Pilz PSEN sg2c-5CCLLE User manual

PSEN sg2c-5CCLLE
Operating Manual-1004172-EN-02
}PSEN sensor technology

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
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1 Introduction ............................................................................................................................5
1.1 Validity of documentation.......................................................................................................... 5
1.2 Using the documentation .......................................................................................................... 5
1.3 Definition of symbols................................................................................................................. 5
2 Overview .................................................................................................................................7
2.1 Range of PSEN sg2c-5CCLLE Unit.......................................................................................... 7
2.2 Unit features ............................................................................................................................. 7
3 Safety ...................................................................................................................................... 8
3.1 Intended use ............................................................................................................................. 8
3.2 Safety regulations ..................................................................................................................... 8
3.2.1 Safety assessment ................................................................................................................... 8
3.2.2 Use of qualified personnel ........................................................................................................ 8
3.2.3 Warranty and liability ................................................................................................................ 9
3.2.4 Disposal .................................................................................................................................... 9
3.3 For your safety.......................................................................................................................... 9
4 Function description ............................................................................................................. 10
4.1 Unlock mode............................................................................................................................. 10
4.2 Escape release on swing gates and revolving gates................................................................ 10
4.3 Auxiliary release ....................................................................................................................... 13
4.4 Restart interlock........................................................................................................................ 15
4.5 Holding forces........................................................................................................................... 16
4.6 Pushbutton................................................................................................................................ 17
4.7 Block diagram ........................................................................................................................... 18
5 Wiring ......................................................................................................................................19
5.1 Notes on cable run.................................................................................................................... 19
5.2 Recommended cable cross sections ........................................................................................ 20
5.3 General wiring guidelines ......................................................................................................... 20
5.4 Terminal configuration .............................................................................................................. 21
5.5 Wiring the connection terminals................................................................................................ 22
5.6 E-STOP pushbutton connection ............................................................................................... 22
5.7 EMC requirements.................................................................................................................... 23
5.8 Connection to evaluation devices ............................................................................................. 23
5.8.1 Connection examples PNOZmulti............................................................................................. 23
5.8.2 Connection examples PSS ....................................................................................................... 24
5.9 Single connection ..................................................................................................................... 24
5.10 Series connection ..................................................................................................................... 25
6 Installation ..............................................................................................................................27
6.1 Initial installation of safety switch.............................................................................................. 28
6.2 Initial installation of handle unit................................................................................................. 33
6.3 Second installation of safety switch and handle unit / upgrade for left-hinged gates ............... 35
6.4 Labelling the pushbuttons......................................................................................................... 36
6.5 Dimensions in mm .................................................................................................................... 37
6.5.1 Drill holes .................................................................................................................................. 37

Contents
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6.5.2 Unit ........................................................................................................................................... 38
7 Adjustment ............................................................................................................................. 39
8 Maintenance ........................................................................................................................... 40
9 Operation ................................................................................................................................41
9.1 Status table............................................................................................................................... 42
9.2 Remedy .................................................................................................................................... 43
10 Technical details ....................................................................................................................45
11 Classification according to ZVEI, CB24I .............................................................................. 49
12 Safety characteristic data ..................................................................................................... 50
13 Order reference ......................................................................................................................51
13.1 Unit ........................................................................................................................................... 51
13.2 Safety switch............................................................................................................................. 51
13.3 Handle unit with actuator .......................................................................................................... 51
13.4 Accessories .............................................................................................................................. 51
14 Supplementary data ..............................................................................................................52
14.1 Radio approval.......................................................................................................................... 52
14.2 EC declaration of conformity..................................................................................................... 52

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSEN sg2c-5CCLLE. It is valid until new docu-
mentation is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
1.2 Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
1.3 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.

Introduction
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INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
2.1 Range of PSEN sg2c-5CCLLE Unit
}Safety switch
}Handle unit with actuator
}Colour covers for illuminated buttons
}Pin for escape release
2.2 Unit features
}Safe guard locking
}Safe interlocking (position monitoring)
}Transponder technology
}2 safety inputs for series connection of multiple safety switches
}2 safety outputs
}Guard locking element keeps the safety gate from being opened unintentionally
}Detection of broken bolt tongue and broken guard locking element
}Handle unit with locking lever to attach padlocks as a restart interlock
}Auxiliary release for opening the safety gate, when the plant's voltage is switched off
}Only on revolving and swing gates: Escape release for fast manual release of the guard
locking in emergency situations from within the danger zone
}Suitable for left and right hinged safety gates
}Plug-in spring-loaded terminals
}LED display for:
– Supply voltage/fault
– Gate locked
– State of the hazardous machine
– State of the inputs
– Bolt tongue engaged
}2 illuminated pushbuttons
}1 E-STOP pushbutton
}coded

Safety
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3 Safety
3.1 Intended use
The safety gate system is used for guard locking and interlocking swing gates, revolving
gates and sliding gates.
It meets the requirements in accordance with:
}EN 60947-5-3
}EN ISO 14119
}EN 62061: SIL CL 3
}EN ISO 13849-1: Up to PL e (Cat. 4)
The safety level PL e (Cat. 4)/SIL CL 3 can be achieved when
}The safety outputs use 2-channel processing and
}The solenoid is operated 2-channel via safe relay outputs, suitable for PL e (Cat. 4)/SIL
CL 3 applications.
Wiring errors should be excluded using appropriate measures. The potential solutions are
the protected cable layout or the use of pulsed semiconductor outputs.
3.2 Safety regulations
3.2.1 Safety assessment
Before using a device it is necessary to perform a safety assessment in accordance with
the Machinery Directive.
Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.
3.2.2 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
It is the company’s responsibility only to employ personnel who
}Are familiar with the basic regulations concerning health and safety / accident prevention,
}Have read and understood the information provided in the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the specific
application.

Safety
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3.2.3 Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended,
}Damage can be attributed to not having followed the guidelines in the manual,
}Operating personnel are not suitably qualified,
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
3.2.4 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-related
characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).
3.3 For your safety
WARNING!
Potential loss of safety function during adjustment and repair work!
When carrying out adjustment and repair work, make sure that the power
supply of the plant is switched off and protected against switching on again.
WARNING!
Loss of safety function due to manipulative use of substitute actuating
elements!
When substitute actuating elements are used, these have to be installed as
described in chapter Install at profile. When substitute actuating elements
are used in a manipulative way to defeat the protective device, operating
the plant presents a threat to life.
The operator has to consider this in the hazard analysis and he must de-
termine possible countermeasures.

Function description
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4 Function description
The interlocking and guard locking system prevents the safety gates to the danger zone
from opening while the hazardous machine is switched on.
There is a high signal (safety gate closed and locked) at safety outputs X1-3 and X1-4 if the
following conditions are met simultaneously:
}Inputs X2-3 and X2-4 are high and
}The bolt tongue is within the response range and
}The guard locking element is engaged in the bolt tongue and
}The escape or auxiliary release pin is in the correct position.
Signal output X1-9 is high if:
}The bolt tongue is within the response rang
There is a low signal (safety gate open and hazardous machine function interlocked) at
safety outputs X1-3 and X1-4 if the following occurs:
}Inputs X2-3 or X2-4 are low or
}The guard locking element is outside the bolt tongue or
}The escape or auxiliary release has been operated or
}The guard locking element is not engaged in the bolt tongue.
If the safety outputs have been shut down by either of the inputs X2-3 or X2-4, they cannot
be switched back on until both inputs are low simultaneously.
To operate the solenoid, a high signal must be present at X1-6 (X2-6) and at X1-7 (X2-7)
after the hazardous movement has been ended.
4.1 Unlock mode
The system is operate in Unlock mode:
The safety gate to the danger zone is unlocked when the hazardous machine is stopped.
This enables easier access for cleaning staff once the shift has ended, for example.
}The guard locking element is disengaged from the bolt tongue as soon as the signal
status at terminals X1-6 and X1-7 or X2-6 and X2-7 switches from Low to High.
4.2 Escape release on swing gates and revolving gates
The escape release enables the guard locking to be manually released from within the
danger zone.
NOTICE
The escape release does not work on sliding gates. The PSEN sg2c may
only be used on sliding gates if the risk analysis shows that nobody can be-
come trapped in the danger zone.

Function description
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[1]
[2]
[3]
[4]
[1]
[2]
Mode of operation
Within the danger zone, if the escape release pin [1] is pressed in the direction of the safety
gate, the cover on the escape release [2] detaches from the locked position and lifts up-
wards. The swivel piece [3] folds downwards. The bolt tongue [4] behind the swivel piece is
released. The safety gate can be opened immediately, enabling the operator to leave the
danger zone.
WARNING!
Loss of safety function due to the incorrect installation of the escape
release!
If the escape release pin is accessible from the outside, the guard locking
device can be released from the outside and the safety gates opened, al-
though the hazardous machine is switched on.
Depending on the application, serious injury or death may result.
The escape release should be installed so that it is only accessible from in-
side the danger zone.
It is also important to refer to the maintenance instructions (see chapter en-
titled Maintenance)

Function description
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INFORMATION
When the escape or auxiliary release is operated, there is a low signal at
the safety outputs X1-3 and X1-4. An error code is issued (see section en-
titled Remedy). The PSEN sg2c is not ready for operation again until the es-
cape release or auxiliary release has been reset to its unoperated state and
the error has been rectified and reset.
Please note that, following operation, the cover for the escape release must
be inspected and reassembled.

Function description
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4.3 Auxiliary release
When the plant is powered down, the auxiliary release enables the guard locking device to
be released from the access side to the danger zone.
INFORMATION
When the escape or auxiliary release is operated, there is a low signal at
the safety outputs X1-3 and X1-4. An error code is issued (see section en-
titled Remedy). The PSEN sg2c is not ready for operation again until the es-
cape release or auxiliary release has been reset to its unoperated state and
the error has been rectified and reset.
Please note that, following operation, the cover for the escape release must
be inspected and reassembled.
Mode of operation on revolving and swing gates:
Carefully remove the cover of the escape release (1) from the latch below. Use a screw-
driver (2) to pull out the escape or auxiliary release pin (3) from the swivel piece (4). The
swivel piece folds downwards, the bolt tongue behind the swivel piece is released. The
safety gate to the danger zone can be opened.
[

Function description
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Mode of operation on sliding gates:
On sliding gate applications, a screwdriver [2] must be used to carefully push the locking
pin [4] into the safety switch.
[1]
[2]
[4]
[3]

Function description
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4.4 Restart interlock
To prevent the machine restarting while there is someone inside the danger zone, a pad-
lock can be attached to one of the locking levers (see illustration). As a result, the guard
locking element cannot engage in the bolt tongue, the guard locking device is not activated
and the machine is prevented from restarting.
The padlock's shackle diameter may be max. 8 mm.

Function description
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4.5 Holding forces
The maximum holding forces that can be used to lock the safety gate are stated in the tech-
nical details.
A distinction is made between the following holding forces:
}Holding force in pan direction and
}Holding force in closing direction
On sliding gates the maximum holding force corresponds to the holding force in closing dir-
ection
Holding force in closing direction
Holding force in pan direction

Function description
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4.6 Pushbutton
Pushbutton 3
Pushbutton 4
E-STOP
}Pushbutton 3 and pushbutton 4
The two illuminated pushbuttons can be used depending on the application:
– Operating a pushbutton switches the pushbutton output
– The LEDs of the pushbuttons can be operated via the LED inputs.
}E-STOP pushbuttons

Function description
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4.7 Block diagram
6
3
24 V
Escape
Release Pin
24 V

Wiring
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5 Wiring
5.1 Notes on cable run
The maximum cable run depends on the voltage drop in the supply voltage conductors for
solenoid operation. The level of voltage drop is determined by the
}cable resistance of the cables
}solenoid current of the solenoid
If the voltage drop in the supply voltage conductors becomes too high, the voltage for
solenoid operation can permanently be set to the upper tolerance range (see Technical de-
tails).
The max. cable diameter is 10 mm.
Example:
}Connecting 3 safety switches in series
}Total cable run: 25 m
}Conductor cross section: 0.5 mm2
}Solenoid current per solenoid: 1.5 A
}Voltage for solenoid operation: 24 V
4
U~0.05*10*1.5*4.5~3.4 V U~0.05*5*1.5*3~1.1 V U~0.05*10*1.5*1.5~1.5 V
U~cable specific impedence*cable length*cable factor*current
Cable impedence(2x0.25 mm²)
=0.05 Ohm/meter
25 m
0
The voltage drop over all the safety switches is 6 V. This means, there are only 18.0 V at
the terminals of the last solenoid. The solenoid is no longer operated reliably. If the voltage
for operating the solenoid is increased by the max. permitted tolerance to 26.4, there are
still 20.4 V at the terminals of the last solenoid. The solenoid switches reliably.

Wiring
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5.2 Recommended cable cross sections
The values in the table are valid for a series connection with max. 3 sensors and a voltage
for solenoid operation of 24 V. The solenoid current is 1.5 A per solenoid.
For differing values the conductor cross section must be calculated.
Total cable run [m] 1 safety switches 2 safety switches 3 safety switches
5 0.25 mm2, AWG24 0.25 mm2, AWG24 0.5 mm2, AWG21
10 0.25 mm2, AWG24 0.25 mm2, AWG24 0.5 mm2, AWG21
15 0.25 mm2, AWG24 0.25 mm2, AWG24 0.5 mm2, AWG21
20 0.25 mm2, AWG24 0.5 mm2, AWG21 x
25 0.25 mm2, AWG24 0.5 mm2, AWG21 x
30 0.25 mm2, AWG24 x x
40 0.5 mm2, AWG21 x x
50 0.5 mm2, AWG21 x x
60 0.5 mm2, AWG21 x x
70 x x x
Cable runs marked with an x are not recommended.
For operating several safety switches with greater cable runs, the cables for solenoid oper-
ation (terminals X1-6 and X1-7) have to be carried individually, or several cables have to be
used. If more than three safety switches are connected in series or cable runs over 60 m
are required, please contact Pilz.
The permitted conductor cross section is at least 0.25 mm². To have a higher conductor
cross section, two cable cores can be inserted into a terminal. This adds together the con-
ductor cross sections and halves the cable resistances. In this case, use a terminal lug! The
signals important for cable resistance are:
}24 V (X1-1 or X2-1)
}0 V (X1-2 or X2-2)
}the two solenoid operation signals (X1-6 and X1-7 or X2-6 and X2-7).
5.3 General wiring guidelines
Please note:
}All metallic surfaces on the safety switch are connected to 0 V via a resistor (100 kOhm)
for functional earthing.
}UL requirements:
– Use copper wiring with a temperature stability of 75 °C.
– Use an LVLC supply (LVLC: limited voltage, limited current).
– Use multicore cable with a cable diameter of 6 ... 10 mm.
}When 2 cables are used, make sure that both cables have the same cable diameter, oth-
erwise the strain relief will fail.
}The permitted conductor cross section for the connectors is 0.25 - 1.0 mm², 23 - 17 AWG.