SICK deTem4 Core IP69K User manual

OPERATING INSTRUCTIONS
deTem4 Core IP69K
Safety multibeam sensor

Described product
deTem4 Core IP69K
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 6
1.1 Function of this document....................................................................... 6
1.2 Scope......................................................................................................... 6
1.3 Target groups of these operating instructions........................................ 6
1.4 Additional information.............................................................................. 6
1.5 Symbols and document conventions...................................................... 7
2 Safety information............................................................................ 8
2.1 General safety notes................................................................................ 8
2.2 Intended use............................................................................................. 8
2.3 Improper use............................................................................................. 8
2.4 Requirements for the qualification of personnel.................................... 9
3 Product description........................................................................... 10
3.1 Setup and function................................................................................... 10
3.2 Product characteristics............................................................................ 11
3.2.1 Device overview....................................................................... 11
3.2.2 IP69K protective housing....................................................... 11
3.2.3 Status indicators...................................................................... 12
3.3 Example applications............................................................................... 14
4 Project planning................................................................................ 15
4.1 Manufacturer of the machine.................................................................. 15
4.2 Operating entity of the machine.............................................................. 15
4.3 Design........................................................................................................ 15
4.3.1 Minimum distance from the hazardous point....................... 16
4.3.2 Minimum distance from reflective surfaces.......................... 18
4.3.3 Protection against interference from systems in close prox‐
imity to each other................................................................... 19
4.4 Integrating into the electrical control....................................................... 20
4.4.1 Restart interlock...................................................................... 22
4.4.2 External device monitoring (EDM).......................................... 22
4.4.3 Connection diagrams.............................................................. 23
4.5 Testing plan............................................................................................... 24
4.5.1 Test rod check.......................................................................... 25
4.5.2 Visual check of the machine and the protective device........ 26
5 Mounting............................................................................................. 27
5.1 Safety......................................................................................................... 27
5.2 Unpacking.................................................................................................. 27
5.3 Mounting................................................................................................... 27
5.3.1 Mounting the reinforced stainless steel bracket................... 29
5.3.2 Mounting the stainless steel bracket..................................... 30
5.3.3 Mounting the stainless steel supporting bracket.................. 30
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6 Electrical installation........................................................................ 32
6.1 Safety......................................................................................................... 32
6.2 System connection (flying leads, 5-wire)................................................. 33
7 Commissioning.................................................................................. 34
7.1 Safety......................................................................................................... 34
7.2 Overview.................................................................................................... 34
7.3 Switching on.............................................................................................. 35
7.4 Sender and receiver alignment................................................................ 35
7.4.1 Aligning the sender and receiver............................................ 35
7.4.2 Alignment with the reinforced stainless steel bracket.......... 36
7.4.3 Alignment with the stainless steel bracket............................ 37
7.4.4 Indication of the alignment quality......................................... 37
7.5 Check during commissioning and modifications.................................... 38
8 Operation............................................................................................ 39
8.1 Safety......................................................................................................... 39
8.2 Regular thorough check........................................................................... 39
9 Maintenance...................................................................................... 40
9.1 Regular cleaning....................................................................................... 40
9.2 Replacing the protective housing............................................................ 41
9.3 Regular thorough check........................................................................... 42
10 Troubleshooting................................................................................. 43
10.1 Safety......................................................................................................... 43
10.2 Diagnostic LEDs........................................................................................ 43
10.2.1 Fault indicators........................................................................ 43
11 Decommissioning............................................................................. 46
11.1 Disposal..................................................................................................... 46
12 Technical data.................................................................................... 47
12.1 Data sheet................................................................................................. 47
12.2 Table of weights........................................................................................ 49
12.3 Dimensional drawings.............................................................................. 50
13 Ordering information........................................................................ 51
13.1 Scope of delivery....................................................................................... 51
13.2 Ordering information................................................................................. 51
14 Spare parts......................................................................................... 52
14.1 Protective housing.................................................................................... 52
15 Accessories........................................................................................ 53
15.1 Brackets.................................................................................................... 53
15.2 Connectivity............................................................................................... 55
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15.3 Deflector mirrors....................................................................................... 55
15.3.1 Function and use..................................................................... 55
15.3.2 Change in scanning range using deflector mirrors................ 56
15.3.3 Deflector mirror – ordering information................................. 56
15.4 Mirror columns.......................................................................................... 56
15.5 Device columns......................................................................................... 57
15.6 Accessories for mirror columns and device columns............................. 57
15.7 Cleaning agent.......................................................................................... 57
15.8 Test rods.................................................................................................... 57
16 Annex.................................................................................................. 58
16.1 Conformities and certificates................................................................... 58
16.1.1 EU declaration of conformity................................................... 58
16.1.2 UK declaration of conformity.................................................. 58
16.2 Note on standards.................................................................................... 58
16.3 Checklist for initial commissioning and commissioning........................ 60
17 List of figures..................................................................................... 61
18 List of tables....................................................................................... 62
CONTENTS
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1 About this document
1.1 Function of this document
These operating instructions contain the information needed during the life cycle of the
safety multibeam sensor.
Operating instructions of the safety multibeam sensor must be made available to all
people who work with the device.
Please read these operating instructions carefully and make sure that you understand
the content fully before working with the safety multibeam sensor.
1.2 Scope
Product
This document applies to the following products:
•Product code: deTem4 Core IP69K
•“Operating instructions” type label entry: 8021557
Document identification
Document part number:
•This document: 8021559
•Available language versions of this document: 8021557
You can find the current version of all documents at www.sick.com.
1.3 Target groups of these operating instructions
Some chapters of these operating instructions are intended for certain target groups.
However, the entire operating instructions are relevant for intended use of the product.
Table 1: Target groups and selected chapters of these operating instructions
Target group Chapters of these operating instructions
Project developers
(planners, developers,
designers)
"Project planning", page 15
"Technical data", page 47
see "Accessories", page 53
Installers "Mounting", page 27
Electricians "Electrical installation", page 32
Safety experts (such
as CE authorized
representatives, com‐
pliance officers, peo‐
ple who test and
approve the applica‐
tion)
"Project planning", page 15
"Commissioning", page 34
"Technical data", page 47
"Checklist for initial commissioning and commissioning", page 60
Operators "Operation", page 39
"Troubleshooting", page 43
Maintenance person‐
nel
"Maintenance", page 40
"Troubleshooting", page 43
1.4 Additional information
www.sick.com
The following information is available on the Internet:
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•Data sheets and application examples
•CAD data and dimensional drawings
•Certificates (e.g. EU declaration of conformity)
•Guide for Safe Machinery Six steps to a safe machine
1.5 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indicates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indicates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indicates useful tips and recommendations.
Instructions to action
bThe arrow denotes instructions to action.
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
✓The check mark denotes the result of an instruction.
LED symbols
These symbols indicate the status of an LED:
oThe LED is off.
ÖThe LED is flashing.
OThe LED is illuminated continuously.
Sender and receiver
These symbols indicate the sender and receiver of the device:
sThe symbol indicates the sender.
rThe symbol indicates the receiver.
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2 Safety information
2.1 General safety notes
DANGER
The product can not offer the expected protection if it is integrated incorrectly.
bPlan the integration of the product in accordance with the machine requirements
(project planning).
bImplement the integration of the product in accordance with the project planning.
DANGER
Death or severe injury due to electrical voltage and/or an unexpected startup of the
machine
bMake sure that the machine is (and remains) disconnected from the voltage
supply during mounting and electrical installation.
bMake sure that the dangerous state of the machine is and remains switched off.
DANGER
Improper work on the product
A modified product may not offer the expected protection if it is integrated incorrectly.
bApart from the procedures described in this document, do not repair, open, manip‐
ulate or otherwise modify the product.
2.2 Intended use
The deTem4 Core IP69K safety multibeam sensor is an electro-sensitive protective
device (ESPE) and is suitable for the following applications:
•Single-sided access protection
•Multi-sided access protection
The product may be used in safety functions.
The safety multibeam sensor fulfills the requirements of the IP69K enclosure rating.
The deTem4 Core IP69K safety multibeam sensor must only be used within the limits of
the prescribed and specified technical data and operating conditions at all times.
Any instance of improper use, incorrect modification, or manipulation of the deTem4
Core IP69K safety multibeam sensor shall void any warranty provided by SICK AG;
furthermore, SICK AG shall not accept any responsibility or liability for any resulting
damage and consequential damage.
2.3 Improper use
The safety multibeam sensor works as an indirect protective measure and cannot
provide protection from pieces thrown from the application nor from emitted radiation.
Transparent objects are not detected.
Among others, the deTem4 Core IP69K safety multibeam sensor is not suitable for
the following applications:
•Outdoors
•Underwater
•In explosion-hazardous areas
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•At altitudes over 3,000m above sea level
•In environments with increased levels of ionizing radiation
2.4 Requirements for the qualification of personnel
The protective device must be planned in, installed, connected, commissioned, and
serviced by qualified safety personnel only.
Project planning
You need safety expertise to implement safety functions and select suitable products
for that purpose. You need expert knowledge of the applicable standards and regula‐
tions.
Mounting, electrical installation and commissioning
You need suitable expertise and experience. You must be able to assess if the machine
is operating safely.
Operation and maintenance
You need suitable expertise and experience. You must be instructed in machine oper‐
ation by the machine operator. For maintenance, you must be able to assess if the
machine is operating safely.
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3 Product description
3.1 Setup and function
Overview
The deTem4 Core IP69K safety multibeam sensor is an electro-sensitive protective
device (ESPE) consisting of a sender and receiver.
Parallel infrared light beams between the sender and receiver protect the hazardous
area. When one or more light beams are completely interrupted, the safety multibeam
sensor reports the interruption in the light path to the secure output signal switching
devices (OSSDs) by a signal change. The machine or its control must safely analyze the
signals (for example using a safe control or safety relays) and stop the dangerous state.
Sender and receiver automatically synchronize themselves optically. An electrical con‐
nection between both components is not required.
Figure 1: Sender and receiver
Beam separation and number of beams
The beam separation is the distance between two adjacent light beams, measured
from the center of one beam to the center of the next.
The beam separation and number of beams depend on the device variant.
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Scanning range
The scanning range is the maximum dimension of the light path between sender and
receiver.
The scanning range is reduced by using deflector mirrors.
Further topics
•"Data sheet", page 47
•"Deflector mirrors", page 55
3.2 Product characteristics
3.2.1 Device overview
1
2
3
4
5
6
Figure 2: Device overview
1Pressure equalizing element (aeration and ventilation membrane)
2IP69K protective housing
3Sender or receiver
4Cable gland
5Cable with flying leads
6End caps
3.2.2 IP69K protective housing
The safety multibeam sensor is mounted in an IP69K protective housing.
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The protective housing is well resistant to standard cleaning agents, high-pressure
cleaners with a water pressure up to 100bar, and water temperatures up to 80°C.
A pressure equalizing element (aeration and ventilation membrane) prevents plastic
tubes being covered in condensation and liquids from entering the housing.
3.2.3 Status indicators
Overview
The sender and receiver LEDs indicate the operational status of the safety multibeam
sensor.
Sender indicators
ERR
PWR
1
2
Figure 3: Sender indicators
Two light emitting diodes on the sender indicate the operational status:
Position LED color Display Labeling
!Yellow Status indicator PWR
"Red Fault indicator ERR
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Receiver indicators
ERR
OSSD
1 2 3 4
1
2
3
Figure 4: Receiver indicators
Six light emitting diodes on the receiver indicate the operational status:
Position LED color Display Labeling
!Red/green OSSD status OSSD
"Red Fault indication ERR
§Blue Alignment quality 1, 2, 3, 4
The blue alignment quality light emitting diodes in combination with the red flashing
ERR LED also denote faults.
Further topics
•"Diagnostic LEDs", page 43
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3.3 Example applications
Figure 5: Single-sided access protection
Figure 6: Multi-sided access protection
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4 Project planning
4.1 Manufacturer of the machine
DANGER
Hazard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of
non-observance.
bUse of the safety multibeam sensor requires a risk assessment. Check whether
additional protective measures are required.
bComply with the applicable national regulations derived from the application (e.g.,
work safety regulations, safety rules, or other relevant safety guidelines).
bDo not combine the components of the safety multibeam sensor with components
from other safety multibeam sensor.
bApart from the procedures described in this document, the components of the
safety multibeam sensor must not be opened.
bThe components of the safety multibeam sensor must not be tampered with or
changed.
bImproper repair of the protective device can lead to a loss of the protective
function. Do not carry out any repairs on the device components.
4.2 Operating entity of the machine
DANGER
Hazard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of
non-observance.
bChanges to the electrical integration of the safety multibeam sensor in the
machine controller and changes to the mechanical mounting of the safety mul‐
tibeam sensor necessitate a new risk assessment. The results of this risk assess‐
ment may require the entity operating the machine to meet the obligations of a
manufacturer.
bApart from the procedures described in this document, the components of the
safety multibeam sensor must not be opened.
bThe components of the safety multibeam sensor must not be tampered with or
changed.
bImproper repair of the protective device can lead to a loss of the protective
function. Do not carry out any repairs on the device components.
4.3 Design
Overview
This chapter contains important information about the design.
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Important information
DANGER
Hazard due to lack of effectiveness of the protective device
Persons and parts of the body to be protected may not be recognized in case of
non-observance.
bMake sure that the following design requirements are met so that the safety
multibeam sensor can fulfill its protective function.
°Sender and receiver must be arranged such that persons or parts of the body
are reliably detected when they enter the hazardous area.
°Ensure that nobody can pass under the lowest light beam, pass over the
highest light beam, get between two light beams, or pass by the side of the
protective device.
°If people can stay between the protective device and the hazardous point
without being detected, check if additional protective measures (e.g., restart
interlock) are required.
Further topics
•"Mounting", page 27
4.3.1 Minimum distance from the hazardous point
A minimum distance must be maintained between the safety multibeam sensor and
the hazardous point. This distance is required to prevent a person or part of the body
from reaching the hazardous area before the dangerous state of the machine state has
completed.
Calculating the minimum distance according to ISO13855
The calculation of the minimum distance is based on international or national stand‐
ards and statutory requirements applicable at the place of installation of the machine.
If the minimum distance is calculated according to ISO 13855, then it depends on the
following points:
•Machine stopping time (time interval between triggering the sensor function and
the end of the machine’s dangerous state)
•Response time of the protective device
•Approach speed of personnel
•Type of approach:orthogonal (at right angles)
•Parameters specified based on the application
For the USA (scope of OSHA and ANSI), different regulations may apply, e.g.:
a) Laws: Code of Federal Regulations, Title 29 (CFR29) Part 1910.217
b) Standards: ANSI B11.19
Complementary information
Additional information is available in the ISO 13855 standard and in the Guidelines
Safe Machinery.
SICK offers a stopping/run-down time measurement service in many countries.
Further topics
•"Technical data", page 47
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4.3.1.1 Calculating minimum distance from the hazardous point
Important information
DANGER
Minimum distance from the hazardous point is too small
The dangerous state of the machine may not be stopped or not be stopped in a timely
manner due to a minimum distance that is too small.
bCalculate the minimum distances for the machine in which the safety multibeam
sensor is integrated.
bWhen mounting the safety multibeam sensor, observe the minimum distance.
Approach
The example shows the calculation of the minimum distance for an orthogonal (at right
angles) approach to the safety multibeam sensor. Depending on the application and
the ambient conditions, a different calculation may be required (e.g., at a different
angle to the direction of approach or an indirect approach).
1. Calculate S using the following formula:
S = 1,600mm/s × T + C
where:
°S =minimum distance in millimeters (mm)
°T = machine stopping time + response time of the protective device after
interruption in the light path in seconds (s)
°C = supplement in accordance with ISO 13855:
•If it is not possible to reach over the protective device: C = 850mm
•If it is possible to reach over the protective device, the value CRO must be
used for C in accordance with ISO 13855, provided that this is greater
than 850mm: C ≥850mm and C ≥CRO
The reach/approach speed is already included in the formula.
!"
§
S
Figure 7: Minimum distance from the hazardous point
!Height of the light beams above ground
"Hazardous point
§Depending on the application and distance, persons must be prevented from standing
behind the protective device.
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Example calculation
Machine stopping time = 290ms
Response time after interruption of the light path = 20ms
T = 290ms + 20ms = 310ms = 0.31s
S = 1,600mm/s × 0.31s + 850mm = 1,346mm
4.3.2 Minimum distance from reflective surfaces
Overview
The light beams from the sender may be deflected by reflective surfaces and dispersive
media. This can prevent an object from being detected.
Therefore, all reflective surfaces and objects (e.g., material bins, machine table, etc.)
must maintain a minimum distance (a) from the light beams. This minimum distance
(a) must be maintained on all sides of the light beams. This applies in horizontal,
vertical and diagonal directions as well as at the end of the device. The same area must
be free of dispersive media (e.g., dust, fog, or smoke).
The minimum distance (a) depends on the distance (D) between sender and receiver.
rs
D
a
Figure 8: Minimum distance from reflective surfaces
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
Reflective surfaces and dispersive media can prevent persons or parts of the body to
be protected from being properly reflected and therefore, they remain undetected.
bMake sure that all reflective surfaces and objects maintain a minimum distance
from the light beams.
bMake sure that no dispersive media (e.g., dust, fog, or smoke) are within the
calculated minimum distance from the light beams.
Determining minimum distance to reflective surfaces
The minimum distance can be determined as follows:
bDetermine the distance between sender and receiver D in meters (m).
bRead the minimum distance a in millimeters (mm) in the graph or calculate using
the respective formula to determine the minimum distance to reflective surfaces:
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10 20 30 40 50 60 70 D/m
500
1000
2000
1500
2500
3000
3500
a/mm
131
3
Figure 9: Graph, minimum distance from reflective surfaces
Table 2: Formula for calculating the minimum distance from reflective surfaces
Distance between sender and
receiver D in m
Calculating the minimum distance from reflective surfa‐
ces a in mm
D ≤3m a = 131mm
D >3m a = tan (2.5°) × 1,000mm/m × D = 43.66 × 1mm/m ×
D
4.3.3 Protection against interference from systems in close proximity to each other
Overview
s
r
s
r
!
"
Figure 10: Preventing mutual interference from system
1 and system 2
The infrared light beams of the sender of system 1 can interfere with the receiver of
system 2. This can disrupt the protective function of system 2. This would mean that
the operator is at risk.
Avoid such installation situations or take appropriate action, e.g., install optically opa‐
que partitions or reverse the direction of transmission of a system.
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
Systems of safety multibeam sensor in close proximity to each other can mutually
interfere with each other.
bUse suitable measures to prevent interference between systems in close proximity
to each other.
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4.3.3.1 Using reversed direction of transmission
The direction of transmission of the system " can be changed during mounting by
switching the positions of the sender and receiver. With reversed direction of mounting,
the receiver " is not affected by the infrared light from the sender !.
"
!
s
s
s
s
s
s
s
s
s
s
s
s
s
s
s
rs
r
Figure 11: Trouble-free operation due to reversed direction of transmission of system
1 and
system
2
4.4 Integrating into the electrical control
This chapter contains important information about integration in the electrical control.
Information about the individual steps for electrical installation of the device: see
"Electrical installation", page 32.
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
In the case of non-compliance, it is possible that the dangerous state of the machine
may not be stopped or not stopped in a timely manner.
bMake sure that the following control and electrical requirements are met so that
the product can fulfill its protective function.
Requirements for use
The output signals of the protective device must be analyzed by downstream controllers
in such a way that the dangerous state of the machine is ended safely. Depending
on the safety concept, signal evaluation is carried out e.g. with safety relays or with a
safety controller.
•It must be possible to electrically influence the control of the machine.
•The electrical control of the machine must meet the requirements of IEC 60204-1.
•A restart interlock must be implemented depending on applicable national regula‐
tions or required reliability of the safety function. Because the protective device
does not have an integrated restart interlock, this must be implemented in the
external control, if required.
•When using a safety controller, different signal levels of both OSSDs must be
detected depending on applicable national regulations or required reliability of the
safety function. The maximum discrepancy time tolerated by the controller must
be selected according to the application
•The OSSD1 and OSSD2 output signals must not be connected to each other.
•In the machine controller, the signals of both OSSDs must be processed sepa‐
rately.
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