SICK C 4000 User manual

OPERATING INSTRUCTIONS
Safety Light Curtain
C 4000

Operating Instructions Chapter 2
C4000
8©SICK AG • Safety Systems • Germany • All rights reserved 8 009 221/L057/15-03-01
On safety
2On safety
This chapter deals with your own safety and the safety of the equipment operators.
!Please read this chapter carefully before working with the C 4000 or with the machine
protected by the C 4000.
2.1 Specialist personnel
The safety light curtain C 4000 must be installed, commissioned and serviced only by spe-
cialist personnel. Specialist personnel is defined as persons who
•have undergone the appropriate technical training
and
•who have been instructed by the responsible machine operator in the operation of the
machine and the currently valid safety guidelines
and
•who have access to these operating instructions
2.2 Range of uses of the device
The safety light curtain C 4000 is an electro-sensitive protective equipment (ESPE). The
physical resolution is 14, 20, 30 or 40 mm with a maximum protective field width of 19 me-
ters (resolution 20 mm and higher). The realisable protective field height is between 300
and 1,800 mm.
The device is a Type 4 ESPE as defined by IEC 61496-1 and -2 and is therefore allowed for
use with controls in safety category 4 in compliance with EN 954. The device is suitable for
•Hazardous point protection (finger and hand protection)
•Hazardous area protection
•Access protection
Access to the hazardous point must be allowed only through the protective field. The plant/
system is not allowed to start as long as personnel are within the hazardous area. Refer to
chapter 3.3 “Examples of range of use” on page 12 for an illustration of the protection
modes.
Depending on the application, mechanical protection devices may be required in addition
to the safety light curtain.
Note The safety light curtain C 4000 operates as standalone system, comprising a sender and
receiver, or in combination with other cascadable C 4000 systems. This means that the
protective field can be adapted to suit individual safety requirements.
2.3 Proper use
The safety light curtain C 4000 must be used only as defined in the chapter 2.2 “Range of
uses of the device”. It must be used only by qualified personnel and only on the machine
where it has been installed and initialized by qualified personnel.
If the device is used for any other purposes or modified in any way – also during mounting
and installation – any warranty claim against SICK AG shall become void.

Operating Instructions Chapter 2
C4000
On safety
8 009 221/L057/15-03-01 ©SICK AG • Safety Systems • Germany • All rights reserved 9
2.4 General protective notes and protective measures
WARNING
Safety notes
Please observe the following items in order to ensure the proper and safe use of the safety
light curtain C 4000.
•The national/international rules and regulations apply to the installation, use and recur-
ring technical inspections of the safety light curtain, in particular:
– Machine Directive 98/37/EEC
– Equipment Usage Directive 89/655/EEC
– the work safety regulations/safety rules
– other relevant health and safety regulations
Manufacturers and users of the machine by which the safety light curtain is used are re-
sponsible for obtaining and observing all applicable safety regulations and rules.
•The notices, in particular the test regulations (see “Test notes” on page 36) of these op-
erating instructions (e.g. on use, mounting, installation or integration into the existing ma-
chine controller) must be observed.
•The tests must be carried out by specialist personnel or specially qualified and authorized
personnel and must be recorded and documented to ensure that the tests can be recon-
structed and retraced at any time.
•The operating instructions must be made available to the user of the machine where the
safety light curtain C 4000 is fitted. The machine operator is to be instructed in the use
of the device by specialist personnel and must be instructed to read the operating in-
structions.
•The external voltage supply of the device must be capable of buffering brief mains fail-
ures of 20 ms as specified in EN 60204. Suitable power supplies are available as acces-
sories from SICK (Siemens type series 6 EP 1).
2.5 Protection of the environment
The safety light curtain C 4000 has been designed to minimize environmental impact. It
uses only a minimum of power and natural resources.
At work, always act in an environmentally responsible manner. For this reason please note
the following information on disposal.
Disposal
%Always dispose of unserviceable or irreparable units in compliance with local/national
rules and regulations with respect to waste disposal.
%Remove the plastic panel and dispose of the aluminium housing of the light curtain as
recyclable waste.
%Dispose all electronic assemblies as special or hazardous waste. The electronic assem-
blies are easy to dismantle.
Note SICK AG will not accept unserviceable or irreparable units returned to the company.

Operating Instructions Chapter 5
C4000
30 ©SICK AG • Safety Systems • Germany • All rights reserved 8 009 221/L057/15-03-01
Electrical installation
5Electrical installation
WARNING
Switch the entire machine system off line!
The machine system could inadvertently start up while you are connecting the unit.
%Make sure that the entire machine/system is disconnected during the electrical instal-
lation.
Notes •The safety light curtain is a Class A device. It may cause radio interference in residential
areas. If radio interference occurs, the person(s) affected may demand that the operator
take appropriate action for suppressing interference.
•To ensure full electromagnetic compatibility (EMC), functional earthing (FE) must be con-
nected.
•The external voltage supply of the device must be capable of buffering brief mains fail-
ures of 20 ms as specified in EN 60204. Suitable power supplies are available as acces-
sories from SICK (Siemens type series 6 EP 1).
•The plug alignment (direction of turn) in the housing may vary from unit to unit. You can
identify the proper pin assignment by the position of the pins in relation to each other as
shown in the drawings.
•System connections and extension connections in a cascaded system must be connect-
ed only if the system is off line. The RS 232 interface may be connected/disconnected
with the system on line.
5.1 System connection M26×11 + FE
Fig. 23: Pin assignment system
connection M26×11 + FE
Pin Wire colour 'Sender (Receiver
1 brown 24 V DC input (voltage supply) 24 V DC input (voltage supply)
2 blue 0 V DC (voltage supply) 0 V DC (voltage supply)
3 grey test input:
0 V: external test active
24 V: external test inactive
OSSD1 (switching output 1)
4 pink reserved OSSD2 (switching output 2)
5 red reserved reset/restart
6 yellow reserved external device monitoring
(EDM)
7 white reserved reserved
4 3 2 9 1
5 10 6 7 11 8
FE
4 3 2 9 1
5 10 6 7 11 8
FE
Tab. 7: Pin assignment system
connection M26×11 + FE

Operating Instructions Chapter 5
C4000
Electrical installation
8 009 221/L057/15-03-01 ©SICK AG • Safety Systems • Germany • All rights reserved 31
5.2 Configuration connection
M8×4 (serial interface)
Fig. 24: Pin assignment config-
uration connection M8×4
Notes The pin assignment of sender and receiver is identical.
%After the configuration of the device has been completed, press the attached protection
cap over the configuration connection.
8 red/blue reserved reserved
9 black device communication device communication
10 purple device communication device communication
11 grey/pink input host/guest SEL input host/guest SEL
FE green functional earthing functional earthing
Pin Wire colour 'Sender (Receiver
Tab. 7: Pin assignment system
connection M26×11 + FE
(contd.)
Pin 'Sender/(receiver PC-side RS 232 SubD
1notassigned
2RxD pin3
30VDC(voltagesupply) pin5
4TxD pin2
3
1
4
2
Tab.
8
: Pin assignment
configuration connection
M8×4

Operating Instructions Chapter 6
C4000
Commissioning
8 009 221/L057/15-03-01 ©SICK AG • Safety Systems • Germany • All rights reserved 35
6Commissioning
WARNING
No commissioning without a thorough check-up by qualified personnel!
Before you operate a system protected by the safety light curtain C 4000 for the first time,
make sure that the system is first checked and approved by qualified personnel. Please
note the notices in the chapter “On safety” on page 8.
6.1 Display sequence during power-up
After the system is activated, sender and receive go through the power-up cycle. The 7-seg-
ment display indicates the device status during the power-up cycle.
The display values have the following meaning:
6.2 Aligning sender and receiver
After the light curtain has been mounted and connected, sender and receiver must be
aligned in relation to each other. The light beams emitted by the sender must hit the receiv-
er with pin-point accuracy.
Note If you wish to align a cascaded system, always align the individual systems in the following
sequence: host, guest 1, guest 2.
This is how to align sender and receiver in relation to each other:
WARNING
Secure the plant/system. No dangerous state!
Make sure that the dangerous state of the machine is (and remains) switched off! During
the alignment process, the outputs of the safety light curtain are not allowed to have any
effect on the machine.
%Loosen the clamping bolts which hold the light curtain in place.
%Switch on the power supply of the light curtain.
%Watch the alignment information on the 7-segment display of the receiver (see table 11).
Correct the alignment, until the 7-segment display goes off.
%Using the clamping bolts, fix the light curtain in place.
Display Meaning
3,4,5,6,
7,8,9,:
Testing the 7-segment display. All segments are activated sequen-
tially.
2Approx. 0.5 s. Is displayed only at the receiver and only in operation
with large scanning range.
;,<or =Approx. 0.5 s. System operates as host (;) or as guest 1 (<) or
guest 2 (=) in a cascaded system.
-,.or /Approx. 0.5 s. Non-coded operation or operation with code 1 or 2.
No display
or *
The device is operational. Display *appears if the device is oper-
ated with reduced resolution and/or with blanking.
0,1or 'Receivers only: Receiver-sender alignment incorrect (see
“Aligning sender and receiver” below).
Other display Device error. See „Fault diagnosis“ on page 40.
Tab. 10: Displays shown during
the power-up cycle

Operating Instructions Chapter 6
C4000
36 ©SICK AG • Safety Systems • Germany • All rights reserved 8 009 221/L057/15-03-01
Commissioning
%Switch the power supply off and then back on again and check via the 7-segment display
whether the alignment is correct after tightening the clamping bolts table 11.
The display values have the following meaning:
Notes •If the optimum alignment (= no display) persists for longer than 2 minutes, the system
automatically deactivates the alignment mode.
•If you wish to readjust the alignment later, switch the power supply of the C 4000 off and
back on again.
•The host in a cascaded system remains on red until all guests have been accurately
aligned.
6.3 Test notes
6.3.1 Tests before the first commissioning
The purpose of the tests before the first commissioning is to confirm the safety require-
ments specified in the national/international rules and regulations, especially in the
Machine and Equipment Usage Directive (EU Conformity).
%Check the effectiveness of the protective device mounted to the machine, using all
selectable operating modes as specified in the checklist in the annex (see 12.2 on
page 60).
%Make sure that the operating personnel of the machine secured by the light curtain are
properly instructed by specialist personnel before being allowed to operate the machine.
Instructing the operating personnel is the responsibility of the machine operator.
%Annex 12.2 of this document shows a checklist for review by the manufacturer and OEM.
Use this checklist as reference before commissioning the system for the first time.
6.3.2 Regular inspection of the protective device by qualified personnel
%Check the system, following the inspection intervals specified in the national rules and
regulations. This procedure ensures that any changes on the machine or manipulations
of the protective device are detected before commissioning.
%If substantial modifications have been made to the machine or the protective device, or
if the safety light curtain has been changed or repaired, the system must be checked
again as specified in the checklist in the annex.
Display Meaning
0The receiver cannot synchronise with the sender; the alignment is
highly inaccurate.
1Some light beams do not hit the receiver.
'All the light beams hit the receiver, but the alignment is still slightly off.
No display
or *
The alignment is now true; the devices must be locked in this position.
Display *appears if the device is operated with reduced resolution
and/or with blanking.
Tab. 11: Display values during
the alignment of sender and
receiver

Operating Instructions Chapter 6
C4000
Commissioning
8 009 221/L057/15-03-01 ©SICK AG • Safety Systems • Germany • All rights reserved 37
6.3.3 Daily function checks of the protective device
The effectiveness of the protective device must be checked daily by a specialist or by au-
thorized personnel, using the proper test rod.
Note Always align the test movements along the hazardous area to be protected, never along the
mounting position of the light curtain.
How to check the effectiveness and proper function of the safety light curtain:
%Select the correct test rod depending on device resolution. If you operate the unit with
reduced resolution (display *on the receiver), select the test rod using the following
table:
WARNING
No operation while the green or yellow LED is lit during the test!
If the green or yellow LED lights up during the test even for a short period, work must stop
at the machine. In this case the installation of the safety light curtain must be checked by
specialized personnel (see chapter 4).
%Before inserting the test rod, check that the green LED is lit if the internal restart inter-
lock is deactivated and that the yellow LED flashes (“Reset required”) If this is not the case,
make sure that this condition is reached. The test is otherwise meaningless.
%Move the test rod slowly through the protective field to be tested, as shown in !
in figure 28.
%Then move the test rod along the edges of the protective field, as shown in "in
figure 28. This procedure allows you to test if the point-of-operation guard/reaching
behind protection is functioning properly (see 4.2 “Steps for mounting the device” on
page 25).
Note In both tests, the receiver of the C 4000 must show the red LED only.
Fig. 28: Daily checks of the pro-
tective device
Physical resolution Reduction Effective resolution
14 mm 1 beam 22 mm
2 beams 30 mm
3 beams 37 mm
20 mm 1 beam 30 mm
2 beams 40 mm
Tab. 12: Selecting the test rod
under reduced resolution
"
!

Operating Instructions Chapter 9
C4000
40 ©SICK AG • Safety Systems • Germany • All rights reserved 8 009 221/L057/15-03-01
Fault diagnosis
9Fault diagnosis
This chapter describes how to identify and remedy errors and malfunctions during the op-
eration of the safety light curtain.
9.1 What to do in case of faults
WARNING
No operation if the cause of the malfunction has not been clearly identified!
Stop the machine if you cannot clearly identify or allocate the error and if you cannot safely
remedy the malfunction.
9.2 SICK Support
If you cannot remedy an error with the help of the information provided in this chapter,
please contact your local SICK agency.
9.3 Error displays of the LEDs
This chapter explains the meaning of the error displays of the LEDS and how to respond.
Please refer to the description in the chapter “Indicator elements” on page 20.
Display Cause Remedying the error
!Orange LED of receiver
lights up
Weak signal %Check the alignment of
sender and receiver.
%Check the front screen (dirt)
and clean, if necessary
#Yellow LED of receiver
flashes
Reset required %Press the reset button.
)Yellow LED of sender fails to
light up
No operating volt-
age, or voltage too
low
%Check the voltage supply and
activate, if necessary.
)Neither the red nor the
green receiver LED lights up
Tab. 13: Error displays of
the LEDs

Operating Instructions Chapter 9
C4000
Fault diagnosis
8 009 221/L057/15-03-01 ©SICK AG • Safety Systems • Germany • All rights reserved 41
9.4 Error displays of the 7-segment display
This chapter explains the meaning of the error displays of the 7-segment display and how
to respond to the messages. Please refer to chapter “Indicator elements” on page 20 for a
description of the 7-segment display.
Display Cause Remedying the error
0,1
or '
Inadequate alignment %Re-align sender and receiver (see page 35).
The display goes off after 2 minutes.
>Configuration
incomplete
%The display goes off automatically once the con-
figuration has been successfully transferred.
If display >does not go off:
%Check the configuration of the system using the
CDS (Configuration & Diagnostic Software).
%Re-transfer the corrected configuration to the
system.
(
or
)
EDM error %Check the contactors and their wiring, eliminate
any wiring errors, if necessary.
%If )is displayed, switch the device off and back
on again.
?Error in reset button/
restart button
%Check the reset button/restart button for proper
function. The button may be defective or stuck.
%Check the wiring of the reset button/restart but-
ton for any short circuit at 24 V.
+System error %Replace the unit (receiver or sender).
%#1 Overcurrent at
switching output 1
%Check the contactor. Replace, if necessary.
%Check the wiring for short-circuit at 0 V.
%#' Short circuit at
switching output 1
%Check the wiring for short-circuit at 24 V.
%#@ Short circuit at
switching output 1
%Check the wiring for short-circuit at 0 V.
%#A Overcurrent at switch-
ing output 2
%Check the contactor. Replace, if necessary.
%Check the wiring for short-circuit at 0 V.
%#B Short circuit at switch-
ing output 2
%Check the wiring for short-circuit at 24 V.
%#> Short circuit at
switching output 2
%Check the wiring for short-circuit at 0 V.
%#C Short circuit between
switching output 1
and 2
%Check the wiring and remedy the error.
Tab. 14: Error displays of
the 7-segment display

Operating Instructions Chapter 9
C4000
42 ©SICK AG • Safety Systems • Germany • All rights reserved 8 009 221/L057/15-03-01
Fault diagnosis
9.5 Extended diagnosis
The CDS software supplied with the device (Configuration & Diagnostic Software) includes
extended diagnosis options. It allows you to narrow down the problem if the error is non-
specific or if you experience availability problems. Detailed information to be found
•in the online help function of the CDS (Configuration & Diagnostic Software)
•in the user manual for the CDS
!#' Invalid configuration of
the EDM
%Verify that the machine-side EDM is connected
properly.
!#@ External sender
detected
%Check the distance from reflecting surfaces
(page 24) or from other light curtains.
%If necessary, re-configure the device with another
beam coding (page 14) or mount non-reflecting
partition walls.
!#A Connection problem
between host and
guest
%Check the connection between the cascaded
devices. If necessary, replace defective cables.
!#B Communication in cas-
caded system failed
%Verify the configuration of the system using the
CDS (Configuration & Diagnostic Software).
Retransfer the corrected configuration to the
system.
%Check the connection between the cascaded
devices. If necessary, replace defective cables.
!#? Supply voltage too low %Check the supply voltage and the power supply. If
necessary, replace defective components.
%Switch the device off and back on again.
Display Cause Remedying the error
Tab. 14: Error displays of
the 7-segment display
(contd.)

Operating Instructions Chapter 10
C4000
Technical specifications
8 009 221/L057/15-03-01 ©SICK AG • Safety Systems • Germany • All rights reserved 43
10 Technical specifications
10.1 Data sheet
minimum typical maximum
General system data
Protective field height, depending
on type
300 mm to 1800 mm
Resolution, depending on type 14 mm to 40 mm
Protective field width
Resolution14mm 0m 6m
Resolution 20, 30 or 40 mm 0m 19m
Protection class (VDE 106) III
Enclosure rating IP 65
Supply voltage UVat appliance1) 19.2 V 24 V 28.8 V
Residual ripple2) ±10%
Synchronisation Optical, without separate synchronisation
Safety category (EN 61496) Type 4
ON time after applying the supply
voltage of sender and receiver
8s
Sender unit
Test input
Input resistance (High) 10 kΩ
Sender inactive (test) –1 V 0 V 5 V
Sender active (High) 15 V 24 V 28.8 V
Response time to test Depending on number of beams
Wavelength of sender 940 nm
Power consumption 2 A (host/
guest/guest)
Weight Depending on protective field height (see page 47)
Receiver unit
Switching outputs (OSSDs) 2 PNP semiconductor, short-circuit protected3),
cross-circuit monitored
Switching voltage HIGH active
(Ueff )4)
15 V 24 V 28.8 V
SwitchingvoltageLOW0V0V3.5V
Switching current 500 mA
Leakage current5) 0.25 mA
Load capacity 2.2 µF
Switching sequence Depending on load inductance
Load inductance6) 2.2 H
Test pulse data7)
Test pulse width 120 µs150µs300µs
Test pulse rate 3 1/s5 1/s10 1/s
Tab. 15: Technical
s
pecifications C 4000

Operating Instructions Chapter 10
C4000
44 ©SICK AG • Safety Systems • Germany • All rights reserved 8 009 221/L057/15-03-01
Technical specifications
Permissible line resistance
between device and load8) 2.5 Ω
Supply lead 1 Ω
ON time after light beam
disruption
double
response time
Power consumption 3 A (host/
guest/guest)
Contactors
Permissible fall time 300 ms
Permissible response time 300 ms
Control switch input9) 15 V 24 V 28.8 V
Weight Depending on protective field height (see page 47)
Operating data
Connection Hirschmann plug M26×11 + FE
Cable length Depending on load, power supply and wire cross-
section. The technical specifications must be
observed.
Wire cross-section10) 0.75 mm2
Ambient operating temperature 0°C +55°C
Air humidity (non-dewing) 15% 95%
Storage temperature –25°C +70°C
Housing cross-section 40 mm × 48 mm
Rigidity 5 g, 10-55 Hz acc. to IEC 68-2-6
Shock resistance 10 g, 16 ms acc. to IEC 68-2-29
1) The external voltage supply must be capable of buffering brief mains failures of 20 ms as specified in
EN 60204. Suitable power supplies are available as accessories from SICK (Siemens type series 6 EP 1).
2) Within the limits of UV.
3) Applies to the voltage range between UVand 0 V.
4) In compliance with IEC 61131.
5) In case of malfunction (disruption of 0 V lead) the output acts like a resistor >13 kΩafter UV. The down-
stream controller must detect this status as LOW. A safe SPC (Stored-Programme Controller) must be able
to identify this status.
6) The maximum rated load inductance is higher with lower switching sequence.
7) When active, the outputs are tested cyclically (brief LOW). When selecting the downstream controllers,
make sure that the test pulses do not result in deactivation when using the above parameters.
8) Make sure to limit the individual line core resistance to the downstream controller to this value to ensure
that the cross-circuit between the outputs is safely detected. (Also note EN 60204 Electrical Machine
Equipment, Part 1: General Requirements.)
9) In compliance with IEC 61131-2.
10) Maximum cable length ≤50 m.
minimum typical maximum
Tab. 15: Technical specifi-
cations C 4000 (contd.)