SICK IN4000 Direct User manual

OPERATING INSTRUCTIONS
IN4000 Direct
Safety switches

Described product
IN4000 Direct
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
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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........................................................................ 5
1.1 Purpose of this document........................................................................ 5
1.2 Target group.............................................................................................. 5
1.3 Information depth..................................................................................... 5
1.4 Scope......................................................................................................... 5
1.5 Symbols and document conventions...................................................... 6
2 On safety............................................................................................. 7
2.1 Qualified safety personnel....................................................................... 7
2.2 Applications of the safety switches......................................................... 7
2.3 Intended use............................................................................................. 8
2.4 Reasonably foreseeable misuse.............................................................. 8
2.5 General safety notes and protective measures...................................... 8
3 Product description........................................................................... 10
3.1 IN4000 Direct Series safety switches..................................................... 10
3.2 Features and principle of operation........................................................ 10
3.3 Enable zone and assured switch-off distance........................................ 10
3.4 LED indicators........................................................................................... 11
3.4.1 Displays in operating mode..................................................... 11
3.4.2 Displays in adjustment mode................................................. 12
3.5 Signal behavior......................................................................................... 12
3.6 Manipulation prevention.......................................................................... 13
4 Mounting............................................................................................. 14
4.1 Mounting the safety switch...................................................................... 14
5 Connection and adjustment............................................................ 17
5.1 Electrical connection................................................................................ 17
5.2 Adjustment................................................................................................ 17
5.3 Connecting cables.................................................................................... 18
5.3.1 Requirements for the connecting cables............................... 18
5.3.2 Maximum length of cable........................................................ 18
5.3.3 Determining the cable length - case study............................. 19
6 Commissioning and operation........................................................ 20
6.1 Checks before initial commissioning....................................................... 20
6.1.1 Checking the start function..................................................... 20
6.2 Periodic technical inspections................................................................. 20
6.2.1 Daily check............................................................................... 20
6.2.2 Inspections by qualified safety personnel.............................. 20
7 Troubleshooting................................................................................. 21
7.1 Safety......................................................................................................... 21
7.2 Troubleshooting........................................................................................ 21
CONTENTS
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7.3 Safe status when an error occurs............................................................ 21
8 Maintenance...................................................................................... 22
8.1 Maintenance............................................................................................. 22
9 Decommissioning............................................................................. 23
9.1 Disposal..................................................................................................... 23
10 Technical data.................................................................................... 24
10.1 Data sheet................................................................................................. 24
10.2 Pin assignment......................................................................................... 25
10.3 Dimensional drawings.............................................................................. 26
11 Ordering information........................................................................ 27
11.1 Devices...................................................................................................... 27
11.2 Accessories............................................................................................... 27
12 Annex.................................................................................................. 28
12.1 Conformities and certificates................................................................... 28
12.1.1 EU declaration of conformity................................................... 28
12.1.2 UK declaration of conformity.................................................. 28
13 List of figures..................................................................................... 29
14 List of tables....................................................................................... 30
CONTENTS
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1 About this document
1.1 Purpose of this document
These operating instructions provide technical personnel of the machine manufacturer
ormachine operator with instructions regarding the safe mounting, parameterization,
electrical installation, commissioning, operation and thorough check of the inductive
safety switch.
These operating instructions do not provide information on operating the machine in
which a safety switch is integrated. For information about this, refer to the operating
instructions of the specific machine.
1.2 Target group
These operating instructions are intended for planning engineers, developers, and oper‐
ating entities of plants and systems that are to be protected by one or more inductive
safety switches. They are also intended for people who integrate the safety switch into a
machine, or perform the initial commissioning or inspection.
1.3 Information depth
These operating instructions contain information about the inductive safety switch on
the following topics:
•Mounting,
•Electrical installation,
•Hardware commissioning,
•Fault diagnosis and troubleshooting,
•Part numbers,
•Conformity and approval.
Please note that technical skills not covered by this document are also required when
planning and using SICK protective devices.
The official and legal regulations for operating the inductive safety switch must always
be complied with.
General information on the topic of safety technology can be found in the “Guide for
Safe Machinery”.
NOTE
Please also refer to the website at: www.sick.com
There you will find:
•example applications
•a list of frequently asked questions
1.4 Scope
Product
This document applies to the following products:
•Product code: IN4000 Direct
Document identification
Document part number:
•This document: 8027271
•Available language versions of this document: 8012183
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You can find the current version of all documents at www.sick.com.
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.
1 ABOUT THIS DOCUMENT
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2 On safety
This section concerns your own safety and the safety of the system operator.
bPlease read this section carefully before you begin working with the IN4000 Direct
series of inductive safety switches, or the machine protected by these safety
switches in conjunction with the corresponding protective devices.
National and international legal regulations apply to the use/installation of the IN4000
Direct series of safety switches as well as to their commissioning and recurring techni‐
cal inspections, in particular
•the Machinery Directive,
•the EMC Directive,
•the Work Equipment Directive,
•the safety regulations, and
•the accident prevention regulations and work safety regulations.
2.1 Qualified safety personnel
The safety switches must only be installed and commissioned by qualified safety per‐
sonnel. A person is considered qualified safety personnel if he/she
•has taken part in adequate technical training
and
•has been instructed by the machine operator in machine operation and the appli‐
cable safety guidelines
and
•can access these operating instructions.
2.2 Applications of the safety switches
The IN4000 Direct series of safety switches are inductive safety proximity switches that
are actuated by metal in a non-contact manner. The safe state is the de-energized state
(logical “0” of an OSSD).
The IN4000 Direct series of safety switches and the corresponding machine or system
controller can be used, for example, to protect movable physical guards in such a way
that:
•the dangerous state of the machine or system can only be switched on when the
protective devices are closed.
•a stop command is triggered if a protective device is opened while the machine is
running.
For the controller, this means that:
•switch-on commands that result in dangerous states may only be activated when
the protective devices are in the protective position,
and
•dangerous states must be ended before the protective devices are moved out of
the protective position.
Before using the safety switches, a risk assessment must be carried out on the
machine.
Intended use also includes compliance with the relevant requirements for installation
and operation.
ON SAFETY 2
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The safety switches must be subjected to periodic technical inspections (see "Periodic
technical inspections", page 20).
2.3 Intended use
The IN4000 Standard series of safety switches may only be used as described in
section “Applications of the safety switches”. The safety switches may only be installed
by qualified safety personnel and may only be used on the machine on which they
were installed and commissioned for the first time by qualified safety personnel in
accordance with these operating instructions.
The product may be used in safety functions.
The safety switch must only be used within the limits of the prescribed and specified
technical data and operating conditions at all times.
If used in any other way or if alterations are made to the devices – including in the
context of mounting and installation – any warranty claims directed to SICK AG will be
rendered void.
2.4 Reasonably foreseeable misuse
The safety switch is not suitable for the following applications, among others:
•In the vicinity of chemical and biological media (solid, liquid, gaseous)
•In environments with increased levels of ionizing radiation
2.5 General safety notes and protective measures
The safety switch performs a personal protection function. Improper installation or
manipulation can lead to serious personal injuries.
The safety switch complies with the following safety requirements:
•SIL3 according to IEC 61508,
•SILCL3 according to EN 62061,
•Performance Level e according to EN ISO 13849-1 (depending on application).
Change information
•For devices up to CW24 2018, the following applies:
PFHD 1.33 × 10–9/Category 4 (EN ISO 13849-1)
•For devices on or after CW25 2018, the following applies :
PFHD 1.0 × 10–8/Category 3 (EN ISO 13849-1)
bPlease check whether the device meets the safety requirements of your applica‐
tion.
Note regarding the classification of the device according to EN60947--5-2:
•The IN40-E0101K safety switch complies with the I1C40SP2M or I2C40SP2M
classification, depending on the installation method.
•The IN40-E0109K safety switch complies with the I2C40SP2M classification,
depending on the installation method.
2 ON SAFETY
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WARNING
Safety switches must not be circumvented, rotated away, removed, or rendered ineffec‐
tive in any other way. Their contacts must not be bridged.
The inductive safety switches respond to metallic objects. Other metallic objects that
are not intended to trigger the safety function must not be placed on the sensing face
of the safety switches under any circumstances. Appropriate measures must therefore
be taken to prevent this.
Please observe the installation measures according to ENISO14119.
Damaged devices must be replaced.
ON SAFETY 2
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3 Product description
3.1 IN4000 Direct Series safety switches
The safety switch has a cuboid housing with an alignable active sensor face. Its classi‐
fication according to EN60 947--5-2 depends on the mounting method (see table 4,
page 14).
3.2 Features and principle of operation
The IN4000 Direct series of safety switches are typically used for safe position detec‐
tion, as is the case, for example, when monitoring a movable protective device. The
sensor detects the presence of metal. In order to meet the requirements against easy
manipulation, the switching range of the sensor is monitored in time and space.
Its status can be read directly on the sensor or the protective device by means of
LEDs. Errors, such as a coil break, short-circuit or wire break are detected by the
self-monitoring function of the sensor.
The safety switch can be connected directly to a safe PLC or to a SICK safety controller,
e.g., Flexi Classic or Flexi Soft.
3.3 Enable zone and assured switch-off distance
Near range Enable Zone Actuating object
(metal)
Safe switch off
distance
Sensor
Distance
Figure 1: Schematic illustration of the zones
The output of the safety switch is only enabled in the event of actuation within the
enable zone. Outside the enable zone, i.e., also in the close range, the output remains
switched off.
After actuation in the close range, either the supply voltage must be interrupted or the
actuator must be brought into the assured switch-off distance for more than 2s before
it can be enabled again.
The enable zone depends on the type of safety switch and the material and shape of
the actuator. Using other actuators (material, shape) results in a different enable zone.
Typically, the following enable zones are achieved at an ambient temperature of 20°C
with non-flush installation of the safety switch using a standard plate according to
EN60 947-5-2 (IN40-E0101K: 45×45×1mm³, IN40-E0109K: 60×60×1mm³)
and with different materials:
3 PRODUCT DESCRIPTION
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Table 1: Enable zone and assured switch-off distance IN40-E0101K
Material Enable zone Assured switch-off dis‐
tance
Lower boundary Upper boundary
FE360 steel 10mm 15.0mm 30mm
1.4302 stainless steel
(V2A)
7.5mm 13.2mm
AlMg 3G22 2.0mm 5.8mm
Al 99% 1.4mm 5.0mm
CuZn 37 2.3mm 6.2mm
Cu 0.8mm 4.3mm
Table 2: Enable zone and assured switch-off distance IN40-E0109K
Material Enable zone Assured switch-off dis‐
tance
Lower boundary Upper boundary
FE360 steel 4.0mm 20.0mm 45mm
1.4302 stainless steel
(V2A)
2.0mm 17.6mm
AlMg 3G22 0.0mm 9.6mm
Al 99% 0.0mm 8.6mm
CuZn 37 0.0mm 10.0mm
Cu 0.0mm 7.0mm
3.4 LED indicators
The safety switches have two LEDs that indicate the status of the supply voltage and
the operational status.
12
Figure 2: LED displays for voltage supply and operational status
1Power LED, green
2Signal LED, yellow
3.4.1 Displays in operating mode
The yellow signal LED lights up immediately or after a time delay, depending on the
duration of the preceding de-actuation, when an actuator enters the enable zone.
NOTE
Regardless of the behavior of the yellow LED, the output always switches within the
normal response times without any additional delay.
•If the actuator is in the enable range when the supply voltage is switched on, the
yellow signal LED switches after a time delay of 5s.
•If the actuator was ≥2s away from the sensor at the assured switch-off distance
and is then brought back into the enable zone, the yellow signal LED switches after
a delay of 3s.
PRODUCT DESCRIPTION 3
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•If the actuator was <2s away from the sensor at the assured switch-off distance
and is then brought back into the enable zone, the yellow signal LED switches
without a time delay.
•If the actuator is brought to the assured switch-off distance from the sensor, the
yellow signal LED switches off without delay.
•If the actuator is brought into the close range, the yellow signal LED switches off
after a delay of 2s.
Further topics
•"Enable zone and assured switch-off distance", page 10
•"Data sheet", page 24
3.4.2 Displays in adjustment mode
•In adjustment mode, the yellow signal LED flashes when the actuator is outside
the enable zone.
•In adjustment mode, the yellow signal LED goes out when the actuator is within
the enable zone or in the assured switch-off range.
NOTE
In adjustment mode, the output remains in the safe state.
Display Meaning Output states of the outputs
OUT1 (OSSD1) OUT2 (OSSD2)
o Yellow
o Green
No supply voltage 0 0
o Yellow
Ö Green, flash‐
ing slowly
Undervoltage 0 0
o Yellow
Ö Green, flash‐
ing quickly
Overvoltage 0 0
o Yellow
O Green
Output switched off (safe state);
actuator outside the enable zone
(operating mode) or actuator within
the enable zone (adjustment mode)
0 0
O Yellow
O Green
Output activated; actuator within the
enable zone (operating mode)
1 1
Ö Yellow
O Green
Output switched off (safe state);
actuator outside the enable zone
(adjustment mode)
0 0
Ö Yellow
o Green
Internal or external error: 0 0
•e.g., cross-circuit between the
outputs
•
0 1
•e.g., short-circuit of an output to
supply or ground
see "Troubleshooting", page 21
1 0
•"Adjustment", page 17
3.5 Signal behavior
The safe state is the switched off state (de-energized state: logical “0” of an OSSD).
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If the actuator is in the enable zone and no sensor error is present, both output stages
(OSSD) are activated (logical “1”).
The output characteristics are compatible with the input characteristics according to
EN61131-2 type 1 or 2:
Table 3: Output characteristics
Logical “1” ≥15V
≥11V
2 ... 15mA
15 ... 30mA
Logical “0” ≤5V Off-state current: 0.2mA
Pull-down current, typ: 30mA
If the actuator is outside the enable zone, the output is switched off (logical “0”; safe
state).
WARNING
Cross-circuits between the two outputs are detected by the safety switch and lead to
the outputs being switched off (OSSD).
Cross-circuits between the supply voltage and one output are detected and cause the
other output to be switched off.
3.6 Manipulation prevention
WARNING
The inductive safety switches respond to metallic objects, e.g, the frame of a safety
door. Other metallic objects that are not intended to trigger the safety function must
not be placed near the sensing face of the safety switches under any circumstances.
Appropriate measures must therefore be taken to prevent this.
The safety switch is protected against simple circumvention by the following switching
behavior:
•When slowly bringing a metallic object into the enable zone, the output is triggered
immediately, but is only indicated by the signal LED after a time delay of approx.
3s. As a result, the object is usually in the close range zone before the signal
LED lights up. The technical regulations relating to restarting the system must be
observed.
•If this object remains in the close range zone for longer than approx. 2s, the
output is completely blocked and is no longer enable if actuation occurs in the
enable zone. If the object remains in the close range zone for longer than approx.
5s, adjustment mode is activated see "Adjustment", page 17.
The enable zone can be unlocked either
•by de-actuation (IN40-E0101K: >30mm, IN40-E0109K: >45mm) for a period of
more than 2s
or
•by interrupting the voltage see "Adjustment", page 17.
PRODUCT DESCRIPTION 3
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4 Mounting
WARNING
The safety system must only be mounted by authorized qualified personnel.
Select the mounting location and the mounting position of the safety switch in such a
way that
•the safety switch is difficult to access for operating personnel when the protective
device is open,
•thorough checking and replacement of the safety switch is possible.
WARNING
Circumvention of the inductive safety switch in a simple way or unintentional
actuation must be prevented by suitable installation measures in accordance with
ENISO14119.
DANGER
Damage to the safety switch due to mechanical stress
Loss of the safety function
bProtect the safety switch from mechanical stress such as impacts or permanent
contact pressure, for example by means of an additional stop.
4.1 Mounting the safety switch
WARNING
Observe the prescribed mounting method and the resulting classification according to
EN60947-5-2!
Table 4: Permissible mounting methods and resulting classification according to EN60947--5-2
Surrounding material Permissible mounting methods
IN40-E0101K IN40-E0109K
Copper, aluminum, brass Flush
→ I1C40SP2
Non-flush
→ I2C40SP2
Steel Flush on one side or non-flush
→ I2C40SP2
•Note the assured switch-off distance and enable zone (see figure 1, page 10).
•The specified minimum distances for adjacent and opposite sensors and the
minimum distances to fixed system components and walls must be maintained
(see figure 3 and figure 4).
4 MOUNTING
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Figure 3: Minimum distances when mounting the IN40--E0101K safety switch
Figure 4: Minimum distances when mounting the IN40-E0109K safety switch
•The safety switch must be mounted so that the sensing face of the sensor is
oriented towards the moving part of the protective device (door or the like). The
sensing face can be aligned if necessary.
•The safety switch is supplied pre-mounted on a mounting bracket. The mounting
bracket does not need to removed to align the sensing face of the sensor.
Align the sensing face of the safety switch so that it is oriented towards the moving part
of the protective device after mounting.
To align the safety switch:
1. Unscrew the hexagon socket screw on the sensor bracket and pull the sensor off
the bracket (see figure 5 a-b).
2. Loosen the two screws at the lower corner of the sensor housing and rotate the
active sensor face into the correct position (see figure 5 c-d).
3. Screw the sensor housing back on and remount the sensor on the sensor bracket
(see figure 5 e-f).
MOUNTING 4
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a b
dc
e f
Figure 5: Alignment of the active sensor face of the safety switch
4. Fasten the safety switch as securely as possible at the selected mounting location
and position using the mounting bracket. Tighten the non-loosening screws to
1.0Nm.
4 MOUNTING
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5 Connection and adjustment
5.1 Electrical connection
The supply voltage (L+...L-) must be connected between pin 1 and pin 3 of the male
connector. The nominal voltage is 24VDC. This voltage is allowed to fluctuate between
19.2V and 30V with a residual ripple of 5% in accordance with EN 61131--2.
WARNING
The supply voltage must comply with SELV according to EN 60950--1.
To deploy and use the device in accordance with cULus requirements, the supply
voltage must be provided by a secondary fuse-protected transformer. A safe industrial
power supply unit with overvoltage protection must be used. In the event of an error,
60VDC must not be exceeded.
One of the following requirements must be met:
•max. 5A for voltages from 0 ... 20Vrms (0 ... 28.3Vp)
•100/Vp for voltages from 20 ... 30Vrms (28.3 ... 42.4Vp)
WARNING
Prevent the formation of a potential difference between the load and the protective
device!
bIf you connect loads to the OSSDs or safety outputs that are not protected against
polarity reversal, you must connect the 0V connections of these loads and the
connections of the corresponding protective device individually and directly to the
same 0V terminal strip. In the event of an error, this is the only way to ensure that
there can be no potential difference between the 0V connections of the loads and
those of the corresponding protective device.
OSSD1
Sicherheitsausgang
1
OSSD2
Sicherheitsausgang 2
OSSD1
Sicherheitsausgang 1
OSSD2
Sicherheitsausgang 2
5.2 Adjustment
To determine a suitable mounting position, the sensor can be put into an adjustment
mode.
1. Hold a metallic object for about 5s in the close range (see "Enable zone and
assured switch-off distance", page 10) of the sensor; when the yellow signal LED
flashes, the sensor is in adjustment mode.
NOTE
In adjustment mode, the output remains in the safe state.
2. To determine the enable zone, move the actuator in front of the sensor; the yellow
signal LED goes out when the actuator is in the enable zone.
3. Securely mount the sensor and actuator in the position found.
4. Switch off the adjustment mode again by interrupting the voltage or de-actuating
the sensor for more than 2s.
CONNECTION AND ADJUSTMENT 5
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5.3 Connecting cables
5.3.1 Requirements for the connecting cables
Incorrect sizing of the connecting cables can lead to failure of the safety function.
If possible, use connection components and connecting cables from SICK AG. The
connecting cables must meet the following conditions:
Table 5: Suitable connecting cables
Value
Min. wire cross-section 0.34mm²
R max. 60 Ω/km
C max. 120nF/km
L max. 0.65mH/km
Recommended cable type LIYY 8× or 5×0.34mm²
5.3.2 Maximum length of cable
Taking into account the rated cable resistance, the following cable lengths are permissi‐
ble per channel depending on the output current Iout.
SPS
Figure 6: Maximum length of cable
Table 6: Maximum length of cable
Iout [mA] Possible output cur‐
rent per channel OUT1/OUT2
L1 [m] Maximum cable length Rmax [Ω] Maximum permissible
cable resistance
20 65 6.4
30 45 4.4
40 30 3.2
50 25 2.6
70 18 1.8
90 15 1.4
100 12 1.3
WARNING
Limit the cable length and cable resistance to the downstream safety monitoring mod‐
ule to the determined maximum cable length L1 and maximum cable resistance Rmax so
that a cross-circuit between the outputs is reliably detected.
5 CONNECTION AND ADJUSTMENT
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5.3.3 Determining the cable length - case study
The downstream safety monitoring module to which the IN4000 Direct is connected
draws 75mA current on each of the two safety inputs. All relevant values can be
determined with the help of the corresponding table (see table 6).
•In the Iout column, search for a current ≥75mA (example: 90mA).
•The maximum cable length can be found in the L1 column (example: 15m).
•The maximum permissible cable resistance can be found in the Rmax column
(example: 1.4Ω).
CONNECTION AND ADJUSTMENT 5
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6 Commissioning and operation
WARNING
Prior to initial commissioning, qualified safety personnel must thoroughly check and
document the safety functions of the machine or system.
After each modification and after maintenance and repair work, the entire protective
device must be tested for effectiveness by qualified safety personnel.
6.1 Checks before initial commissioning
1. Check adherence to the mounting requirements (see "Mounting", page 14).
2. Perform an electrical function check of the sensor in conjunction with a safety
controller or a safe PLC.
6.1.1 Checking the start function
The check must be performed separately for each protective device.
1. Switch off the machine or system.
2. Move the actuator (metal) to outside the response range of the sensor.
3. Start the machine or system; if the safety function of the protective device is
working, the machine or system must not start.
WARNING
If the machine or system starts nevertheless, check again that the mounting require‐
ments have been adhered to and all electrical connections are of the correct type, and
establish the functional readiness of the safety system.
6.2 Periodic technical inspections
No maintenance is required. Regular thorough checks are required to ensure proper
and lasting function.
6.2.1 Daily check
Every day or before the start of a shift, the operating personnel must check the safety
switch for the following:
•fault-free operation
•no recognizable manipulation
6.2.2 Inspections by qualified safety personnel
The inspection by qualified safety personnel must be carried out regularly in accord‐
ance with the nationally applicable regulations and at the intervals specified therein. If
any changes are made to the machine or someone tampers with the protective device
after initial commissioning, this will ensure that any such issues are detected.
6 COMMISSIONING AND OPERATION
20 O P E R A T I N G I N S T R U C T I O N S | IN4000 Direct 8027271/1CZ5/2022-10-24 | SICK
Subject to change without notice