SICK MLP1 User manual

OPERATING INSTRUCTIONS
MLP1
Safety switch

Described product
MLP1
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 modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten 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 Function of this document....................................................................... 5
1.2 Scope......................................................................................................... 5
1.3 Target groups and structure of these operating instructions................ 5
1.4 Additional information.............................................................................. 5
1.5 Symbols and document conventions...................................................... 5
2 Safety information............................................................................ 7
2.1 General safety notes................................................................................ 7
2.2 Intended use............................................................................................. 7
2.3 Requirements for the qualification of personnel.................................... 8
3 Product description........................................................................... 9
3.1 Structure and function............................................................................. 9
3.2 Product characteristics............................................................................ 9
4 Project planning................................................................................ 12
4.1 Manufacturer of the machine.................................................................. 12
4.2 Operating entity of the machine.............................................................. 12
4.3 Assembly................................................................................................... 13
4.4 Integration into the electrical control...................................................... 13
4.5 Thorough check concept.......................................................................... 19
5 Mounting............................................................................................. 20
5.1 Mounting several safety switches............................................................ 20
5.2 Mounting................................................................................................... 20
6 Electrical installation........................................................................ 23
6.1 Notes on cULus......................................................................................... 23
6.2 Device connection (M12, 5-pin).............................................................. 23
6.3 Device connection (2 x M12, 5-pin)........................................................ 23
6.4 Device connection (M12, 8-pin).............................................................. 24
6.5 Connecting a cascade.............................................................................. 24
7 Commissioning.................................................................................. 30
7.1 Safety......................................................................................................... 30
7.2 Switching on.............................................................................................. 30
7.3 Thorough check........................................................................................ 30
8 Troubleshooting................................................................................. 31
8.1 Safety......................................................................................................... 31
8.2 Troubleshooting........................................................................................ 31
9 Maintenance...................................................................................... 32
9.1 Cleaning..................................................................................................... 32
CONTENTS
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9.2 Regular thorough check........................................................................... 32
10 Decommissioning............................................................................. 33
10.1 Protection of the environment................................................................. 33
10.2 Disposal..................................................................................................... 33
11 Technical data.................................................................................... 34
11.1 Technical data........................................................................................... 34
11.2 Dimensional drawings.............................................................................. 37
12 Ordering information........................................................................ 39
12.1 Scope of delivery....................................................................................... 39
12.2 MLP1 ordering information...................................................................... 39
13 Spare parts......................................................................................... 40
13.1 Actuator..................................................................................................... 40
14 Accessories........................................................................................ 41
14.1 Connectivity............................................................................................... 41
15 Annex.................................................................................................. 44
15.1 Compliance with EU directives................................................................. 44
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 switch.
They must be made available to all people who work with the safety switch.
1.2 Scope
These operating instructions apply only to the MLP1 safety switch.
This document is included with the following SICK part numbers (this document in all
available language versions):
8019902
1.3 Target groups and structure of these operating instructions
These operating instructions are intended for the following target groups: project devel‐
opers (planners, developers, designers), installers, electricians, safety experts (such as
CE authorized representatives, compliance officers, people who test and approve the
application), operators, and maintenance personnel.
The structure of these operating instructions is based on the life cycle phases of the
safety switch: project planning, mounting, electrical installation, commissioning, opera‐
tion, and maintenance.
1.4 Additional information
www.sick.com
The following information is available on the Internet:
•This document in other languages
•Data sheets and application examples
•CAD data of drawings 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.
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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.
Terminology
Dangerous state
A dangerous state is a status of the machine or facility, where people may be injured.
Protective devices prevent this risk if the machine is operated within its intended use.
The figures in this document always show the dangerous state of the machine as move‐
ment of a machine part. In practice, there are different dangerous states, such as:
•Machine movements
•Electrical parts
•Visible and invisible beam
•A combination of multiple hazards
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2 Safety information
2.1 General safety notes
This chapter contains general safety information about the safety switch.
Further information about specific product use situations can be found in the relevant
chapters.
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.
bPlease read this document carefully and make sure that you understand the con‐
tent fully before working with the device.
bFollow all safety notes in this document.
2.2 Intended use
The MLP1 safety switch is a transponder safety switch with a locking function, which is
controlled without contact by actuators and is suitable for the following applications:
•Monitoring of movable physical guards
•Locking device for process protection
The safety switch must only be used within the limits of the prescribed and specified
technical data and operating conditions at all times.
Incorrect use, improper modification of, or tampering with the safety switch will invali‐
date any warranty from SICK; in addition, any responsibility and liability of SICK for dam‐
age and secondary damage caused by this is excluded.
The safety switch is not suitable for the ambient conditions such as, but not limited, to
the following:
•Applications in which the dangerous state cannot be ended immediately (stop‐
ping/run-down time)
•Radioactivity (exception: natural radioactivity)
•Vacuum or high pressure
•High UV load
•In the vicinity of low-frequency RFID devices
•In the vicinity of magnetic fields
WARNING
Improper use of the safety switch
In the event of a voltage drop, the locking device unlocks regardless of whether the
dangerous state of the machine has ended
This safety switch has a simple electromagnetic locking device. There is no locking
device monitoring.
bDo not use the safety switch as a safety locking device according to EN 14119.
bDo not use the safety switch in applications in which the dangerous state cannot
be ended immediately (stopping/run-down time).
The following may impair the function of the safety switch:
•Passing metal chips
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2.3 Requirements for the qualification of personnel
The safety switch must be configured, mounted, connected, commissioned, and ser‐
viced by qualified safety personnel only.
Project planning
For project planning, a person is considered competent when he/she has expertise and
experience in the selection and use of protective devices on machines and is familiar
with the relevant technical rules and national work safety regulations.
Mechanical mounting, electrical installation, and commissioning
For the task, a person is considered qualified when he/she has the expertise and expe‐
rience in the relevant field and is sufficiently familiar with the application of the protec‐
tive device on the machine to be able to assess whether it is in an operationally safe
state.
Operation and maintenance
For operation and maintenance, a person is considered competent when he/she has
the expertise and experience in the relevant field and is sufficiently familiar with the
application of the protective device on the machine and has been instructed by the
machine operator in its operation.
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3 Product description
3.1 Structure and function
The safety switch is an interlocking device with a locking device consisting of a non-con‐
tact sensor with locking solenoid and a coded actuator. The actuator has a low coding
level.
If the protective device is closed, the actuator is led to the sensor. If the actuation field
is reached, the actuator code is read out and evaluated by RFID. If the code is valid, the
safe output signal switching device (OSSD) switches.
If the locking solenoid is supplied with power, the locking device is active.
3.2 Product characteristics
3.2.1 Device overview
12 3
4
5
6
7
Figure 1: Sensor
1Locking solenoid
2Sensor surface
3Cover plate
4Plug connector IN
5Plug connector OUT
6LOCK light emitting diode
7OSSD light emitting diode
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1 2 3
Figure 2: Actuator
1Anchor plate
2Protective cap
3Actuator surface
3.2.2 Product variants
The safety switch is delivered in different variants. You will find an overview of impor‐
tant distinguishing features of the variants in the following.
•2 cables with M12 plug connector (5-pin)
•1 cable with M12 plug connector (5-pin)
•1 cable with M12 plug connector (8-pin)
3.2.3 Locking principle
Important information
DANGER
Hazard due to lack of effectiveness of the protective device
In the event of a voltage drop, the locking device unlocks regardless of whether the
dangerous state of the machine has ended
bDo not use the safety switch in applications in which the dangerous state cannot
be ended immediately (stopping/run-down time).
Power to lock principle
•Lock locking device: voltage at locking device input
•Unlock locking function: no voltage at locking device input
If voltage is interrupted, the locking device is unlocked and the protective device can be
opened immediately.
Complementary information
•The locking device is not monitored, which means that the safety switch does not
check whether the anchor plate is applied to the solenoid.
•The locking force is not monitored.
•Locking force is not a safety-related function.
3.2.4 Protective functions
The safety switch has the following internal protective functions:
•Short-circuit protection at all outputs
•Cross-circuit monitoring at OSSDs
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•Overload protection on OSSDs
•Supply voltage reverse polarity protection
3.2.5 Status indicators
The safety switch outputs important status information using a number of LEDs.
2 1
Figure 3: Status LEDs
Table 1: Status LEDs
No. Name Color Meaning
1LOCK Yellow Lights up when the
magnet is supplied
with voltage.
2OSSD Red/green Lights up green when
the OSSD pair is in the
ON state.
Lights up red when
the OSSD pair is in the
OFF state.1)
1) When a too high load is applied to the application diagnostic output, the red OSSD LED remains continu‐
ously lit. This will not have any effect on the actual switching behavior of the safety switch.
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4 Project planning
4.1 Manufacturer of the machine
DANGER
Failure to comply with manufacturer’s obligations
Hazard due to lack of effectiveness of the protective device
bCarry out a risk assessment before using the safety switch.
bDo not tamper with, open, or modify the components of the safety switch.
bDo not repair defective devices – they must be replaced instead.
bMake sure that switch-on commands which bring about a dangerous state of the
machine are not enabled until the protective device is closed.
bMake sure that a stop command is triggered when the protective device is opened
during the dangerous machine state.
bThe safety switches must not be defeated (contacts jumpered), rotated away,
removed, or rendered ineffective in any other way. If necessary, put measures in
place to reduce possibilities for defeat.
If several devices are connected in series (cascade) and the simplified process accord‐
ing to EN ISO 13849 is used to determine the performance level (PL), the PL may be
reduced.
As the number of safety switches in a cascade increases, so too does the response
time.
4.2 Operating entity of the machine
DANGER
Failure to comply with operating entity’s obligations
Hazard due to lack of effectiveness of the protective device
bModifications to the machine and modifications to the mechanical mounting of
the safety switch necessitate a new risk assessment. The results of this risk
assessment may require the operating entity of the machine to fulfill the manufac‐
turer’s obligations.
bApart from during the procedures described in this document, the components of
the safety switch must not be opened or modified.
bDo not perform repair work on the components. Improper repair of the safety
switch can lead to a loss of the protective function.
bEnsure that there is no bypassing by replacement actuators. Restrict access to
actuators.
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4.3 Assembly
Important information
DANGER
Bypassing the protective device
Hazard due to lack of effectiveness of the protective device
bAvoid incentives to manipulate the safety switch by taking at least one of the fol‐
lowing measures:
°Cover the sensor and the actuator with additional equipment or protect them
against access.
°If possible use permanent mounting methods for actuators (e.g., glue, safety
screws, or rivets).
Mounting location
bSelect the mounting location so that the sensor and actuator are accessible for
maintenance work and are protected against damage.
bSelect a mounting location that ensures the sensor is as far away from the door
hinge as possible.
bIf necessary, fit an additional stop for the moving protective device.
Distance
When several safety switches are mounted to the machine, they must be mounted at a
minimum distance to one another see "Mounting several safety switches", page 20.
Alignment
The safety switch can be mounted in any alignment. When mounted horizontally, manip‐
ulation protection is increased by the anchor plate with rotating bearings. When
mounted horizontally, if the actuator is triggered by the movable physical guard, the
actuator is held by the magnet. As the anchor plate has rotating bearings, the gravita‐
tional force rotates the actuator surface away from the sensor surface and the OSSDs
go into the OFF state.
2 possible mounting methods
The sensor can be mounted in 2 ways:
•Surface mounting. The sensor is mounted on the fixed part of the protective
device (e.g., door frame).
•Flush mounting. The sensor is mounted in the fixed part of the protective device
(e.g., door frame). There must be a suitable recess in the mounting surface. The
thickness of the mounting surface must be between 1.5 mm and 3 mm.
Complementary information
Dimensional drawing of the recess for flush mounting see figure 17.
4.4 Integration into the electrical control
Switch-on commands that put the machine in a dangerous state may only be activated
when the protective device is closed. When the machine goes into a dangerous state, a
stop command must be triggered if the protective device is opened. Depending on the
safety concept, the signal is analyzed by safety relays or a safety controller, for example.
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The control that is connected and all devices responsible for safety must comply with
the required performance level and the required category (for example, according to
ISO 13849-1).
4.4.1 OSSDs
Safety switches with local inputs and outputs can be directly integrated into the
machine controller.
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 the
protective function can be fulfilled.
•The output signals from an OSSD pair must not be connected to each other.
•In the machine controller, both signals from an OSSD pair must be processed sep‐
arately.
Figure 4: Dual-channel and isolated connection of OSSD 1 and OSSD 2
•The machine must switch to the safe state at any time if at least one OSSD in an
OSSD pair switches to the OFF state.
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•Prevent the formation of a potential difference between the load and the protec‐
tive device. If you connect loads to the OSSDs (safety outputs) that then also
switch if controlled with negative voltage (e.g., electro-mechanical contactor with‐
out reverse polarity protection diode), you must connect the 0 V connections of
these loads and those of the corresponding protective device individually and
directly to the same 0 V terminal strip. In the event of a fault, 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.
Figure 5: No potential difference between load and protective device
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.
Downstream contactors must be positively guided and monitored depending on applic‐
able national regulations or required reliability of the safety function.
bMake sure that downstream contactors are monitored (external device monitoring,
EDM).
Requirements for the electrical control of the machine
•Use the control without test pulses. The safety switch is self-testing.
•The safety switch tests the OSSDs at regular intervals. To do this, it switches each
OSSD briefly (for max. 1 ms) to the OFF state and checks whether this channel is
voltage-free during this time.
Make sure that the machine’s control does not react to these test pulses and the
machine does not switch off.
•The inputs of a connected evaluation unit must be positive-switching (PNP), as the
two outputs of the safety switch send a level of the supply voltage in the switched-
on state.
The OSSDs are short-circuit protected to 24 V DC and 0 V. When the actuator is in the
sensor’s response range, the OSSDs signal the ON state with the HIGH signal level (non-
isolated). If the actuator is removed from the sensor’s response range or there is a
device fault, the OSSDs signal the OFF state with the LOW signal level.
The safety switch complies with the regulations for electromagnetic compatibility (EMC)
for the industrial sector (Radio Safety Class A). Radio interference cannot be ruled out
when used in residential areas.
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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 the
safety switch can fulfill its protective function.
•The external voltage supply of the safety switch must be capable of jumpering brief
power failures of 20 ms as specified in IEC 60204-1.
•The power supply unit must provide safe isolation according to IEC 61140 (SELV/
PELV). Suitable power supply units are available as accessories from SICK.
4.4.2 Course of the OSSD test over time
OSSD 1
V
t
1
OSSD 2
V
t
300 µs
300 µs
Figure 6: Course of the OSSD test over time
1Usually every 40 ms.
The interval is dynamic and can be smaller than 40 ms.
4.4.3 Controlling the locking solenoid
The locking solenoid is activated through the upstream control. There is no internal acti‐
vation or deactivation of the locking solenoid through the safety switch. The locking
device and locking force are not monitored. When the machine starts, the following
sequence must be followed:
1 Check whether safety switch OSSDs are in the ON state.
2 Supply the locking solenoid with power.
3 Start the machine.
4.4.4 Application diagnostic output
Switching behavior of the application diagnostic output
The application diagnostic output signal changes as soon as the actuator is moved into
or out of the response range of the safety switch. That is, when the movable protective
device is opened or closed. This is not a safety output.
Table 2: Switching behavior of the application diagnostic output
Actuator Application diagnostic output
Actuator not in the response area, or safety
switch in an error state
OFF
Actuator in the response area ON
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Further topics
•"Technical data", page 34
4.4.5 Cascading
Several safety switches can be connected using cascading. The connected devices act
like one device.
Structure of a cascade
A cascade can be structured as follows:
•Connecting the safety switches with M12 plug connectors, terminating the cas‐
cade with an end connector (only for variant with 2 M12 plug connectors)
•Connecting the safety switches with special T-connectors, terminating the cascade
with an end connector (only for variant with 8-pin M12 plug connector)
DANGER
Bypassing the protective device
The dangerous state may not be stopped in the event of non-compliance.
1. If a cascade is created with directly connected safety switches, the connecting
cable must be mounted so that a safety switch cannot be easily jumpered; e.g.,
cover plug connector or protect against access with additional means (e.g., protec‐
tive cover with disposable screws).
2. If a cascade is created with T-connectors, the connecting cable must be mounted
so that individual T-connectors (and therefore a safety switch) cannot be easily
jumpered.
Both connection methods can be combined as desired.
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Using other safety switches
NOTE
In a cascade, other safety switches within the cascade can also be used via special T-
connectors as long as the connections are structured as follows:
8
2
3
4
57
1
6
Table 3: Device connection pin assignment (male connector, M12, 8-pin, A-coded)
Pin Wire color 1) Designation Description
1 White – – 2)
2 Brown +24 V DC Safety switch voltage supply
3 Green N. c.
or
+24 V DC
Not connected
or
Voltage supply for locking device
3)
4 Yellow In 2 OSSD 2 input
5 Gray OSSD 1 OSSD 1 output
6 Pink OSSD 2 OSSD 2 output
7 Blue 0 V 0 V DC voltage supply
8 Red In 1 OSSD 1 input
1) Applies to the extension cables recommended as accessories.
2) Pin 1 is not assigned on T-connector. Safety switch signals to pin 1 are not relevant for the cascade (see
figure 18).
3) The locking device must function in accordance with the power to lock principle.
Additional voltage supply
The voltage drop in the cascade must be checked so that the defined minimum voltage
is still applied to each safety switch. If the defined minimum voltage is no longer
applied to a safety switch, a node for voltage supply must be integrated. The node for
voltage supply must be integrated in the direction of the safe evaluation unit, as close
as possible to the relevant switch in the cascade.
Number of safety switches
The maximum number of safety switches depends on the following factors:
•Applied supply voltage
•Length of cables used
•Cable cross-section of cables used
•Load current
•Nodes for voltage supply
•Required performance level (see "Technical data", page 34)
The number of safety switches in a cascade influences the response time of the system
(see "Technical data", page 34).
The maximum number of safety switches in a cascade changes depending on the total
length of cable as follows:
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Table 4: Maximum number of cascadable safety switches in relation to the total length of the cas‐
cade
Maximum number of cascadable safety
switches
Total length of the cascade 1)
1 140 m
2 70 m
3 46 m
4 35 m
5 28 m
6 22 m
7 20 m
1) At a cable cross-section of 0.34 mm²
If a cascade has more safety switches or gets longer, additional voltage must be fed in
via a node for voltage supply.
4.5 Thorough check concept
The safety switch must be tested by appropriately qualified safety personnel during
commissioning, after modifications, and at regular intervals; see "Thorough check",
page 30.
Regular thorough checks serve to investigate the effectiveness of the safety switch and
discover defects resulting from modifications or external influences (such as damage or
manipulation).
The manufacturer and operating entity must define the type and frequency of the thor‐
ough checks on the machine on the basis of the application conditions and the risk
assessment. The process of defining the thorough checks must be documented in a
traceable manner.
4.5.1 Minimum requirements for the regular thorough check
The following thorough checks must be carried out at least once a year:
•Thorough check of the protective function of the safety switch
•Thorough check of the switch housing for damage
•Thorough check of the switch cables for damage
•Thorough check of the safety switch for signs of misuse or manipulation
•Thorough check of the locking solenoid for correct function
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5 Mounting
5.1 Mounting several safety switches
bWhen several safety switches are mounted, the prescribed minimum distance
between the individual systems must be adhered to in order to avoid mutual inter‐
ference.
260mm
260mm
5.2 Mounting
2 possible mounting methods
The sensor can be mounted in 2 ways:
•Surface mounting. The sensor is mounted on the fixed part of the protective
device (e.g., door frame).
•Flush mounting. The sensor is mounted in the fixed part of the protective device
(e.g., door frame). There must be a suitable recess in the mounting surface. The
thickness of the mounting surface must be between 1.5 mm and 3 mm.
Dimensional drawing of the recess for flush mounting see figure 17.
NOTE
Installing the safety switch horizontally increases protection against manipulation.
Mounting the sensor
1. Unscrew the fixing screw (hexagon socket, 2 mm) and remove the cover plate:
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