safety and safety at work
 regular testing by competent persons
Leuze electronic GmbH & Co. KG is not liable in the following cases:
 Safety Relay, sensor and actuator are not used as intended
 Reasonably foreseeable misuse is not taken into account
 Safety notices are not adhered to
 Mounting and electrical connection are not properly performed
 Proper function is not tested (see chapter 8 Testing).
 Combination of sensor and actuator with controls,
 which have not been designed to be safety-oriented

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 for which the current limits are not compatible
 which have not been programmed to be compatible with the respective contact set
 although a PDF system certified in accordance with EN 60947-5-3 was provided