SICK T4000 Direct Unicode User manual

OPERATING INSTRUCTIONS
T4000 Direct
Transponder safety switches

Described product
T4000 Direct
Transponder safety switches
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 Further information................................................................................... 5
1.5 Symbols and document conventions...................................................... 6
2 Safety information............................................................................ 8
2.1 General safety notes................................................................................ 8
2.2 Intended use............................................................................................. 8
2.3 Requirements for the qualification of personnel.................................... 8
3 Product description........................................................................... 10
3.1 Structure and function............................................................................. 10
3.2 Product characteristics............................................................................ 11
4 Project planning................................................................................ 13
4.1 Manufacturer of the machine.................................................................. 13
4.2 Operating entity of the machine.............................................................. 13
4.3 Design........................................................................................................ 14
4.4 Integration into the electrical control...................................................... 14
4.5 Thorough check concept.......................................................................... 14
5 Mounting............................................................................................. 16
5.1 Safety......................................................................................................... 16
5.2 Unpacking.................................................................................................. 16
5.3 Mounting................................................................................................... 16
5.4 Changing the approach direction............................................................ 18
6 Electrical installation........................................................................ 20
6.1 Safety......................................................................................................... 20
6.2 Failsafety................................................................................................... 20
6.3 Protection of the voltage supply.............................................................. 21
6.4 Notes on cULus......................................................................................... 21
6.5 Device connection M12×8....................................................................... 21
6.6 Connecting cables.................................................................................... 22
6.7 Y-distribution and end connector............................................................. 24
6.8 Connection................................................................................................ 25
7 Commissioning.................................................................................. 30
7.1 Safety......................................................................................................... 30
7.2 Switching on.............................................................................................. 30
7.3 Teach-in..................................................................................................... 30
7.4 Thorough check........................................................................................ 32
CONTENTS
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8 Troubleshooting................................................................................. 33
8.1 Safety......................................................................................................... 33
8.2 LED status indicators............................................................................... 33
8.3 System status........................................................................................... 33
9 Maintenance...................................................................................... 35
9.1 Safety......................................................................................................... 35
9.2 Cleaning..................................................................................................... 35
9.3 Regular thorough check........................................................................... 35
9.4 Thorough check of the safety function.................................................... 35
10 Decommissioning............................................................................. 37
10.1 Disposal..................................................................................................... 37
11 Technical data.................................................................................... 38
11.1 Sensor T40-E01.1K.................................................................................. 38
11.2 T4000-1KBA actuator.............................................................................. 40
11.3 T4000-1KBQ actuator.............................................................................. 41
11.4 T4000-1KBR actuator.............................................................................. 43
11.5 Dimensional drawings.............................................................................. 44
12 Ordering information........................................................................ 46
12.1 Devices...................................................................................................... 46
12.2 Accessories............................................................................................... 46
13 Annex.................................................................................................. 47
13.1 Compliance with EU directives................................................................. 47
14 List of figures..................................................................................... 48
15 List of tables....................................................................................... 49
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 T4000 Direct transponder safety
switches as from the date of manufacture:
•0801xxxx
You will find the date of manufacture of the device in the field Date Code on the type
label in the format yywwxxxx (yy = year, ww = calendar week, xxxx = serial number).
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.
In many applications, the target groups consist of the manufacturer and the operating
entity of the machine in which the safety switch is integrated:
Area of responsibility Target group Specific chapters of these operating instruc‐
tions 1)
Manufacturer Project developers
(planners, developers,
designers)
Project planning, page 13
Technical data, page 38
Accessories, page 46
Installers Mounting, page 16
Electricians Electrical installation, page 20
Safety experts Project planning, page 13
Commissioning, page 30
Technical data, page 38
Operating entity Operators Troubleshooting, page 33
Maintenance person‐
nel
Maintenance, page 35
Troubleshooting, page 33
Ordering information, page 46
1) Chapters not listed here are intended for all target groups. All target groups must follow all of the safety
and warning instructions in all chapters of the operating instructions!
In other applications, the operating organization is also the manufacturer of the equip‐
ment with the corresponding allocation of the target groups.
1.4 Further information
www.sick.com
The following information is available via the Internet:
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•This document in other languages
•CAD data for drawings and dimensional drawings
•Certificates (such as the EU declaration of conformity)
•Guide for Safe Machinery Six steps to a safe machine
1.5 Symbols and document conventions
The following symbols and conventions are used in this document:
Safety notes and other notes
DANGER
Indicates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indicates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Indicates useful tips and recommendations.
Instructions to action
bThe arrow denotes instructions to action.
1. The sequence of instructions for action is numbered.
2. Follow the order in which the numbered instructions are given.
✓The check mark denotes the result of an instruction.
LED symbols
These symbols indicate the status of an LED:
oThe LED is off.
ÖThe LED is flashing.
OThe LED is illuminated continuously.
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
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•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
NOTICE
The user is responsible for ensuring that the device is correctly incorporated into a safe
overall system. This involves validating the overall system according to specifications
such as those defined in ISO 13849-2 or EN 62061.
The T4000 Direct transponder safety switch is switched by a non-contact actuator and
is suitable for the following applications:
■Movable physical guards
■Safe position monitoring
The safety switch must be used only on the machine on which it was planned, mounted,
installed and initially commissioned by qualified safety personnel in accordance with
these operating instructions.
Incorrect use, improper modification or manipulation of the safety switch will invalidate
any warranty from SICK; in addition, any responsibility and liability of SICK for damage
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:
•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
The following may impair the function of the safety switch:
•Metal subsurface or metal in direct proximity
•Passing metal chips
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.
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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
Figure 1: Components of the T4000 Direct transponder safety switch
1Sensor
2Actuator (transponder)
The T4000 Direct transponder safety switch can used individually or connected in
series (maximum 20). It consists of two components:
•Sensor
The sensor is mounted on the fixed part of the guard and is connected to the sys‐
tem or machine control.
The sensor version determines whether an actuator has to be taught in at the sen‐
sor before commissioning.
•Actuator (transponder)
The actuator is mounted on the movable part of the guard.
Each actuator has a unique electronic code.
T40-E0101K sensor with universal coding
A sensor with universal coding checks only whether there is a valid actuator type in the
response range. A previous teach-in process is not required. The T4000 Direct with uni‐
versal coding therefore has a low coding level.
T40-E0121K sensor with unique coding
In order for an actuator to be recognized as valid by a sensor with unique coding, it
must first be assigned to this sensor by a teach-in process. The sensor will accept only
the actuator that was taught in last.
This unique assignment permits realization of particularly high protection against
manipulation. The T4000 Direct with unique coding therefore has a high coding level.
Operating principle
The T4000 Direct transponder safety switch monitors movable physical guards in con‐
junction with the corresponding machine and system control:
•Operation of the machine in automatic mode is possible only if the guard is closed.
•A stop command is triggered if the guard is opened while the machine is running.
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The control must meet the following requirements for this:
•Switch-on commands that result in a dangerous state may only be activated when
the guard is in protective position.
•The dangerous state must be ended before the guard is moved from the protective
position.
The actuator mounted on the movable part of the guard approaches the sensor when
the guard is closed.
The sensor reads the actuator code and checks its validity accordance with the coding.
If the code is valid, the sensor enables the safety outputs and the application diagnos‐
tic output OUT is set to HIGH.
When the guard is opened, the safety outputs switch off the safety circuit and the appli‐
cation diagnostic output is switched LOW.
3.2 Product characteristics
3.2.1 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.
Sensor
•Sensor with universal coding
•Sensor with unique coding
Actuator
•Cuboid
•Square
•Round
Complete overview of all variants: see "Ordering information", page 46.
3.2.2 Sensing face
The sensor has a sensing face, see "Dimensional drawings", page 44.
The sensing face is marked yellow. It can be adjusted in five directions, see "Changing
the approach direction", page 18.
The center point of the sensing face also corresponds to the center point of the sensor.
3.2.3 Fault detection
Any faults that occur, including internal device faults, are detected at the latest with the
next request to close the safe contacts (e.g. at the machine start). The safety switch
then switches to safe state.
If a fault is detected, the safety circuit is switched off and the LED ERROR lights up red.
In the case of T4000 Direct transponder safety switches as from date of manufacture
1037 (see "Scope", page 5) a fault can be reset in most cases by opening and closing
the guard for at least 2 seconds in each case.
If the fault is still displayed after this, carry out a hardware reset or briefly disconnect
the device from the voltage supply.
Contact the manufacturer if the fault also cannot be reset by restarting the device.
3.2.4 Status indicators
The LEDs STATE (green) and ERROR (red) indicate the operational status of the safety
switch.
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Overview of the LED statuses and their meanings: see "LED status indicators",
page 33.
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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 ISO 13849 is used to determine the performance level (PL), the PL may be
reduced.
The response time increases with the number of safety switches in a cascade.
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 Design
DANGER
Bypassing the protective device
Hazard due to lack of effectiveness of the protective device
bAvoid incentives to manipulate the safety switch by means of the following mea‐
sure:
°Only for universally coded variant: mount safety switch hidden, shielded or
out of reach.
°Use permanent mountings for actuators (e.g. welding, adhesive bonding,
safety screws or rivets).
bObserve the design requirements in accordance with ISO 14119 for mounting:
°Reduction of bypass possibilities of an interlocking device
°Mounting of safety switch and actuator
Mounting location
If the mounting location is not specified by the machine documentation, it must be cho‐
sen carefully, see "Mounting", page 16.
Distance
If several safety switches are mounted on the machine, they must be mounted at a min‐
imum distance to one another see "Mounting", page 16.
Alignment
The sensor and actuator must be mounted so that their sensing faces are directly
aligned facing each other, see "Dimensional drawings", page 44.
Actuating direction
The actuator must approach the sensing face of the sensor when the guard is closed.
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.
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).
4.5 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 32.
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.
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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 (see "Thorough
check of the safety function", page 35)
•Thorough check of secure mounting of the devices and connections
•Thorough check of the housing, cables and plug connectors for damage
•Thorough check for contamination
•Thorough check of assured switch-off distance Sar
•Thorough check of the safety switch for signs of misuse or manipulation
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5 Mounting
5.1 Safety
DANGER
Hazard due to unexpected starting of the machine
Death or severe injury
bMake sure that the dangerous state of the machine is and remains switched off.
DANGER
Bypassing the protective device
Hazard due to lack of effectiveness of the protective device
bAvoid incentives to manipulate the safety switch by means of the following mea‐
sure:
°Only for universally coded variant: mount safety switch hidden, shielded or
out of reach.
°Use permanent mountings for actuators (e.g. welding, adhesive bonding,
safety screws or rivets).
bObserve the design requirements in accordance with ISO 14119 for mounting:
°Reduction of bypass possibilities of an interlocking device
°Mounting of safety switch and actuator
NOTICE
Incorrect mounting and unsuitable ambient conditions may damage the safety switch.
bArrange the sensor and actuator in a way that prevents damage from foreseeable
external influences.
bDo not use the sensor and actuator as a stop.
bThe holder and mounting method for the sensor and actuator must be stable
enough to ensure that correct operation can take place.
bAlways use reliable mounting elements that can only be removed using tools.
bIf misalignment results in an opening on the physical guard, this must not impair
the protection that is provided.
5.2 Unpacking
bCheck the components to ensure that all parts are complete and undamaged.
bPlease contact your respective SICK subsidiary should you have any complaints.
5.3 Mounting
Selecting the mounting location
CAUTION
Bypassing the safety switch in a simple way or unintentional actuation must be pre‐
vented by suitable installation measures in accordance with ISO 14119.
If the mounting location is not specified by the machine documentation, it must be cho‐
sen carefully.
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bSelect the mounting location so that the sensor and actuator are accessible for
maintenance work and are protected against damage.
bMount the sensor and actuator on a non-ferrous surface and at a distance from
metal parts if possible in order to avoid influencing the sensing range. If this is not
possible, the influence on the assured switch-on distance Sao and the assured
switch-off distance Sar must be checked.
bWhen the guard is closed, the sensor and actuator must be located opposite each
other in the assured switch-on distance 0.8 × Sao or closer. A minimum distance
must be observed between the actuator and sensor if the approach direction is
from the side (see "Technical data", page 38).
bThe switching operation must be triggered only by the actuator specifically
intended for this.
bMake sure that all dangerous states are excluded when the guard is opened, even
if the actuator has not yet reached the assured switch-off distance Sar.
NOTE
At the assured switch-off distance Sar, the safety outputs are reliably switched off
even in the event of an internal component failure.
bThe sensor and actuator must not be used as a mechanical stop. If necessary, fit
an additional stop for the movable physical guard.
Mounting the sensor
bMount the sensor on the fixed part of the guard.
bTightening torque of the fixing screws: 1 Nm
Mounting the actuator
bAlign the actuator to the sensor.
bActuators must be positively mounted on the movable part of the guard, e.g. using
the supplied safety screws.
bTightening torque: 1 Nm
bIt must not be possible to remove or manipulate actuators by simple means.
NOTE
When the actuator is installed flush, the sensing range changes based on the installa‐
tion depth and the material of the guard.
Figure 2: Change in sensing range when installed flush
1Flush installation
2Non-flush installation
3Actuator
4Response range
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Mounting several safety switches
bWhen several safety switches are mounted, the prescribed minimum distance of
40 mm between the individual sensors must be observed in order to avoid mutual
interference.
Figure 3: Minimum distance when several safety switches are mounted
1Minimum distance = 40 mm
5.4 Changing the approach direction
The sensing face of the sensor can be adjusted in five directions.
CAUTION
When changing the approach direction, make sure that no cables are damaged,
trapped or torn off.
Figure 4: Changing the approach direction
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1. Remove the upper part of the mounting base and push the lower part of the
mounting base off the sensor (1).
2. Unscrew the screws of the mounting bracket and pull the mounting bracket off the
sensor (2).
3. Tilt the sensor forward by 90°. The sensing face is now facing downwards (3).
4. Turn the sensor by 180° and screw on the mounting bracket again with a tighten‐
ing torque of 0.6 Nm (4).
5. Turn the sensor to the desired approach direction and then push the lower and
upper parts of the mounting base back onto the sensor (5).
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6 Electrical installation
6.1 Safety
DANGER
Hazard due to electrical voltage
Hazard due to unexpected starting of the machine
bMake sure that the machine is and remains disconnected from the power supply
during the electrical installation.
bMake sure that the dangerous state of the machine is and remains switched off
during electrical installation.
bMake sure that the outputs of the safety switch have no effect on the machine
during electrical installation.
DANGER
Incorrect safety switch connection
Loss of safety function
bWhen using insulation material or stranded connection wires, make sure they
demonstrate the required temperature resistance and mechanical load capability.
bUse only safe contacts for safety functions.
bAll electrical connections must be isolated from the mains supply either by safety
transformers (EN 61558-2-6) or equivalent isolation measures.
bUse protected cable routing to prevent the risk of cross-circuits and short-circuits.
bAll output contacts must have an adequate suppressor circuit for inductive loads.
For this purpose, the outputs must be protected with a suitable suppressor (e.g.
freewheeling diodes, varistors, RC elements).
DANGER
Increased response time
Loss of safety function
The response time increases depending on the selected suppressor circuit.
bPower devices that represent a strong source of interference must be locally iso‐
lated from the input and output circuits for signal processing. The cable routing of
the safety circuits should be separated from the cables of the power circuits by the
greatest possible distance.
bIn order to avoid EMC disturbances, the physical ambient and operating conditions
at the installation location of the device must comply with the requirements of
EN 60204-1 (EMC).
bPay attention to any interference fields for devices such as frequency converters or
induction heating systems.
bObserve the EMC information in the manuals from the respective manufacturer.
6.2 Failsafety
■If the device does not respond when the supply voltage is connected (e.g. green
LED STATE does not flash), the safety switch must be returned to the manufacturer
unopened.
■The supply voltage UB is reverse polarity protected.
■The safety outputs OA/OB are short-circuit protected.
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