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
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.
2O 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

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
8027271/1CZ5/2022-10-24 | SICK O P E R A T I N G I N S T R U C T I O N S | IN4000 Direct 3
Subject to change without notice

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
4O 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

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
ABOUT THIS DOCUMENT 1
8027271/1CZ5/2022-10-24 | SICK O P E R A T I N G I N S T R U C T I O N S | IN4000 Direct 5
Subject to change without notice

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
6O 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

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
8027271/1CZ5/2022-10-24 | SICK O P E R A T I N G I N S T R U C T I O N S | IN4000 Direct 7
Subject to change without notice

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
8O 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

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
8027271/1CZ5/2022-10-24 | SICK O P E R A T I N G I N S T R U C T I O N S | IN4000 Direct 9
Subject to change without notice

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
10 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