Leuze electronic SLS 78/R Quick start guide

Review-Stand, , 17. März 2016
SLS 78/R
Single Beam Safety Light Barrier
EN 50023453-01 - 2016/02 Subject to change without prior notice
CONNECTING AND OPERATING INSTRUCTIONS
Original Instructions

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Notes on Connecting and Operating Instructions
These connecting and operating instructions contain information on the proper use of
SLS 78/R single beam safety devices in accordance with its intended purpose.
All the information contained herein, in particular the safety notes, need to be carefully
observed.
Notes regarding safety and warnings are marked by this symbol .
Notes regarding important pieces of information are marked by the symbol .
These connecting and operating instructions must be stored carefully. It must be available
for the entire operating time of the SLS 78/R.
The Leuze electronic GmbH + Co. KG is not liable for damages caused by improper
use. Acquaintance with these instructions is an element of the knowledge required
for proper use.
© Reprints and reproduction, in whole or in part, are permitted only with the explicit
permission of
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone [phone] / 573-0
Fax [phone] / 573-199
[email protected]
www.leuze.com

Contents
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1 General................................................................................................................................5
1.1 Certifications ........................................................................................................................ 5
2 Safety ..................................................................................................................................6
2.1 Approved purpose and foreseeable improper operation.................................................... 6
2.1.1 Proper use............................................................................................................................6
2.1.2 Foreseeable misuse.............................................................................................................7
2.2 Competent personnel ..........................................................................................................8
2.3 Responsibility for safety ....................................................................................................... 8
2.4 Exemption of liability ............................................................................................................8
2.5 Operating mode.............................................................................................................................9
2.6 AOPD components for access guarding.............................................................................9
2.7 Object size ........................................................................................................................... 9
3 System design and possible uses.................................................................................. 10
3.1 Product features in overview..............................................................................................10
3.2 System design ................................................................................................................... 10
3.3 Applications ....................................................................................................................... 10
4 Display elements.............................................................................................................. 11
4.1 Transmitter .........................................................................................................................11
4.2 Receiver ............................................................................................................................. 11
5 Installation ........................................................................................................................ 12
5.1 General installation specifications ..................................................................................... 12
5.2 Safety distances.................................................................................................................12
5.3 Response time ................................................................................................................... 13
5.4 Protective field heights for SLS 78/R single beam safety devices for vertical access guar-
ding 13
5.5 Multiple beam setup ..........................................................................................................13
5.6 Radiation conditions ..........................................................................................................13
5.7 Distance to reflective surfaces...........................................................................................14
5.8 Deflecting mirror ................................................................................................................15
5.9 Ranges with applications with deflecting mirror ................................................................16
6 Electrical connection ....................................................................................................... 17
6.1 Relay contact spark suppression ......................................................................................17
6.2 Connection graphics..........................................................................................................18
6.3 Examples for the safe integration of the SLS 78/R in the machine control ........................18
7 Initial operation ................................................................................................................19
7.1 Alignment.....................................................................................................................................20

Contents
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8 Testing .............................................................................................................................. 22
8.1 Before the initial start-up and following modifications ....................................................... 22
8.1.1 Checklist - before the initial start-up .................................................................................. 23
8.2 To be performed periodically by competent personnel .................................................... 24
8.3 To be performed daily by the operating personnel........................................................... 24
8.3.1 Check list - daily or at change of shift ............................................................................... 25
8.4 Cleaning the glass optics............................................................................................................26
9 Faults and fault analysis/fault diagnostics.................................................................... 27
10 Technical data.................................................................................................................. 28
10.1 Safety-relevant technical data ........................................................................................... 28
10.2 Transmitter and receiver..............................................................................................................29
10.3 Transmitter......................................................................................................................... 29
10.4 Receiver............................................................................................................................. 30
10.5 Plug connector................................................................................................................... 30
10.6 Dimensional drawings .................................................................................................................31
11 Appendix........................................................................................................................... 37
11.1 Ordering information.......................................................................................................... 37
11.2 Accessories ....................................................................................................................... 37
11.3 Checklist ............................................................................................................................ 38
11.4 EC Declaration of Conformity ......................................................................................................40

General
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1 General
The SLS 78/R Single Beam Safety Device is an a type 4 active opto-electronic protective
device (AOPD) in accordance with EN IEC 61496-1, EN IEC 61496-2 and ISO 13849-1,
and is equipped with two safety relays (positive-driven contacts). A protective field of
infrared beams is generated between the transmitter and receiver of the safety light beam
device. If this protective field is penetrated the guarded machine goes to a safe state
before a person can be put in a dangerous situation.
The additional functions required for the access guarding in accordance with EN 61496-1,
Annex A, can for example, be implemented with a safety-set machine control unit or with a
safety sequential circuit (e.g. MSI-SR4).
Start/restart interlock and the monitoring of the output switching elements are integrated in
the safety sequential circuit, as it is offered by Leuze electronic GmbH + Co. KG (e.g.
MSI-SR4). It can issue the release or lock signal directly for the power-operated
machinery.
1.1 Certifications
Company
Leuze electronic GmbH + Co. KG in D-73277 Owen - Teck, Germany, has a certified
quality assurance system in compliance with ISO 9001.
Products
SLS 78/R single beam devices are developed and manufactured in compliance with
applicable European directives and standards.
TÜV NORD CERT GmbH
Certification center for product safety
Named center: 0044
Langemarckstr. 20
45141 Essen

Safety
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2 Safety
Before using the safety sensor, a risk evaluation must be performed according to valid
standards (e.g. EN ISO 14121, EN ISO 12100-1, ISO 13849-1, IEC 61508, EN 62061). The
result of the risk assessment determines the required safety level of the safety sensor (see
Table 2.1-1.). For mounting, operating and testing, document "SLS 78/R Single Beam
Safety Light Barrier" as well as all applicable national and international standards,
regulations, rules and directives must be observed. Relevant and supplied documents
must be observed, printed out and handed to the affected personnel.
Before working with the safety sensor, 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 sensors:
• Machinery directive 2006/42/EC
• Low voltage directive 2006/95/EC
• Electromagnetic compatibility directive 2004/108/EC
• Use of Work Equipment Directive
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and Labor Protection Act
• Device Safety Act
Notice!
For safety-related information you may also contact the local authorities (e.g., industrial
inspectorate, employer's liability insurance association, labor inspectorate, occupational
safety and health authority).
2.1 Approved purpose and foreseeable improper operation
Warning!
A running machine can cause severe injuries!
Make certain that, during all conversions, maintenance work and inspections, the system is
securely shut down and protected against being restarted again.
2.1.1 Proper use
• The safety sensor must only be used after it has been selected in accordance with the
respectively applicable instructions and relevant standards, rules and regulations
regarding labor protection and occupational safety, and after it has been installed on
the machine, connected, commissioned, and checked by a competent person.
• When selecting the safety sensor it must be ensured that its safety-related capability
meets or exceeds the required performance level PLr ascertained in the risk assess-
ment.

Safety
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The following table shows the safety-related characteristic parameters of the Single Light
Beam Safety Device SLS 78/R.
Tabelle 2.1-1: Safety-related characteristic parameters of the Single Light Beam Safety
Device SLS 78/R.
• The safety sensor protects persons at access points or at points of operation of
machines and plants.
• The safety sensor detects persons only when they enter the danger zone but cannot tell
whether there are any persons inside the danger zone. For this reason, a start/restart
interlock is mandatory.
• The construction of the safety sensor must not be altered. When manipulating the safety
sensor, the protective function is no longer guaranteed. Manipulating the safety sensor
also voids all warranty claims against the manufacturer of the safety sensor.
• The safety sensor must be tested regularly by competent personnel.
• The safety sensor must be exchanged after a maximum of 20 years. Repairs or the
exchange of parts subject to wear and tear do not extend the service life.
• Additional measures must be taken to ensure that the ESPE does not experience a
dangerous failure due to glare from other light sources.
2.1.2 Foreseeable misuse
In principle, the safety sensor is not suitable as a protective device in case of:
• danger of objects being expelled or hot or dangerous liquids spurting from the danger
zone
• applications in explosive or easily flammable atmospheres
• reachability of the point of operation by hand from the mounting location of the safety
sensor
• detection of the presence of persons in danger areas
Type in accordance with IEC/EN 61496 Type 4
Performance Level (PL) in accordance with
ISO 13849-1: 2008
PL e
Category in accordance with ISO 13849-1 Cat. 4
Mean probability of a dangerous failure per hour 
(PFHd) as a function of the mean number of annual
switching cycles of the relay nop*
nop = 4,800:
nop = 28,800:
nop = 86,400:
3.4 x 10-8 1/h
4.9 x 10-8 1/h
9.9 x 10-8 1/h
*nop = mean number of annual actuations, see C.4.2 and C.4.3 of ISO 13849-1: 2008
Use the following formula to calculate the mean number of annual actuations:
In doing so, make the following assumptions with regard to the use of the component:
hop = mean operating time in hours per day
dop = mean operating time in days per year
tcycle = mean time between the start of two successive cycles of the component (e.g
switching of a valve) in seconds per cycle
nop dop hop 3600s/htZyklus =

Safety
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• Optical influence on the ESPE through other forms of light beams:
e.g.
• wireless control devices on cranes
• radiation from welding sparks
• strobe lights
2.2 Competent personnel
Prerequisites for competent personnel:
• has a suitable technical education
• he knows the rules and regulations for occupational safety, safety at work and safety
technology and can assess the safety of the machine
• he knows the instructions for the safety sensor and the machine
• has been instructed by the responsible person on the mounting and operation of the
machine and of the safety sensor
2.3 Responsibility for safety
Manufacturer and operating company must ensure that the machine and implemented
safety sensor 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 the safety sensor
• imparting all relevant information to the operating company
• adhering to all regulations and directives for the safe starting-up of the machine
The operator of the machine is responsible for:
• instructing the operating personnel
• maintaining the safe operation of the machine
• adhering to all regulations and directives for occupational safety and safety at work
• regular testing by competent personnel
2.4 Exemption of liability
Leuze electronic GmbH + Co. KG is not liable in the following cases:
• safety sensor is not used as intended
• safety notices are not adhered to
• reasonably foreseeable misuse is not taken into account
• mounting and electrical connection are not properly performed
• proper function is not tested
• changes (e.g., constructional) are made to the safety sensor

Safety
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2.5 Operating mode
The SLS 78/R works in the “Protective mode without restart interlock” operating mode.
With a connection between terminals 3 and 4 the transmitter sends pulsed infrared light.
With reception of the light beam the OSSD outputs of the receiver switch on. With
interruption the contacts open within the system response time. As soon as the light beam
is free again the OSSDs turn on again automatically.
Important additional functions such as restart interlock, contactor monitoring or muting
can be implemented with MSI series safety sequential circuits.
2.6 AOPD components for access guarding
For these purposes the active opto-electronic protective device (AOPD) consists of the
single light beam safety device (transmitter and receiver), the deflecting mirrors and the
safety sequential circuit with start/restart interlock. All elements of this system must be
coordinated with one another to guarantee safe operation.
It applies for the SLS 78/R that people are only detected during the access; their presence
in the danger zone, however, is not detected! If a person interrupts the light beam or if
there is an AOPD fault, the safety sequential circuit must therefore go into safe interlock.
The start/restart interlock may only be unlocked via a start/restart button, which must be
installed so that the danger area can completely seen from its installation point. It must be
impossible to reach the button from the danger area.
Note!
A harmonized safety system in accordance with the requirements of safety category 4 is
achieved when, for example, the safety sequential circuits MSI-SR2 or MSI-SR2/F
(accessories provided by Leuze electronic GmbH + Co. KG) are used, or the sequential
circuit is set up in accordance with the circuitry example (see chapter 6.3).
2.7 Object size
The SLS 78/R is suitable for detecting objects with a minimum diameter of 30 mm.

System design and possible uses
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3 System design and possible uses
3.1 Product features in overview
• Relay outputs with positive-guided safety contacts
• Easy connection with transparent terminal area
• Plug accessories in acc. with DIN 43651
• Glass optics with spacing bolts for mounting laser alignment aid
• Integrated optics heating for use with extreme ambient conditions
• Compact aluminum housing
• Safe integration in the control system with MSI series safety interfaces
3.2 System design
The SLS 78/R consists of a transmitter (SLS 78/2 SE-24 V) and a receiver SLS 78/RE-
24 V). With free light path between transmitter and receiver the receiver switches on. The
system is set to the frequency of the light pulses. Constant light or other light pulses are
not evaluated. The device is configured for use in harsh environmental conditions. With
the cable connection the requirements of protection rating IP 65 are met; the SLS 78/R is
therefore dust-proof and water-protected. An integrated optics heating prevents the
optics from fogging up on the inside (within specifications).
The system is designed for distances from 0 to 60 m. Errors in the system are detected
within the response time (20 ms) and cause the dangerous movement to switch off.
Transmitter and receiver of the light beam device work with a supply voltage of 24 V DC.
3.3 Applications
Active opto-electronic protective devices with safety sequential circuits are suitable, for
example, for the following areas of application:
• Processing machinery in the metals industry
• Setting machines in the glass and ceramics industry
• Robot application areas
• Automated stacking systems/packaging machinery, etc.
• Storage installations and equipment
• Print and paper processing machinery
• Plastics and rubbers industry
• Wood processing industry machinery
Warning!
The SLS 78/R may never be used as the sole arm, hand or finger protection (e.g. on metal-
processing presses).

Display elements
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4 Display elements
The LED display elements provide quick information on the operating status of the
transmitter and the receiver.
4.1 Transmitter
LED 1 (green): Transmitter is switched active when LED lights
4.2 Receiver
Bild 4.1-1: Transmitter LED display
Bild 4.2-1: Receiver LED displays
Red (1) Yellow (2) Green (3) Description
On Off Off Protective field not free
On Flashing Off Protective field not free; reception level too low
Off Flashing On Protective field free; no function reserve
Off Off On Protective field free; function reserve available
On On Off Fault

Installation
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5 Installation
5.1 General installation specifications
The general safety precautions in chapter 2 must be observed.
The devices must basically be installed in such a way that the danger area can only be
reached by interrupting the beams and a sufficient safety distance between danger area
and protective field is ensured.
The dimension details required for the installation are provided in chapter 10.6.
5.2 Safety distances
The light beam safety device must be mounted at a great enough distance from the
dangerous movement. With an interruption of the light beam it must only be possible to
reach the danger area when the machine has already stopped its movement.
The safety distance “S” between light beam device and danger area is calculated with the
following formula:
S = (K·T)+C (in acc. with EN 999)
S: Safety distance between light beam device and danger area (mm)
K:Approach speed (constant 1600 mm/s)
T: Delay time between beam interruption and the machine’s
motionless state (s)
C:Safety constant = 850 mm
An example:
The beam heights of a light beam device are 400 mm and 900 mm.
The approach speed (T) is set to 1600 mm/s,
the delay time is 0.2 s.
S = 1600 mm/s · 0.2 s + 850 mm
S = 1170 mm
The safety distance must therefore be at least 1170 mm.
Bild 5.2-1: Safety distances
400 mm
900 mm
a
c
b

Installation
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5.3 Response time
The SLS 78/R response time is 20 ms.
5.4 Protective field heights for SLS 78/R single beam safety devices for
vertical access guarding
With the installation of SLS 78/R single beam safety devices as access or area guarding,
danger areas must not be accessible by crawling under, stepping over or reaching over
the light beams. The number of beams and their distances depend on the risk assessment
and the specifications of the individual machine.
EN 999 recommends the following guarding levels:
Tabelle 5.4-1: Guarding heights
5.5 Multiple beam setup
With multiple beam setups the light beams must be parallel to the reference level (e.g.
floor) and aligned parallel with one another. Each beam direction must be provided
inversely here. Otherwise the light beams could influence each other and impair the safety
function. Please observe chapter 5.6.
5.6 Radiation conditions
The SLS 78/R transmitter and receiver have a maximum permissible light beam radiation
angle of ± 2° to the optical axis (with protective field widths of more than 3 m).
Number of beams Height above reference plane,
e.g. floor in mm
4
3
2
300, 600, 900, 1200
300, 700, 1100
400, 900
Bild 5.5-1: Multiple beam setup
b
a
a
b
a = Transmitter
b = Receiver
a = Transmitter
b = Receiver
c = Deflecting mirror

Installation
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5.7 Distance to reflective surfaces
Reflective surfaces within the ± 2° transmission and reception light taper can cause
deflections and therefore non-detection of parts of the body. Therefore a minimum
distance “a” between the optical axis of the SLS 78/R and reflective surfaces, such as
shiny machine parts or material containers, must be complied with. The greater the
distance between transmitter and receiver, the greater the distance “a” to be maintained.
This distance is calculated from the beam spread (± 2.0°) and the distance between
transmitter and reflective surface and protective field width. The following graphic shows
the correct installation and the distance “a” depending on the protective field width.
Bild 5.7-1: Wrong: Danger caused by deflection
Bild 5.7-2: Right: No danger caused by deflection
2˚
2˚
de
f
a = Distance to reflective surface
b = Protective field width
c = Reflective surface
d = Transmitter
e=Receiver
f=Object
de
f
2˚
2˚
c
a = Distance to reflective surface
b = Protective field width
c = Reflective surface
d = Transmitter
e=Receiver
f=Object

Installation
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5.8 Deflecting mirror
A series of important factors must be taken into account with use of deflecting mirrors:
• A range loss occurs with all light beam deflections with deflecting mirrors.
• A dirty deflection mirror must always be prevented.
• The environmental conditions must taken into account, as vapors and dusty air also
considerably restrict the range.
• The distances between transmitter and deflecting mirror and between receiver and
deflecting mirror must not be less than 0.5 m.
Examples for applications with deflecting mirrors:
Bild 5.7-3: Minimum distance of the multiple light beam safety device from
reflective surfaces
Bild 5.8-1: Example 1 for applications with deflecting mirror, side view
Distance “a” (m)
Protective field width “b”
Transmitter
Receiver

Installation
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5.9 Ranges with applications with deflecting mirror
Tabelle 5.9-1: Ranges with applications with deflecting mirror
Bild 5.8-2: Example 2 for applications with deflecting mirror, top view
Configuration Maximum range with 0.85 range factor
SLS 78/R without deflecting
mirror
60 m
SLS 78/R with 1 deflecting
mirror
51 m
SLS 78/R with 2 deflecting
mirror
43 m

Electrical connection
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6 Electrical connection
• Installation and wiring of the SLS78 /R is to be performed in accordance with applicable
standards and safety regulations, particularly when connecting dangerous switching
voltages.
• The electrical connection must be performed by experienced personnel. Knowledge of
all safety notes contained in these operating instructions is part of this competence.
• The external supply voltage of 24 V DC +/- 20% must guarantee safe isolation from the
mains voltage in accordance with IEC 60742 and be able to bridge a power outage
period of at least 20 ms. Leuze electronic GmbH + Co. KG offers suitable power
supplies (see list of accessories in the Appendix chapter 11.2). The power supply
selected must not supply any other parts of the machine with power other than the
safety components connected. Transmitters and receivers must be supplied from a
shared power supply and must be fused against overcurrent.
• Basically both safety related switching outputs OSSD1 and OSSD2 must be looped into
the work circuit of the machine.
• The start/restart button for unlocking the restart interlock must be mounted in such a
way that it cannot be reached from the danger area and the entire danger area is fully
visible from its installation position.
• It is vital during the electrical installation that the power of the machine or system to be
secured is switched off locked, so that the dangerous movements cannot be started up
again unintentionally.
Connection system
Warning:
The housing cover must be screwed off before the electrical connection. Before opening
the cover, the SLS78/R must be disconnected from power. Where required the cover
contact (yellow/green cable) must be removed and replaced again before re-mounting the
cover.
The PG cable glands are suitable for cables with a diameter of 7 to 10 mm. The minimum
conductor cross-section is 0.25 mm2.
Warning:
The PG cable glands and the housing cover must be properly screwed tight so that the
specified IP 65 protection rating for the housing is guaranteed.
The union nut must be screwed tight with the plug configuration (in acc. with DIN 43651).
The sequence control must be connected with the relay outputs in accordance with the
connection graphics. According to the applicable regulations for type 4 AOPDs both
make contacts must be used for the safe switch-off of the technical device.
The contacts must be protected with a fuse (3 AmT).

Electrical connection
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Notice!
Laying cables!
• Lay all connection cables and signal lines within the electrical installation space or
permanently in cable ducts.
• Lay the cables and lines so that they are protected against external damages.
• For further information: see EN ISO 13849-2, Table D.4.
6.1 Relay contact spark suppression
Suitable spark extinction elements (e.g. RC modules, varistors or recovery diodes) are
mandatory with switching inductive loads such as contactors and relays. They must be
switched parallel for inductance.
These extend the delay times of inductive switching elements.
6.2 Connection graphics
Bild 6.2-1: Terminal version connection
1234
a
24 V DC 0 V
1234
24 V DC 0 V
56
a = Active
Transmitter Receiver

Electrical connection
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6.3 Examples for the safe integration of the SLS 78/R in the machine
control
Various SLS 78/R connection options are possible. If the safety-related control system of
the machine has the interlocking and monitoring functions required for the integration,
such as “Start/restart interlock” and “Contactor monitoring", then the direct connection of
the single beam safety device to the control system is possible. The functions are
performed by the MSI-SR4 in the following example.
Bild 6.2-2: Plug version AS78-01/AS78-02 connection
3
5
2
6
1
4
1
6
5
4
3
2
+24V 0V
3 4 1 2 6 3 5 41 2
1 2 3 4 5 6
1 2 3 4
+24V 0V

Coding example
Receiver
Transmitte

Initial operation
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7Initial operation
Warning:
Before putting the SLS 78/R into operation for the first time on a power-driven production
machine, an experienced and commissioned person with suitable training must check the
entire setup and the integration of the opto-electronic protective device into the machine
control system.
Before connecting the supply voltage for the first time and while the transmitters and
receivers are being aligned, it must also be ensured that the outputs of the optical safety
device do not have any effect on the machine. The switching elements that finally set the
dangerous machine in motion must be safely switched off and secured from restarting.
The same precautionary measures apply after every change made to the optical
protective device, e.g. after repairs or during maintenance work, after an alignment or
after longer stopped periods.
Only after it has been determined that the opto-electronic protective device functions
correctly and without fault, including the safety sequential circuit, can it be integrated into
the machine’s control circuit!
Bild 7.0-1: Example: SLS 78/R with MSI-SR4
SLS 7 8 / 2 SE- 2 4 V
+24V
SLS 78/ RE- 24V
+24V
0V 0V PE PE
PE2
2PE
2
-W1
PE
PE
-W2
2
4 51 3 4
5
6
-A2 1 3
1
-W1
-A1
431
-W2
Var . A
-K3 -K4
Var . B
-K4
-K3
6
0V
+24V
PE
14 24 42
13 23 41
A1
A2
-K3
1
2
1
2
L+ L+
L- L-
-S1
-K3
-K4
+24V
0V
MSI-SR4
A1
-A3
A2
S22 S12 S31 S33 S34 S35
2 AOPD-
1 AOPD+
33
34
A1
A2
-K4
1
2
2 AOPD+
IV-0
RES-0
RES-I
*
*
1
2
1
2