Leuze electronic MLC 520 EX Series User manual

MLC 520 EX
Safety Light Curtains
SAFE IMPLEMENTATION AND OPERATION
Original operating instructions
EN 2014/12 - 50127400 We reserve the right to make technical changes

Leuze electronic MLC 520 EX 2
© 2014
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]

Leuze electronic MLC 520 EX 3
1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Approved purpose and foreseeable improper operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Notices for the safe use of sensors in potentially explosive areas . . . . . . . . . . . . . . . . . . . 9
3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Device overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.1 Operating indicators on the MLC 520 receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.2 Alignment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Start/restart interlock RES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 EDM contactor monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Transmission channel changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Range reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Point of operation guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2 Access guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Danger zone guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1 Arrangement of transmitter and receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.1 Calculation of safety distance S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.2 Calculation of safety distance SRT or SRO if protective fields act orthogonally
to the approach direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.3 Calculation of safety distance S for parallel approach to the protective field . . . . . . . . . . 24
6.1.4 Minimum distance to reflective surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.5 Preventing mutual interference between adjacent devices . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Mounting the safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.1 Suitable mounting locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.2 Definition of directions of movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.3 Fastening via BT-NC60 sliding blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2.4 Fastening with BT-R swivel mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.5 One-sided mounting on the machine table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3 Mounting accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.1 Deflecting mirror for multiple-side guarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.1 Pin assignment transmitter and receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.1 MLC 500 transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.2 MLC 520 receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Circuit diagram examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Leuze electronic MLC 520 EX 4
7.2.1 MLC 520 circuit diagram example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8 Starting up the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 Aligning the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.3 Aligning of deflecting mirrors with the laser alignment aid. . . . . . . . . . . . . . . . . . . . . . . . . 38
8.4 Unlocking start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1 Before the initial start-up and following modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.1.1 Checklist for integrator – to be performed prior to the initial start-up and
following modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9.2 To be performed periodically by competent persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3 Periodically by the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.3.1 Checklist – periodically by the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.1 What to do in case of error? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.2 Operating displays of the LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.3 Error messages 7-segment display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
12 Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
14 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
14.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
14.2 Dimensions, weight, response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
14.3 Dimensional drawings: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
15 Ordering information and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
16 EU Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

About this document
Leuze electronic MLC 520 EX 5
1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Table 1.2: Other symbols
Table 1.3: Terms and abbreviations
Symbol indicating dangers to persons
NOTICE Signal word for property damage
Indicates dangers that may result in property damage if the measures for dan-
ger 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 severe 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.
AOPD
Active Optoelectronic Protective Device
EDM Contactor monitoring
(External Device Monitoring)
LED LED, display element in transmitter and receiver
MLC Brief description of the safety sensor, consisting of transmitter and receiver
MTTFd
Mean Time To dangerous Failure
OSSD Safety-related switching output
(Output Signal Switching Device)
PFHd
Probability of dangerous Failure per Hour
PL Performance Level
RES
Start/REStart interlock
Scan Consecutive scans of the protective field from the first to the last beam

About this document
Leuze electronic MLC 520 EX 6
1.2 Checklists
The checklists (see chapter 9) 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.
Safety sensor System consisting of transmitter and receiver
SIL Safety Integrity Level
State ON: device intact, OSSD switched on
OFF: device intact, OSSD switched off
Locking: device, connection or control / operation faulty, OSSD switched off
(lock-out)

Safety
Leuze electronic MLC 520 EX 7
2 Safety
Before using the safety sensor, a risk assessment must be performed according to valid standards (e.g.
EN ISO 12100, EN ISO 13849-1, IEC 61508, EN IEC 62061). The result of the risk assessment deter-
mines the required safety level of the safety sensor . For mounting, operating and testing, this document
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 affected
persons.
Before working with the safety sensor, completely read and observe 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
• EMC directive 2004/108/EC
• Use of work equipment directive 89/655/EEC supplemented by directive 95/63 EC
• OSHA 1910 Subpart O
• Safety regulations
• Accident-prevention regulations and safety rules
• Industrial safety regulation and employment protection act
• Product safety law (ProdSG)
2.1 Approved purpose and foreseeable improper operation
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).
WARNING
A running machine may result in serious injury!
Make certain that the safety sensor is correctly connected and that the protective function of the pro-
tective device is ensured.
Make certain that, during all conversions, maintenance work and inspections, the system is securely
shut down and protected against being restarted.

Safety
Leuze electronic MLC 520 EX 8
2.1.1 Intended use
• The safety sensor may 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
safety at work, and after it has been installed on the machine, connected, commissioned, and
checked by a competent person (see chapter 2.2).
• 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 assessment .
• The safety sensor protects persons or body parts at points of operation, danger zones or access
points of machines and plants.
• With the access guarding function, the safety sensor detects persons only when they enter the dan-
ger zone but cannot tell whether there are any persons inside the danger zone. For this reason, a
start/restart interlock in the safety chain is essential in this case.
• 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 inspected regularly by a competent person to ensure proper integration
and mounting (see chapter 2.2).
• 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.
2.1.2 Foreseeable misuse
Any use other than that defined under the Approved purpose or which goes beyond that use is consid-
ered improper use.
In principle, the safety sensor is not suitable as a protective device for use in the following cases:
• Danger posed by ejected objects or the spraying of hot or hazardous liquids from within the danger
zone
• Applications in explosive or easily flammable atmospheres
2.2 Competent persons
Prerequisites for competent persons:
• They have a suitable technical education.
• They know the rules and regulations for labor protection, safety at work and safety technology and
can assess the safety of the machine.
• They know the instructions for the safety sensor and the machine.
• They have been instructed by the responsible person on the mounting and operation of the machine
and of the safety sensor.1
2.3 Responsibility for safety
Manufacturer and operating company must ensure that the machine and implemented safety sensor func-
tion 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, verified by the initial test performed by a competent person
• imparting all relevant information to the operating company
• adhering to all regulations and directives for the safe starting-up of the machine
1. They perform a task related to the subject matter shortly thereafter and keep their knowledge up to date through continuous
further training.

Safety
Leuze electronic MLC 520 EX 9
The company operating the machine is responsible for:
• instructing the operator
• maintaining the safe operation of the machine
• adhering to all regulations and directives for labor protection and safety at work
• regular testing by competent persons
2.4 Disclaimer
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 9).
• changes (e.g., constructional) are made to the safety sensor.
2.5 Notices for the safe use of sensors in potentially explosive areas
These notices apply for devices with the following classification:
Table 2.1: Classification of the devices
Device group Device category Equipment protection
level
Zone
II 3G Gc 2 (gas)
II 3D Dc 22 (dust)
WARNING
Safe use of sensors in potentially explosive areas!
Check whether the classification of the devices corresponds to the requirements of the application.
Safe operation is only possible if the devices are used properly and for their intended purpose.
Electrical devices may endanger the health of humans and (where applicable) animals and may threat-
en the safety of goods if used under unfavorable conditions or incorrectly in potentially explosive areas.
Observe the applicable national regulations, especially ATEX directive 94/4/EC and/or EN 60079-14,
for the configuration, commissioning, operation and recurring testing of explosion-proof systems.

Device description
Leuze electronic MLC 520 EX 10
3 Device description
The safety sensors from the MLC 500 series are active opto-electronic protective devices. They satisfy the
following standards:
The safety sensors of the MLC 520 EX2 series satisfy the ATEX requirements in accordance with
EN 60079-0, EN 60079-15, EN 60079-28 for category 3G as well as EN 60079-0 and EN 60079-31 for
category 3D.
The safety sensor consists of a transmitter and a receiver (see figure 3.1). It is protected against over-
voltage and overcurrent acc. to IEC 60204-1 (safety class 3). Its infrared beams are not influenced by
ambient light (e.g. welding sparks, warning lights).
3.1 Device overview
The series is characterized by three different receiver classes (Basic, Standard, Extended) with certain
features and properties (see table 3.1).
Table 3.1: Device models in the series with specific features and functions
MLC 500
Type in accordance with EN IEC 61496 4
Category in accordance with EN ISO 13849 4
Performance Level (PL) in accordance with EN ISO 13849-1 e
Safety Integrity Level (SIL) in accordance with IEC 61508 and SILCL in
accordance with EN IEC 62061
3
Transmitter Receiver
Basic Standard Extended
MLC 500
MLC 501
MLC 500/A MLC 502 MLC 510
MLC 511
MLC 510/A MLC 520 MLC 530
OSSDs (2x) 
AS-i 
Transmission chan-
nel changeover

LED indicators 
7-segment display 
Automatic start/
restart

RES 
EDM 
Linkage 
Blanking 
Muting 
Scan mode 
Range reduction 
Test input 