Pilz PSEN sg2c User manual

PSEN sg2c
Operating Manual 1003267-EN-04
}PSEN sensor technology

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation 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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1003267-EN-04 3
Section 1 Introduction 5
1.1 Validity of documentation 5
1.2 Using the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 7
2.1 Scope of PSEN sg2c Unit 7
2.2 Unit features 7
Section 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
Section 4 Function description 10
4.1 Normal /Unlock mode 10
4.2 Escape release 11
4.3 Auxiliary release 13
4.4 Restart interlock 14
4.5 Holding forces 15
4.6 Pushbutton 16
4.7 Device types 17
4.8 Block diagram 21
Section 5 Wiring 22
5.1 Notes on cable run 22
5.2 Recommended cable cross sections 23
5.3 General wiring guidelines 23
5.4 Terminal configuration 24
5.5 Wiring the connection terminals 25
5.6 E-STOP pushbutton connection 26
5.7 Enabling switch connection 26
5.8 EMC requirements 26
5.9 Connection to evaluation devices 27
5.9.1 Connection examples PNOZmulti 27
5.9.2 Connection examples PSS 27
5.10 Single connection 27
5.11 Series connection 28
Section 6 Installation 30
6.1 Initial installation of safety switch 31
6.2 Initial installation of handle unit 36

Contents
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6.3 Second installation of safety switch and handle unit / upgrade for left-
hinged gates
37
6.4 Labelling the pushbuttons 37
6.5 Dimensions in mm 39
6.5.1 Drill holes 39
6.5.2 PSEN sg2c-3xxx 40
6.5.3 PSEN sg2c-5xxxxx 41
6.5.4 PSEN sg2c-5xxxxx-M12/5 42
Section 7 Adjustment 43
Section 8 Maintenance 44
Section 9 Operation 45
9.1 Status table 47
9.2 Toggle normal/unlock mode 48
9.3 Remedy 49
Section 10 Technical Details Order No. 570800-570804 51
Section 11 Technical Details Order No. 570806-570810 56
Section 12 Technical Details Order No. 570812-570816 60
Section 13 Technical Details Order No. 570818-570822 65
Section 14 Technical Details Order No. 570824-570828 69
Section 15 Technical Details Order No. 570830-570834 74
Section 16 Technical Details Order No. 570880-570884 78
Section 17 Safety characteristic data 82
Section 18 Order reference 83
18.1 Unit 83
18.2 Safety switch 84
18.3 Handle unit with actuator 85
18.4 Accessories 85
Section 19 Supplementary data 87
19.1 Radio approval 87
19.2 EC declaration of conformity 87

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSEN sg2c. It is valid until new documentation
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 Scope of PSEN sg2c Unit
}Safety switch
}Handle unit with actuator
}Colour covers for illuminated buttons
}Pin for escape release
2.2 Unit features
}Safe guard locking (only for revolving gates and swing gates)
}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
}Escape release for fast manual release of the guard locking in emergency situations
from within the danger zone (revolving gates and swing gates)
}Suitable for left and right hinged safety gates
Note: The handle unit PSEN sg2c actuator is only suitable for revolving gates and
swing gates.
}Plug-in spring-loaded terminals
}LED indicator for:
– Supply voltage/fault
– Gate locked
– State of the hazardous machine
– Request to stop the machine
– State of the inputs
– Bolt tongue engaged
}Depends on device type
– Various control elements, for example integral E-STOP pushbutton, section stop
pushbutton, key-operated pushbutton, key switch...
– Coding:
- coded
- uniquely coded
See section entitled Device types

Safety
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3 Safety
3.1 Intended use
The safety gate system is used for guard locking and interlocking swing gates and revolving
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 unit 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 someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, devices, systems, plant and machinery in accordance with the general
standards and guidelines for safety technology.
It is the company’s responsibility only to employ personnel who:
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion
}Have read and understood the information provided in this description under "Safety"
}And 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-re-
lated 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 ele-
ments!
When substitute actuating elements are used, these have to be installed as
described in chapter Initial installation of safety switch [ 31]. When sub-
stitute actuating elements are used in a manipulative way to defeat the pro-
tective 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 Normal /Unlock mode
Normal mode:
The safety gate to the danger zone is not unlocked until the hazardous machine is stopped
and the pushbutton for access request has been operated.
}The guard locking element is disengaged from the bolt tongue as soon as there is a
high signal at terminals X1-6 and X1-7 or X2-6 and X2-7, followed by operation of the
pushbutton for access request.
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 there is a
high signal at terminals X1-6 and X1-7 or X2-6 and X2-7.

Function description
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4.2 Escape release
The escape release enables the guard locking to be manually released from within the
danger zone.
[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.

Function description
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WARNING!
Loss of safety function due to the incorrect installation of the escape re-
lease!
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 [ 44])
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 [ 49]). The PSENsgate is not ready for operation again
until the escape release or auxiliary release has been reset to its unoper-
ated state and the error has been rectified and reset.
Please note that the cover of the escape release has to be checked and re-
installed after operation.

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.
[1]
[2]
[4]
[3]
Mode of operation:
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.
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 [ 49]). The PSENsgate is not ready for operation again
until the escape release or auxiliary release has been reset to its unoper-
ated state and the error has been rectified and reset.
Please note that the cover of the escape release has to be checked and re-
installed after operation.

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
Holding force in closing direction
Holding force in pan direction

Function description
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4.6 Pushbutton
Pushbutton 1
Pushbutton 2
Pushbutton 1
Pushbutton 2
Pushbutton 3
Pushbutton 4
PSEN sg2c-3... PSEN sg2c-5...
E-Stop/
Section stop
E-Stop/
Section stop
}Pushbutton 1: pushbutton for activating the safety gate guard locking device
By pressing the pushbutton for activating guard locking, the guard locking element is
engaged in the bolt tongue when the bolt tongue is detected by the sensor and a high
signal is present at X1-6 and X1-7 or at X2-6 and X2-7 (solenoid operation).
}Pushbutton 2: pushbutton for access request and release of the safety gate
– Pressing the pushbutton for access request disengages the guard locking element
from the bolt tongue when a high signal is present at X1-6 and X1-7 or at X2-6 and
X2-7 (solenoid operation).
– Pressing the pushbutton for access request switches output X1-5 (access request)
when a low signal is present at X1-6 and X1-7 or at X2-6 and X2-7 (solenoid opera-
tion).
Depending on the design, the device also has:
}E-STOP / or section stop pushbutton
}Pushbutton 3 and pushbutton 4
Pushbuttons that 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.
Further information on the different types can be found in the section entitled Device
types [ 17].

Function description
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4.7 Device types
21 different versions are available. They differ as follows:
}Number and quality of the pushbuttons
}Coded or uniquely coded
}With or without M12 connection for enabling switch
PSEN sg2c-3xxx PSEN sg2c-5xxxxx PSEN sg2c-5xxxxx-M12/5
[1]
[2]
[3]
[1]
[2]
[3]
[4]
[5]
[1]
[2]
[3]
[4]
[5]
[6]

Function description
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PSEN sg2c-3xxx (3 pushbuttons)
[1] Pushbutton 1: pushbutton for activating the safety gate guard locking device
[2] Pushbutton 2: pushbutton for access request and release of the safety gate
[3] E-STOP / or section stop pushbutton
Type code:
PSEN sg2c - 3 L X X 2.2*
3 pushbuttons = 3
Pushbutton illuminated = L
Pushbutton unilluminated = P
Key switch = B
E-STOP pushbutton = E
Section stop pushbutton = S
No pushbutton = C
uniquely coded
[1] [2] [3]
*not included with all versions
Types:
Pushbutton 1 Pushbutton 2 E-Stop/
Section stop
Coding
-3LPE Pushbutton
illuminated
Pushbutton
unilluminated
E-Stop coded
-3LBE Pushbutton
illuminated
Key
switch
E-Stop coded
-3LPS Pushbutton
illuminated
Pushbutton
unilluminated
Section
stop
coded
-3LBS Pushbutton
illuminated
Key-operated
pushbutton
Section
stop
coded
-3LPC Pushbutton
illuminated
Pushbutton
unilluminated
--- coded
-3LBC Pushbutton
illuminated
Key-operated
pushbutton
--- coded
-3LPE 2.2 Pushbutton
illuminated
Pushbutton
unilluminated
E-Stop uniquely coded

Function description
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PSEN sg2c-5-xxxxx and PSEN sg2c-5-xxxxx-M12 (5 pushbuttons):
[1] Pushbutton 1: pushbutton for activating the safety gate guard locking device
[2] Pushbutton 2: pushbutton for access request and release of the safety gate
[3], [4] pushbuttons 3 - 4: can be used depending on the application
[5] E-STOP / or section stop pushbutton
[6] M12 connection for enabling switch
Type code:
PSEN sg2c - 5 L X X L X - M12/5* 2.2*
5 pushbuttons = 5
Enabling switch
Pushbutton illuminated = L
Pushbutton unilluminated = P
Key switch = B
E-STOP pushbutton = E
Section stop pushbutton = S
No pushbutton = C
uniquely coded
Pushbutton illuminated = L
Key switch = B
Pushbutton illuminated = L
[1] [2] [3] [4] [5] [6]
Fig.: *not included with all versions
Types:
Pushbut-
ton 1
Pushbut-
ton 2
Pushbut-
ton 3
Pushbut-
ton 4
E-Stop/
Section
stop
M1
2
Coding
-5LPLLE Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
E-Stop --- coded
-5LBLLE Pushbut-
ton
illuminated
Key-oper-
ated
pushbutton
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
E-Stop --- coded
-5LPLLS Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
Section
stop
--- coded

Function description
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-5LBLLS Pushbut-
ton
illuminated
Key-oper-
ated
pushbutton
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
Section
stop
--- coded
-5LPLLC Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
--- --- coded
-5LBLLC Pushbut-
ton
illuminated
Key-oper-
ated
pushbutton
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
--- --- coded
-5LPKLE-
M12/5
Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Key
switch
Pushbut-
ton
illuminated
E-Stop Yes coded
-5LBKLE-
M12/5
Pushbut-
ton
illuminated
Key-oper-
ated
pushbutton
Key
switch
Pushbut-
ton
illuminated
E-Stop Yes coded
-5LPKLS-
M12/5
Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Key
switch
Pushbut-
ton
illuminated
Section
stop
Yes coded
-5LBKLS-
M12/5
Pushbut-
ton
illuminated
Key-oper-
ated
pushbutton
Key
switch
Pushbut-
ton
illuminated
Section
stop
Yes coded
-5LPKLC-
M12/5
Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Key
switch
Pushbut-
ton
illuminated
--- --- coded
-5LBKLC-
M12/5
Pushbut-
ton
illuminated
Key-oper-
ated
pushbutton
Key
switch
Pushbut-
ton
illuminated
--- Yes coded
-5LPLLE
2.2
Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Pushbut-
ton
illuminated
Pushbut-
ton
illuminated
E-Stop --- uniquely
coded
-5LPKLE-
M12/5 2.2
Pushbut-
ton
illuminated
Pushbut-
ton
unillumin-
ated
Key
switch
Pushbut-
ton
illuminated
E-Stop Yes uniquely
coded