Leuze electronic SOLID-2SF-M Quick start guide

SOLID-2SF-M
Guarding the delivery of sheet
fed offset printing machines
604058 - 2015/04 Subject to change without prior notice
CONNECTING AND OPERATING INSTRUCTIONS
Original Instructions

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Notes on Connecting and Operating Instructions
This connecting and operating instructions manual contains information on the proper use
of SOLID-2SF-M Multiple Light Beam Safety Devices in accordance with its intended
purpose. It is included with delivery.
Warning!
All the information contained herein, in particular the safety notes, must be carefully obser-
ved.
This connecting and operating instructions manual must be stored carefully. It must be
available for the entire operating time of the optical safety device.
Notes regarding safety and warnings are marked by this symbol .
Notes regarding important pieces of information are marked by the symbol .
Leuze electronic GmbH + Co. KG is not liable for damage resulting from improper use
of its equipment. Familiarity 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 - Teck / Germany
Telefon [phone] / 573-0
Fax [phone] / 573-199
[email protected]
www.leuze.com

Contents
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1 General................................................................................................................................ 6
1.1 Certifications ........................................................................................................................ 6
1.2 Symbols and terms .............................................................................................................. 7
2 Safety .................................................................................................................................. 9
2.1 Approved purpose and foreseeable improper operation...................................................... 9
2.2 Proper use ........................................................................................................................... 9
2.2.1 Foreseeable misuse.....................................................................................................................10
2.3 Competent personnel......................................................................................................... 11
2.4 Responsibility for safety ..................................................................................................... 11
2.5 Exemption of liability .......................................................................................................... 11
3 Safety notes...................................................................................................................... 12
3.1 The opto-electronic protective device ................................................................................ 12
3.2 Transmission channel ........................................................................................................ 13
4 Display elements.............................................................................................................. 14
4.1 Transmitter status displays ................................................................................................ 14
4.2 Receiver status displays .................................................................................................... 15
4.2.1 7-Segment display .......................................................................................................................16
4.2.2 LED displays ................................................................................................................................16
5 Installation ........................................................................................................................ 17
5.1 Location of the AOPD ........................................................................................................ 17
5.2 Calculating the safety distance .......................................................................................... 17
5.3 Minimum distance from reflective surfaces........................................................................ 18
5.4 Mechanical mounting ......................................................................................................... 19
5.5 Mounting types................................................................................................................... 19
5.5.1 Standard mounting.......................................................................................................................19
5.5.2 Mounting with swiveling brackets.................................................................................................20
5.5.3 Side mounting ..............................................................................................................................20
6 Electrical connection....................................................................................................... 21
6.1 M12 connection.................................................................................................................. 21
6.1.1 Transmitter ...................................................................................................................................21
6.1.2 Testing .........................................................................................................................................22
6.1.3 Receiver .......................................................................................................................................23
7 Troubleshooting............................................................................................................... 25
7.1 What should I do if an error occurs? .................................................................................. 25
7.2 Diagnostics ........................................................................................................................ 25
7.2.1 Transmitter diagnostics ................................................................................................................25
7.2.2 Receiver diagnostics ....................................................................................................................25
7.3 AutoReset .......................................................................................................................... 26

Contents
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8 Technical data .................................................................................................................. 27
8.1 General data ...................................................................................................................... 27
8.1.1 Beam data ................................................................................................................................... 27
8.1.2 Safety relevant technical data...................................................................................................... 27
8.1.3 General system data.................................................................................................................... 27
8.1.4 Transmitter, signal input .............................................................................................................. 28
8.1.5 Receiver, transistor outputs ......................................................................................................... 29
8.2 Dimensions, weights ..........................................................................................................30
8.2.1 Multiple Light Beam Safety Devices ............................................................................................ 30
8.2.2 Mounting bracket dimensions ...................................................................................................... 31
9 Order data......................................................................................................................... 33
9.1 Scope of delivery ............................................................................................................... 33
9.2 Order numbers................................................................................................................... 33
9.3 Accessories........................................................................................................................ 33
10 Tests.................................................................................................................................. 35
10.1 Testing before initial operation........................................................................................... 35
10.2 Regular tests...................................................................................................................... 35
10.3 Daily testing with the test rod .............................................................................................36
10.4 Checklists........................................................................................................................... 37
10.4.1 Checklist for access guarding...................................................................................................... 37
10.5 EC Declaration of Conformity ............................................................................................ 38

Contents
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General
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1 General
The SOLID-2 SF Multiple Light Beam Safety Devices are optimized for use on sheet delivery
on sheet-fed printing machines. This requires defined interruption of beams without a stop
being activated. Temporary bridging in accordance with EN 1010 can, for example, be
activated by a suitable control unit.
With a suitable control unit, SOLID-2 SF are type 2 Active Optoelectronic Protective Devices
(AOPDs) in acc. with EN/IEC 61496-1, EN/IEC 61496-2, PL c in acc. with ISO 13849-1, and
comply with SIL 1 in acc. with IEC EN 61508.
All SOLID-2 SF Multiple Light Beam Safety Devices are equipped with integrated cyclical
testing and display elements (LEDs and 7-Segment). This is especially convenient when
starting a unit up or performing diagnostics.
SOLID-2 SF has the appropriate number of beams via 2-4 SSDs, enabling the definitive
assignment of the interruption of individual beams. Each SOLID-2 SF also has a dynamic
SSD, which transfers the result of the integrated cyclical testing to the control unit.
The devices of the SOLID-2 SF series are available with up to 4 beams and in various
lengths (beam distances), so that they provide an optimum solution for specific applications.
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
SOLID-2 SF Safety Light Curtains are developed and manufactured in compliance with
applicable European directives and international standards.
EC prototype test in accordance with
EN/IEC 61496 Part 1 and Part 2
TÜV PRODUCT SERVICE GmbH, IQSE
Ridlerstrasse 65
D-80339 Munich

General
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1.2 Symbols and terms
Symbols used
Table 1.1: Symbols
Warning sign – This symbol indicates possible dangers. Please pay especially close
attention to these instructions!
Sign indicating important information.
A note, which also refers to a course of action, provides information about special
attributes or describes set-up procedures
Symbols for SOLID-2 SF Transmitter, SD2T
General transmitter symbol
Transmitter not active
Transmitter active
Symbols for SOLID-2 SF Receiver, SD2R
General Receiver symbol
The Receiver’s active protective field is not free; outputs in OFF state
The Receiver's active protective field is free; outputs in ON state
The Receiver's active protective field is free; outputs in OFF state
Signal output
Signal input
Signal input and/or output

General
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Terms used in this manual
Table 1.2: Terms
AOPD Active Opto-electronic Protective Device
AOPD response time Time between penetration into the active protective field of the AOPD and
the actual switching off of the OSSDs.
AutoReset When an error indication occurs, caused, for example, by faulty external
wiring, the AOPD attempts to start again. If the error is no longer present,
the AOPD returns to normal operation mode.
Contactor Monitoring (EDM) Also called "External Device Monitoring", monitors the positive-guided
normally closed contacts of downstream relays, contactors or valves
DoubleScan Two scans are made: Beams must be interrupted in two consecutive
scans, before the Receiver switches OFF.
FS Factory setting
S/RS interlock Start/restart interlock
Scan All beams, beginning with the synchronization beam, are activated and
deactivated one after the other, i.e. only one beam is active at a time.
SSD1,.. ,SSD4, Dyn SSD Safety-relevant switching outputs (transistors)
Start/restart interlock Prevents automatic start after the supply voltage has been turned on, or
after the protective field has been penetrated

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). For mounting, operating and testing, document "SOLID-2SF-M, Optoelectronic
delivery guard of sheet-fed printing machines" 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 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
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.
2.2 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 PLrascertained in the risk assessment.

Safety
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Listed in the following table are the safety-related characteristic parameters of the SOLID-
2SF-M optoelectronic delivery guard for sheet-fed printing machines.
Table 2.1: Safety-related characteristic parameters of the SOLID-2SF-M optoelectronic
delivery guard of sheet-fed printing machines
• The safety sensor protects persons at access points or at points of operation of
machines and plants.
• When mounted vertically at entry points to hazard locations, the safety sensor detects
the human body.
• The safety sensor only detects persons upon entry to the danger zone; it does not
detect persons who are located within 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.
2.2.1 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
Type in accordance with IEC/EN 61496 Type 2
SIL in accordance with IEC 61508 SIL 1
SILCL in accordance with IEC/EN 62061 SILCL 1
Performance Level (PL) in accordance with ISO 13849-1: 2008 PL c
Category in accordance with ISO 13849 Cat. 2
Average probability of a failure to danger per hour (PFHd)
For protective field heights up to 900 mm, all resolutions
For protective field heights up to 1800 mm, all resolutions
For protective field heights up to 2850 mm, all resolutions
8.2 x 10-8 1/h
8.9 x 10-8 1/h
On request
Service life (TM) 20 years

Safety
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2.3 Competent personnel
Prerequisites for competent personnel:
• he 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
• he has been instructed by the responsible person on the mounting and operation of
the machine and of the safety sensor
2.4 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 company operating 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
2.5 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 (see Chapter 10)
• changes (e.g., constructional) are made to the safety sensor

Safety notes
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3 Safety notes
3.1 The opto-electronic protective device
Working principle
SOLID-2 SF consists of a transmitter and a receiver. Beginning with the first beam
(synchronization beam) directly after the display panel, the Transmitter pulses beam for
beam in rapid sequence. The synchronization between Transmitter and Receiver is
performed optically.
The Receiver recognizes the specially coded pulse packages of the Transmitter beams and
opens the corresponding Receiver elements in sequence in the same rhythm. A protective
field is consequently formed in the area between Transmitter and Receiver. Its height
depends on the geometrical dimensions of the protective device and its width is determined
by the distance selected between the Transmitter and Receiver within the permissible
range.
The safety output consists of the 1-channel SSDs, which provide the status of the
corresponding beams (SSD 1 shows the status of beam 1, SSD 2 the status of beam 2,
SSD 3 the status of beam 3 and SSD 4 the status of beam 4), and the Dyn SSD output
shared for all beams. When no errors are present on the SOLID-2 SF, this delivers a
symmetrical square-wave signal with 300 ms pulse width. This dynamic signal must be
monitored by the downstream control unit. If the Dyn SSD signal fails to appear, the power-
driven machinery must be switched off. Correct connection must be checked with the
machine's first startup!
Picture 3.1:Working principle of the opto-electronic protective device
{
Control unit
Receiver
Transmitte
Additionally for
4-beam system
Dyn SSD
1 to 4 beam status outputs (1
output per beam)
Beam 1
Beam 2
Beam 3
Beam 4

Safety notes
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3.2 Transmission channel
The infrared beams are modulated with specially coded pulse packages so that they are
distinct from ambient light, thus ensuring undisturbed operation. Welding sparks or warning
flash lights from passing forklifts do not having any effect on the protective field.
If two protective fields are located directly next to each other for two adjacent machines,
however, measures must be taken to ensure the optical protective devices do not affect
each other.
Another possible way to suppress mutual influence is to switch one of the two protective
devices from transmission channel 1 to 2 and therefore to differently formed pulse packages.
This solution should be considered when more than two optical protective devices must be
arranged next to each other.
The change from transmission channel 1 to 2 must be made both on the Transmitter and
the Receiver of the optical protective device in question. You will find more detailed
information in Chapter 6.
aAOPD "A" transmission channel 1
bAOPD "B" transmission channel 2, not affected by AOPD "A"
Picture 3.2:Transmission channel selection (AOPD = Active Opto-electronic Protective
Device)
a
b

Display elements
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4 Display elements
4.1 Transmitter status displays
When the Transmitter’s green LED1 is lit, this indicates that the current supply is available.
Display of the current state of the Transmitter:
Table 4.1: Transmitter, LED status displays
aLED1 (green/red)
bLED2 (green/red)
Picture 4.1:Transmitter, LED status displays
ab
Display Meaning
LED1 green LED2 off Operating voltage present, transmission channel 1 selected
LED1 green LED2 green Operating voltage present, transmission channel 2 selected
LED1 green LED2 red Operating voltage present, transmission channel 1 or
transmission channel 2 selected, external test signal activated
LED1 red LED2 any Device fault

Display elements
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4.2 Receiver status displays
LED1 and the 7-Segment display signal the operating states of the Receiver.
aLED1 = (green/red)
Picture 4.2:Receiver, status displays

Display elements
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4.2.1 7-Segment display
After the supply voltage is switched on, the following data appears on the 7-Segment
display of the Receiver:
Table 4.2: Receiver, 7-Segment permanent displays
Table 4.3: Receiver, 7-Segment temporary event display
4.2.2 LED displays
Receiver, LED status displays
Table 4.4: Receiver LED displays
7-Segment display Meaning
Permanent display after startup
1 or 2 Transmission channel TC1 or TC2 display
7-Segment display Meaning
Temporary event displays, 1 s per display
E xx Display of locking status “Malfunction”, which can be released by the user;
E xx = Error code (see Chapter 9). The display shows E, 3 (1st position)
and 0 (2nd position) alternating, and then repeats this sequence.
F xx. Locking status display "device fault" and an internal fault code. Receiver
must be replaced.
1 or 2 flashing Flashing transmission channel number -> weak signal display, device not
adjusted optimally or dirty
LED Color Meaning
LED1 Red/
green
Red = At least one safety output SSD in OFF state
Green = All safety outputs SSDs in the ON state
No display = Device without supply voltage

Installation
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5 Installation
5.1 Location of the AOPD
EN 1010-2 specifies the position of the beams on the sheet delivery for sheet-fed printing
machines in the following table:
Select the suitable SOLID-2 SF type according to the access heights on the sheet delivery
(e.g. 2, 3 or 4-beam, see order data) and mount the SOLID-2 SF at the appropriate height.
5.2 Calculating the safety distance
With general applications, i.e. in cases where SOLID-2SF is not used for guarding the sheet
delivery of a sheet-fed printing machine, the safety distance must be calculated in acc. with
EN 999.
The safety distance is calculated here using the following formula:
S = (K x T) +C
S: Safety distance between SOLID-2SF and the danger zone (mm)
K: Approach speed – 1600 mm/s
T: Total time of the delay in seconds, i.e. the total of the response time of the protective
device and the downstream control unit or safety interface and the machine's stopping
time
C: Additional amount – 850 mm
Access height h Location of the AOPD for the access level(s)
Beam 1 aBeam 2 bBeam 3 c
h ≤ 1200 mm 300 mm If d n/a 400 mm below h
(h-400)
1200 mm < h ≤ 1500 mm 300 mm Centered between
beams 1 and 3
400 mm below h)
(h-400)
h > 1500 mm 300 mm 700 mm 1100 mm
aPosition measured from access level or from fixed or swiveling platform; because of
structural tolerances where installed, the permissible tolerance for the position is ± 35
mm.
bBeam between beams 1 and 3, if distance between beam 1 and 3 > 500 mm
cmaximum 1100 mm high
dSome blanking functions require 3 beams for guarding the access side. Where these
blanking functions are to be used, with access heights over 1200 mm a third beam that is
positioned centered between the top and the bottom beam must be provided.

Installation
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5.3 Minimum distance from reflective surfaces
Reflective surfaces near opto-electronic protective devices can indirectly deflect beams from
the Transmitter into the Receiver. This can cause an object in the protective field not to be
detected! All reflective surfaces and objects (material containers, cans, etc.) must therefore
be kept at a minimum distance "a" from the protective field. The minimum distance "a"
depends on the distance “b” between the Transmitter and the Receiver.
a = Minimum distance
b = Protective field width
c = Reflective surface
Picture 5.1:Minimum distances from reflective surfaces
c
b
a
4°± 25% 4°± 25%
a = Required distance from reflective surfaces [mm]
b = Protective field width [m]
Picture 5.2:Minimum distance to reflective surfaces depending on protective field width
a
b
130130

Installation
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5.4 Mechanical mounting
What should generally be taken into consideration during installation?
• Make certain that the Transmitter and Receiver are mounted on even surfaces.
• The Transmitter and Receiver must be positioned at the same height and their
connection plugs must be pointing in the same direction.
• Use screws for mounting that can only be loosened with a tool.
• Fasten and secure the Transmitter and Receiver so that they cannot be swiveled or
moved. Securing the Transmitter and Receiver so they cannot be moved or swiveled
is especially important in the close area with a narrow protective field.
• The safety distance between the protective field and the danger zone must be
observed.
• Make sure that access to the danger point/danger zone is only possible through the
protective field. Additional access routes must be secured separately (for example by
hard guards, additional Safety Light Curtains or doors with locking devices).
5.5 Mounting types
5.5.1 Standard mounting
Straddle brackets (for Transmitter and Receiver) are included with delivery.
Picture 5.3:Clamping bracket for C-slot mounting
80
40
20
14

Installation
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5.5.2 Mounting with swiveling brackets
Swiveling mounting brackets with shock absorbers can be ordered optionally. They are not
included with delivery. The swivel range is ± 8°.
5.5.3 Side mounting
Optionally, mounting is possible with mounting brackets and sliding nuts on the side slot.
They are not included with delivery.
Picture 5.4:Swiveling bracket with shock absorber
Picture 5.5:Mounting examples, L-mounting bracket and Z-mounting bracket
L-mounting bracket Z-mounting