Leuze lumiflex Compact C14 Series Quick start guide

Leuze lumiflex
COMPACT
Sicherheits-Lichtvorhänge und -Lichtgitter
(der Baureihen C14, C30, C50, C90, C300/4, C400/3, C500/2, C301/4, C401/3 und C501/2)
Anschluß- und Betriebsanleitung
Safety Light Curtains and Light Grids
(Series C14, C30, C50, C90, C300/4, C400/3, C500/2, C301/4, C401/3 und C501/2)
Connecting and operating Instructions
600980 - 05/02 Technische Änderungen vorbehalten. Subjects to change without prior notice
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44 COMPACT Leuze lumiflex
Notes on connecting and operating instructions
These instructions contain information on the efficiency in the use of COMPACT safety light curtains and light
grids in accordance with their intended applications. These instructions constitute a part of the scope of
delivery.
Warning and safety notes are indicated by the symbol .
The Leuze lumiflex GmbH + Co.KG is not liable for damage resulting from improper use.
Acquaintance with these instructions constitutes part of the knowledge required for proper use.
 Reprint and reproduction, in whole or in part, only with the explicit permission from:
Leuze lumiflex GmbH+Co.KG
Liebig Straße 4
D-82256 FÜRSTENFELDBRUCK
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Leuze lumiflex COMPACT 45
TABLE OF CONTENTS
1 System Overview and Scope of Applications ............................47
1.1 General ...........................................................................................47
1.2 Approvals ........................................................................................48
1.3 Overview of Product Characteristics ...............................................48
1.4 Equipment Variants and scope of Applications ...............................49
1.5 Deflection Mirrors ............................................................................50
2 Notes on Safety 10
2.1 General hazards for non-observance of notes on safety ................51
2.2 Use according to Intended Applications .........................................51
2.3 Operating Conditions ......................................................................51
3 Design and Function 11
3.1 System Overview ............................................................................52
3.2 Operating Mode ..............................................................................53
3.3 Cascading .......................................................................................54
3.4 Display Elements ............................................................................54
3.5 Selectable System Functions .........................................................55
3.5.1 Different Transmission Channels to Prevent Mutual
Interference .....................................................................................66
3.5.2 Multiple Evaluation Procedure for Environments with
Sources of Extreme Infrared Pulses ...............................................66
3.5.3 Contamination and Fault Signal Output ..........................................66
3.5.4 Test input ........................................................................................57
3.6 Fail-safe Semiconductor Outputs ....................................................57
3.7 Diagnostic Function ........................................................................58
4 Installation 18
4.1 General Installation Procedures .....................................................59
4.1.1 Clearance .......................................................................................59
4.1.2 Distance from Reflective Surfaces ..................................................59
4.1.3 Prevention of Mutual Interference ...................................................60
4.2 Mounting Procedures for COMPACT Light Curtains
(Series C14 and C30) .....................................................................62
4.3 Mounting Procedures for COMPACT Light Grids for
Vertical Access Protection (Series C300/4, C400/3,
C500/2, C301/4, C401/3 and C501/2) ............................................63
4.4 Installation Specifications for COMPACT Light Grids
for Danger Area Safeguard, Horizontal Arrangement
(Series C50 and C90) ......................................................................64
4.5 Mechanical Installation ...................................................................65
Englisch
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46 COMPACT Leuze lumiflex
5 Electrical Installation ....................................................................66
5.1 Installation Regulations ...................................................................66
5.2 Power Supply ..................................................................................67
5.3 Connecting Cables .........................................................................67
5.4 Examples of Connections ...............................................................67
5.5 Connecting Techniques ...................................................................69
6 Commissioning .............................................................................72
6.1 Functional Check ............................................................................72
6.2 Notes on Rectification of Faults ......................................................73
7 Cleaning .........................................................................................73
8 Technical Data and Dimensions ..................................................74
9 Selection and notes on ordering .................................................79
9.1 Selection of a COMPACT Safety Light Curtain or Light Grid ..........79
9.2 Scope of Delivery and Accessories ................................................82
10 Declaration of Conformity.............................................................84
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Leuze lumiflex COMPACT 47
1 System Overview and Scope of Applications
1.1 General
The COMPACT safety light curtains and light grids are active optoelectronic
protection devices (AOPD) of the type 4 according to IEC 61496-1, -2 and
EN 61496-1, -2. A two-dimensional protective field of infrared radiation is
generated between transmitter and receiver. Penetrating this protective field
will trigger the safeguarded machine to go into a safe mode before the person
can enter a potentially hazardous area.
Parameters of COMPACT safety light curtains
Parameters of COMPACT safety light grids
a = transmitter e = protected width, range
b = protected height f = to machine control
c = sensing field g = receiver
d = object sensitivity h = distance between beams
(smallest detected object) i = number of beams
Fig. 1 The major parameters of an AOPD
a
+24V DC
c
STOP
f
g
b
e
d
+24V DC
i
STOP
h
a
f
g
e
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48 COMPACT Leuze lumiflex
1.2 Approvals
EU Prototype Testing (Europe)
TÜV PRODUCT SERVICE GMBH
Ridlerstraße 31
80339 Munich
IEC 61496-2 testing conducted by:
BIA
Berufsgenossenschaftliches Institut für
Arbeitssicherheit
Alte Heerstraße 111
53757 St. Augustin
1.3 Overview of Product Characteristics
•High immunity to ambient lighting, welding arcs and stroboscopic light by the application of paten-
ted evaluation procedures and special ASIC’s for signal processing
•Interference-free operation of neighboring equipment by the selection of differing transmission
channels
•Multiple evaluation procedures for environments with sources of extreme infrared impulsive dis-
turbance
•Non-wear function through fail-safe semiconductor outputs
•Cascading of several units possible, e.g. hand protection and step-over protection
•Use of modern micro-controller engineering techniques
•Robust aluminium housing of small cross-section (52 x 55 mm, or 2 x 2.16 inch)
•Flexibility in add-on functions by connection to safety relays MSI-SR2/F or, for example, MSI-m/R
(muting)
•Straight forward connections through plug-in terminal compartment
•Integrated self-diagnostics systems for quick on-site fault localisation and PC-supported diagnos-
tic routines in the workshop
North America
UL and C(UL)
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Leuze lumiflex COMPACT 49
1
.4 Equipment Variants and Scope of applications
The COMPACT is available in different models in order to provide an optimum price/performance
ratio for differing applications. All models have one thing in common: the same engineering!
COMPACT light curtains of series C30 and C14 for hand and finger
protection at danger points
Resolution: 14 mm (finger) and 30 mm (hand)
Protected range: series C14: 0.3 - 6 m, series C30: 0.8 - 18 m
Protected heights: 150, 225, 300, 450, 750, 900, 1050, 1200, 1350,
1500, 1650, 1800 mm (1950, 2100, 2250 mm
on request)
COMPACT light grids of series C50 safeguarding danger areas close
to the ground (height: from 0 mm on)
Resolution: 50 mm (lower leg)
Protected range: 0.8 - 18 m
Protected heights: 450, 600, 750, 900, 1050, 1200, 1350,1500,1650,
1800, 2100, 2400, 2700, 3000 mm
COMPACT light grids of series C90 safeguarding danger areas at a
height of 600 - 1000 mm
Resolution: 90 mm (upper leg)
Protected range: 0.8 - 18 m
Protected heights: 750,900,1050,1200,1350,1500,1650,1800,
2100, 2400, 2700, 3000 mm
COMPACT light grids of series C500/2. C400/3, C300/4 safeguarding
access
Dist. betw. beams: 500, 400, and 300 mm according to EN 999
Protected range: 0,8 - 18 m
number of beams: 2, 3, and 4 beams according to EN 999
COMPACT light grids of series C501/2. C401/3, C301/4 safeguarding
access to large areas
Dist. betw. beams: 500, 400, and 300 mm according to EN 999
Protected range: 6 - 60 m
number of beams: 2, 3, and 4 beams according to EN 999
Fig. 2 COMPACT equipment variants and their scope of applications
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50 COMPACT Leuze lumiflex
1.5 Deflection Mirrors
A hazard location or a danger area can be guarded on more than one front by employing deflection
mirrors. The maximum possible width of the protection zone is reduced for each mirror accordingly
as shown in the following table. The use of more than two mirrors is not to be recommended
because of the difficulties associated in the alignment.
Fig. 3 Guarding several fronts of a hazard location by means of deflecting mirrors
COMPACT Series Reduction in the Range per Mirror
C14 1 m
C30, C50, C90,
C300/4, C400/3, C500/2
2,3 m
C301/4, C401/3, C501/2 10 m
a = receiver
b = deflecting mirror
c = transmitter
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Leuze lumiflex COMPACT 51
2 Notes on Safety
2.1 General Hazards for Non-observance of Notes on Safety
Care is exercised in accordance with recognised codes of engineering practice in the development
and production of Leuze lumiflex products. The protection function of the equipment can however
be impaired if the units are not used in accordance with their intended application or are not used
properly. Such instances can cause hazards for the health and life of the personnel operating the
machinery. Safety light curtains and light grids do not provide protection against injuries resulting
from flying objects.
2.2 Use according to Intended Applications
For use in the foodstuffs industry and in explosion-endangered areas, the COMPACT is not suitable
in its standard design. Special housings on request.
2.3 Operating Conditions
Applicable regulations (e. g. machinery-specific C-Standards in the EU or the OSHA and ANSI
standards in the USA) apply for the use and installation of COMPACT safety light curtains and light
grids. The appropriate authorities for the country in question are available for answering questions
regarding safety engineering. In general, compliance with the following operating is required:
•The COMPACT units shall be installed such that access from above, beneath or behind the pro-
tected field is ruled out. If this is not assured, then additional protection measures must be
installed
COMPACT equipment type Use according to intended
application
Light curtain, series C14 Finger protection
Light curtain, series C30 Hand protection
Light grid, series C50 and C90 Horizontal guard over areas of
danger, detection of a person
Light grid, series C300/4, C400/3,
C500/2, C301/4, C401/3, C501/2
Vertical guard against access to
areas of danger, detection of a person
Englisch
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52 COMPACT Leuze lumiflex
Fig. 4 Access from above, beneath or behind must be ruled out
•Intervention in the controls of the machine by electrical means must be possible so as to enable
immediate termination of potentially hazardous states in each working phase.
•The safety clearance between hazard location and protection zone must be
sufficiently large enough such that the potentially hazardous state is terminated before the person
has reached the hazard location (refer to 4.1).
•The mechanical and electrical installation shall be carried out by trained and qualified personnel.
The switching outputs of the COMPACT (OSSD’s) shall be connected as two-channel outputs to
the shutoff path for the potentially hazardous condition (refer to 5.1 and 5.2).
3 Design and Function
3.1 System Overview
The COMPACT equipment consists of transmitter and receiver. The transmitter consists of the con-
trol electronics and a modular arrangement of IR-radiation sources which are sequentially triggered
in quick succession and send out coded infrared pulses. The receiver consists of a control and eval-
uation assembly with the switching outputs and modular IR reception elements which are evaluated
in synchronisation with the transmitter. The synchronisation is realised by optical means. Intercon-
nection of both components by a cable is not necessary. The control assemblies are identical for all
COMPACT models, the IR transmitter and reception modules differ however in their radiation range
and optical characteristics. Each component is housed in a robust aluminium profile casing of stand-
ard design and is powered by 24 V DC.
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Fig. 5 COMPACT System design
3.2 Operating Mode
The COMPACT works in the operating mode „Protection operating mode without restart disable“.
Reception of all light planes switches the output voltage at the OSSD’s to +24 V. Interruption of one
or more light planes shuts off the output voltage at the OSSD’s within the response time for the sys-
tem. The OSSD’s automatically revert to +24 V as soon as the planes of light are free again.
Additional functions such as restart disable and protection control can be realised by the safety
relays MSI-SR2/F or MSI-SR2 or directly from a fail-safe PLC (refer to Chapter 5.2). For additional
intelligent functions like single break/double break or muting the modular safety interfaces of the MSI
series can be connected.
a = connecting caps
b = control electronic
c = IR transmitter module
d = control and evaluation electronic
e = IR receiver module
f = cap
g = aluminium profile
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54 COMPACT Leuze lumiflex
3.3 Cascading
COMPACT basic and follower equipment can be connected in succession in order to realise linked
protection zones. Units of different resolution can thereby be combined with up to 240 planes of
light (e.g. a basic unit 1650 mm with 14 mm resolution as finger protection and a follower unit with
450 mm and 50 mm resolution as step-over protection), see Table 2, Page 78. The follower units
are available starting at a protection height of 150 mm and in graduations of 150 mm.
Fig. 6 Cascading of basic and follower units over plug-in cable connection
3.4 Display Elements
Fig. 7 Display elements in transmitter and in receiver
a
reset/action
receiver
d-scan
1channel1
2channel2
Ffailure
5selftest
.
b
a = master
b = slave with 250 mm cable and
M12 connector, 8pol + shield
*
COMPACT
Transmitter CT
COMPACT
Receiver CR
a = system status
b = test active
c = multiple analysis d-scan active
d = outputs OSSD off
e = outputs OSSD on
f = weak receiving signals
* = display reserved for future
expansion of functions
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Leuze lumiflex COMPACT 55
Englisch
3.5 Selectable System Functions
The COMPACT is equipped with functions for the prevention of mutual interference and for an
increased suppression of interference for operation in environments where there are sources of
extreme infrared pulses, such as welding arcs.
These functions are optional and can be activated by means of DIP switches. The switches are
mounted on the circuit boards in the plug-in terminal caps. In the event that the unit has to be
replaced, then the set equipment parametrisation is retained in the terminal cap for that position and
does not need to be set again.
Fig. 8 Selection of function by means of DIP switches on the terminal circuit boards for the transmitter
and receiver.
S1 = pnp status output or RS-485 interface
contamination status pnp
RS-485 pour diagnostic PC
NOTE: The possibility of options is only for the receiver. For the transmitter S1 always has to be
in the position shown above.
S2 = transmission channel
channel 1
channel 2
NOTE: The same channel has to be set always for the transmitter and receiver.
S3 = task
standard
d-scan
NOTE: d-scan can only be selected at the receiver. S3 is not connected at the transmitter.
Switching over to d-scan increases the device‘s response time and thus also the safety
distance required!
(see identification plate: response time and/or chart 1, page 77).
Switch 3 at the transmitter board has no function. Switches are preset according to the figure.
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56 COMPACT Leuze lumiflex
3.5.1 Different Transmission Channels to Prevent Mutual Interference
Two differing transmission channels can be set by means of the DIP switch S2 in order to prevent
functional disturbance from mutual interference by two neighboring units. The selected transmission
channel 1 or 2 is indicated in the transmitter and receiver displays.
Fig. 9 Differing transmission channels prevent mutual interference
3.5.2 Multiple Evaluation Procedure for Environments with Sources of
Extreme Infrared Pulses
High immunity to interference is already realised by the component technology used in the
COMPACT in combination with a special software algorithm for the suppression of interference.
For applications in environments of extreme disturbance from interfering light, e.g. from many
welding robots, the multiple scanning mode d-scan can be set by means of the DIP switch S3. The
response time of the unit is thereby increased to the value which is indicated on the type plate and
in Table 1 (Chapter 8, Technical data and dimensions).
3.5.3 Contamination and Fault Signal Output
A short-circuit-proof signal output for „weak signals or fault“can be connected by means of the DIP
switch S1 to the connecting terminal 6 in place of the RS-485 interface. The pnp output carries +24
V, and is switched to high resistance in the case of contamination or a fault.
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Leuze lumiflex COMPACT 57
3.5.4 Test Input
The COMPACT is equipped as AOPD Type 4 with a permanent self-monitoring function, which
automatically detects faults in the system as well as cross-circuits and short-circuits to the output
cables. An external signal is not required for this. In order to test connected circuits for follower pro-
tection devices, an external control (e.g. combination of protection devices) can switch off the OSSD
outputs by means of a test signal and thereby test the drop in the switching devices (refer to Chapter
5.4 in this context). If this test function is not required, then the connecting terminal 3-4 of the trans-
mitted shall be bridged by a jumper (already set by factory).
3.6 Fail-safe Semiconductor Outputs
Both switching outputs OSSD1 and OSSD2 of the receiver are active-monitored pnp semiconductor
outputs for switching earthed loads up to 0.3 A. The outputs are HIGH-active and carry the voltage
UOSSD = Usupply - 2,7 V for an uninterrupted protection zone. UOSSD amounts to max. 2 V for an
interrupted protection zone.
In order to monitor the safe function of the outputs, they are switched OFF cyclically every 140 µs
(Channel 1) and every 80 µs (Channel 2). A cross-circuit between the output cables 3 and 4 of the
COMPACT receiver is detected immediately after signal changing of the outputs from OFF to ON
by the self monitoring system. Then both outputs are switching to OFF as long as the cross-circuit
exists. In case of a short-circuit of an output to + 24 V the other OSSD output will be switched to
OFF as long as the short-circuit exists. Short-circuits to +24 V and 0 V are well as cross-circuits
between OSSD1 and OSSD2 are indicated and do not lead to a destruction of the outputs (refer to
Chapter 5.2 for circuits).
The semiconductor outputs are equipped with a fast de-energising function. Radio interference
suppression circuits are not necessary. The fast de-energising function reduces the release time to
a fraction in comparison with the conventional actuation of relays with recovery diodes. In total, this
leads to a shorter reaction time of the protective fixture.
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58 COMPACT Leuze lumiflex
3.7 Diagnostic Function
Transmitter and receiver are equipped with extensive self-diagnostic functions. An „F“is indicated
in the 7-segment display for a discrepant unit in the event of a component failure. This enables the
quick on-site identification of defective components (refer to Chapter 6.2). A PC can be connected
to the serial RS-485 interface for visualizing the light axes during alignment or for locating problems
in the workshop. An adapter for converting from RS-485 to RS-232 is available as an optional
accessory. The adapter is connected to the receiver power cable by means of a cable set suited to
the connector type. The serial interface of the PC must permit a transmission rate up to 57.6 kBaud.
The diagnostics software required for visualization can be run on Windows 3.1 and higher. Software,
RS-485/RS-232 interface converter and diagnostics cable set are available as accessories.
a = COMPACT receiver
b = diagnostics cable set suited to the connector type
c = RS-485/232 converter
d = RS-232 serial cable
e = COMPACT diagnostics software
f = Receiver connector cable for machine control
Fig. 10 Straightforward light axis visualization and on-site fault diagnostics, PC-supported
diagnostics in the workshop
a
b
c
d
e
f
F + fault number 6, 7, 8,
or 9 (blinking symmetri
cally)
= fault in the external
circuit
F + other fault numbers
= fault in the device
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Leuze lumiflex COMPACT 59
4 Installation
4.1 General Installation Procedures
Attention shall be paid to the general notes on safety given in Chapter 2.
Principally, all units shall be installed such that the hazard location can be reached only by the
interruption of at least one plane of light and sufficient clearance is maintained between hazard
location and the protection zone.
4.1.1Clearance
The clearance S is calculated in accordance with EN 999 according to the following formula:
S = (K x T) + C
where:
SMinimum clearance between the protection zone and the hazard location in mm
KRate of approach by the body or the person in mm/ms
TOvertravel time of the machine + the response time of the optoelectronic protection device
(AOPD) in ms
CAllowance in mm, which depends on the detection capacity d of the AOPD
Depending on the differing applications (e.g. hand and finger protection, access protection), there
are differing approach rates K and allowances C applicable in accordance with EN 999. The fol-
lowing installation procedures take the formula into account to be used in each application case.
4.1.2 Distance from Reflective Surfaces
Reflective surfaces within the 4˚transmission and reception cone can lead to reflections and hence
to a non-detection of bodies. It is for this reason that a minimum distance (a) must be maintained
between the optical plane of the COMPACT and such reflective surfaces as polished parts of
machines and receptacles for material. The greater the distance between transmitter and receiver,
the greater is the distance (a) which has to be maintained. The following diagrams illustrate the
correct installation and this distance (a) as a dependency of the width of the protection zone.
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60 COMPACT Leuze lumiflex
Fig. 11 Sufficiently large distance (a) from reflective surfaces must be assured.
a [m] = 0.035 x protection zone width [m] + 0.005 m
4.1.3 Prevention of Mutual Interference
Radiation from the transmitter and receiver is in the form of divergent cones with an angle of 4˚. The
diameter of the radiated light beam thus increases with increasing distance and irradiates the
receiver accordingly. Mutual interference and hence functional disturbance can result if a second
receiver is positioned within this range.
Two differing transmission channels can be set by means of the DIP switch S2 in order to prevent
this. The units can be mounted in opposite directions or be separated by appropriate shielding.
a = distance to reflecting field
b = reflecting field
c = transmission cone
d = optical axis
e = receiving cone
protection width in m
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Leuze lumiflex COMPACT 61
Fig. 12 Prevention of mutual interference by the selection of different transmission channels
or by mounting in opposite directions
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62 COMPACT Leuze lumiflex
4.2 Mounting Procedures for COMPACT Light Curtains (Series C14 and C30)
With the COMPACT light curtains for finger and hand protection, it shall be observed that access to
the protection zone is not possible from above, below or around, as well as from stepping over the
curtain, by the incorporation of additional mechanical safeguards or by cascading the COMPACT
units.
The minimum clearance for protection is calculated as follows:
S = (K x T) + C
where:
SMinimum clearance between protection zone and hazard location, in mm (Smin ≥100 mm)
KAccessing rate 2 mm/ms
TOvertravel time of the machine + the response time of the optoelectronic protection device
(AOPD), in ms
C8 (d - 14 mm), not less than 0 however
d Detection capacity (resolution) of the AOPD, in mm
If this calculation gives a value for S which is greater than 500 mm, then the calculation shall be
repeated for K = 1.6 mm/ms. In this case the value of Smin may not be less than 500 mm.
Fig. 13 Light curtain for hand or finger protection at hazard location
c
b
a
S
a = follow through of machine
b=≤75 mm or stepping behind
protection
c = machine STOP
S= minimum safety distance
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