Wenglor SG4-I User manual

Available as PDF only
Status: 17.10.2017
Version: 12
www.wenglor.com
EN
SG4-I
Safety Light Curtain
Operating instructions

2
EN
Table of Contents
1. General 4
1.1 Function and Use for Intended Purpose 4
1.2 Features 4
1.3 Applications Examples 4
1.3.1 Single Curtain Protection 5
1.3.2 Cascading Two Light Curtains 5
1.3.3 Use at Brake Presses 5
1.4 Brief Explanation of Function- and Operating Modes 6
1.5 Explanation of symbols 7
2. Initial Start-Up Flowchart 7
3. Important Notes Concerning Use 8
3.1 General Comments 8
3.2 Securing the Danger Zone 9
3.3 Calculating Safety Clearance per EN ISO 13855 10
3.3.1 Direction of Approach to the Safety Field 11
3.3.1.1 Perpendicular Approach to the Safety Field 11
3.3.1.2 Parallel Approach to the Safety Field 11
3.3.2 Sample Calculations 12
3.4 Minimum Clearance to Reflective Surfaces 13
4. Connection and Installation to the Machine 14
4.1 Installation 14
4.2 Default Settings 16
5. Operating the Light Curtain 17
5.1 Pilot Beam 17
5.2 Adjustment 17
5.2.1 Using the Aligning Tool 17
5.2.2 Adjustment Procedure 18
5.3 Function Modes 19
5.3.1 Safety Operating Mode 19
5.3.2 Start Inhibit and Restart Inhibit 19
5.3.3 Contactor Monitoring 21
5.4 Blanking Options 23
5.4.1 Fix Blanking 23
5.4.1.1 Principle 24
5.4.1.2 Fix Blanking Procedure 26
5.4.1.3 Calculating Safety Clearance 27
5.4.2 Floating Blanking 27
5.4.2.1 Principle 27
5.4.2.2 Floating Blanking Procedure 29
5.4.2.3 Calculating Safety Clearance 29
5.4.3 Auto Floating Blanking 32
5.4.3.1 Principle 32
5.4.3.2 Auto Floating Blanking Procedure 33
5.4.3.3 Calculating Safety Clearance 34
5.4.4 Reduced Resolution 35
5.4.4.1 Principle 35
5.4.4.2 Reduced Resolution Procedure 37
5.4.4.3 Calculating Safety Clearance 38
5.4.5 Summary of Blanking Options 39

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5.5 Cascading (Linking Several Light Curtains) 39
5.5.1 Principle 40
5.5.2 Cascading Procedure 40
5.5.3 Functions 42
5.5.4 Coding 43
6. Expanding the Light Curtain System 44
6.1 Relay Unit 44
6.2 Muting Module 45
6.3 Connection to a PC 46
6.4 Path-Folding Mirror 47
7. Display 48
7.1 Display of Operating Modes 48
7.2 Diagnostic information 49
8. Condensed Start-Up Instructions 50
9. Inspection Instructions 50
9.1 Inspection Prior to Initial Start-Up 51
9.2 Daily Inspection and Maintenance of the Effectiveness of the Safety De-
vice 51
10. Environmentally Sound Disposal 52
11. Dimensional Drawings 52
11.1 Finger Protection Emitter 52
11.2 Finger Protection Receiver 52
11.3 Hand Protection Emitter 53
11.4 Hand Protection Receiver 53
11.5 Mounting Bracket BEF-SET-33 54
12. Technical Data 54
12.1 Safety Light Curtains 54
12.2 System Components 56
12.2.1 Relay Unit Type 2/Type 4 SG4-00VA000R2 56
12.2.2 Adapter Box RS-232 to A485-232 56
12.2.3 Laser Alignment Aid SZ0-LAH1 56
12.2.4 Mounting Elements 56
12.2.5 Connection Line 57
12.2.6 Connection Cables 57
12.2.7 Interface Cable 57
13. Checklist for Initial Start-Up 58
14. Certification 58
15. EU Declaration of Conformity 59
Due to the fact that they describe the operation of a safety device, these operating instructions are of a binding
nature.

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EN
1. General
The SG4 light curtain system is a design-approved, electro-sensitive protection equipment (ESPE) in accordance
with EN 61496-1. It’s a class 4 Light Curtain, i.e. it’s an ESPE for which the safety function remains intact even if
several errors occur. Furthermore, it’s a category 4 Safety Light Curtain, and is thus a self-testing safety device.
The light curtain system consists of a emitter module and a receiver module. A muting module and a relay unit are
available as accessory equipment.
1.1 Function and Use for Intended Purpose
The light curtain monitors the safety field between the emitter and the receiver. If the safety field is penetrat-
ed by an obstruction, a switching command is triggered. This switching command may prevent initialization
of a hazardous machine motion, or may stop an action which has already been started.
Use of the light curtain is only permissible if:
• Hazardous motion can be stopped by electrical means using the light curtain’s safety output
• Adequate detection of possible obstruction is assured with existing resolution
• An application of Light Curtain of Category 4 is permissible.
1.2 Features
• Safety device per EN 61496-1
• TÜV approved
• Finger protection: 14 mm resolution, 7 m range
• Hand protection: 30 mm resolution, 20 m range
• Visible red light
• PNP semiconductor safety outputs
• PNP signal output
• Fix Blanking
• Floating Blanking
• Auto Floating Blanking
• Electronically reduced resolution
• Simple cascading
• Serial interface with visualization program
• Restart inhibit
• Monitoring of external relays
• Muting (optional)
• Relay unit (optional)
• Coding
1.3 Applications Examples
Safety protection at:
• Presses
• Saws
• Textile machinery
• Transfer lines, assembly lines
• Automatic insertion equipment
• Packaging machines
• Rotary indexing machines
• Woodworking machines

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1.3.1 Single Curtain Protection
Example: securing an area
1.3.2 Cascading Two Light Curtains
Example: securing off an area plus side-stepping protection
1.3.3 Use at Brake Presses
Example: floating blanking

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EN
1.4 Brief Explanation of Function- and Operating Modes
Auto Floating Blanking
This operating mode is the same as Floating Blanking, except that in this case the object (for example a skid carrier
or lifting forks) moves through and exits the safety field. The direction at which the object enters and exits the safety
field, as well as its dwell time within the safety field, must be defined. Any other intrusions into the safety field cause
the safety output to switch and stop hazardous motion.
Cascading
Safety devices can be series connected such that they all drive a single safety output in order to monitor several
safety fields simultaneously. Cascaded safety devices demonstrate the same performance characteristics as a sin-
gle safety device.
Contactor Monitoring
An operating mode for which switching performance of the contacts at an external relay is dynamically monitored.
The contacts must close fully within a specified period of time.
Fix Blanking
This operating mode is required for applications including objects which continuously protrude into the safety field,
thus interrupting specific light beams originating from the safety light curtain. Intrusions into any other point within
the safety field cause the output to switch and stop hazardous motion.
Floating Blanking
This operating mode is the same as Fix Blanking, except that in this case the object (for example a cable or a cutting
edge) is permitted to move within the safety field. Any other intrusions into the safety field cause the safety output
to switch and stop hazardous motion.
Reduced Resolution
This function reduces the resolution electronically. Thus objects that are smaller than the selected resolution don’t
deactivate the safety output. The function can also be used to prevent machining chips from interfering with correct
functioning of the safety light curtain.
Restart Inhibit
A function which prevents a machine from starting up automatically after it has been switched on. The machine can
only be enabled by activating an acknowledgement key.
Safety Operating Mode
In this operating mode, the switching outputs are disabled when the safety field is penetrated. The switching outputs
are automatically enabled after penetration of the safety field is ended.
Safety Output – OSSD (Output Signal Switching Device)
The output of the contactless safety device which is connected to the machine controls. The safety output is deac-
tivated when the safety field is interrupted.
Signal Output
A semiconductor output for auxiliary functions without safety monitoring.
Start-Up Inhibit
This function is activated along with the „Restart Inhibit Function“. When power supply is switched on (e.g. after a
power failure), the safety outputs (OSSD) remain in the off state. Acknowledgement is accomplished by activating
an acknowledgment key.

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1.5 Explanation of symbols
Points up suggestion and tips, which simplify the handling of the safety light curtain.
Points at a measure to prevent a concrete danger.
Points at functions, which can only be configured by means of software (PC).
2. Initial Start-Up Flowchart
Determine the required safety category
per EN 1050 (severity of injury, frequency and
duration of hazardous motion etc.)
Chapter 3.1
Chapter 3.2
Chapter 3.3
Chapter 5.4
Chapter 3.2
Chapter 3.4
Chapter 4.1
Chapter 4
Chapter 5.2
Chapter 5.3
Chapter 5.3
through
Chapter 5.4
Chapter 9
Chapter 10
Calculate safety clearance
Mechanically install the light curtain
(consider reaching over or under, side-stepping
and distance to reflective objects)
Adjust the light curtain
Select an operating mode
Important! high resolution
èlarge safety clearance
Test the safety functions

8
EN
3. Important Notes Concerning Use
3.1 General Comments
The use of contactless safety devices is regulated by official directives. National and international regulations apply
to the safe utilisation of contactless safety devices, in particular:
• EN standards
• Accident prevention regulations
• EC Machinery Directive
• Occupational health and safety requirements
ESPE may only be used at power operated machinery whose controls can be electrically influenced such that haz-
ardous motion can be stopped immediately in all operating phases.
If other light beams occur in an application (e.g. infrared controllers, emission due to welding sparks or the effects
of stroboscope light), additional measures may be necessary in order to assure that the ESPE does not fail in a
dangerous mode.
Testing must be performed by an expert prior to initial start-up of ESPE. Testing must establish flawless
interaction of the contactless safety device together with the controls of the power operated machinery, and
correct installation in accordance with these safety precautions.
The cascading terminals on the sensor and the receiver may only be used to connect additional Safety
Light Curtains. Connection of other power consumers is impermissible.
The following standards must be observed during use of the light curtain:
EN ISO 13855 Machine safety: arrangement of safety devices in consideration of approach
speeds of body parts
EN ISO 12100 Machine safety: General design guidelines – risk assessment and risk minimization
EN ISO 13857 Machine safety: Safety distances to prevent hazard zones being reached by
upper and lower limbs
EN 349 Machine safety: Minimum gaps to avoid crushing of parts of the human body
EN ISO 13850 Machine safety: emergency stop devices
EN ISO 14119 Machine safety: Interlocking devices associated with guards
All specified data make reference to the following revision level: 17.10.2017
Technical changes to the product described herein, printing errors and/or any possible incompleteness of this prod-
uct description may not be construed as cause for asserting any legal claims whatsoever against wenglor sensoric
GmbH.

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3.2 Securing the Danger Zone
The danger zone must be secured by means of the light curtain alone, or by means of the light curtain in
combination with additional mechanical safety devices. Reaching around, over and/or under the safety
field must be prevented in any case. It must be impossible to approach the point of danger without passing
through the safety field.
The safety field is located between the line at which light is emitted at the emitter and the line at which light
is received at the receiver. The boundaries of the safety field are identified on the devices.
Examples:
Incorrect Correct
Side-Stepping
Reaching Under
Reaching Over

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EN
3.3 Calculating Safety Clearance per EN ISO 13855
Calculation of safety clearance S is based upon the EN ISO 13855 standard. However, if any special directives and
standards apply to the respective machine, these must be taken into consideration as well. Each contactless safety
device must be mounted such that stepping or reaching into the danger zone is precluded. If required, this may also
be accomplished by means of additional, mechanical safety devices.
Safety clearance S is the minimum distance in mm, measured from the danger zone to the safety field, and is cal-
culated as follows:
S = (K × T) + C or S = K × (t1 + t2) + C
S = minimum clearance in mm, measured from the danger zone to the safety field
K = approach speed in mm per second
T = total response time (t1 + t2) in seconds
t1 = light curtain response time in seconds
t2 = machine or process over-travel time in seconds
C = additional clearance depending upon resolution d in mm
d = resolution (is increased for operation with reduced resolution)
Over-Travel Time T
Due to the fact that interrupting the safety field during hazardous motion does not result in immediate stop-
ping of the machine, over-travel time T must be taken into consideration. The distance between the safety
field and the point of danger must thus be large enough to assure that the point of danger cannot be
reached until hazardous motion has come to a standstill.
Total over-travel time T is the sum of maximum response time of the contactless safety device (t1) and maximum
over-travel time of the hazardous motion (t2). Machine over-travel time must be determined by means of repeated
measurement prior to initial start-up, and each time the machine is retooled (set up)
The response time of the ESPE depends upon the height of the safety field (see table).
Emitter (S)
or Receiver (E)
Type Designation
Field Height
in mm
Number
of Beams
Response
Time in ms
t1
SG4-14Ix015C1 164 21 6
SG4-14Ix030C1 314 42 11
SG4-14Ix045C1 464 63 16
SG4-14Ix060C1 614 84 21
SG4-14Ix075C1 764 105 26
SG4-14Ix090C1 914 126 31
SG4-14Ix105C1 1064 147 36
SG4-30Ix015C1 180 9 3,3
SG4-30Ix030C1 330 18 5,7
SG4-30Ix045C1 480 27 8,2
SG4-30Ix060C1 630 36 10,0
SG4-30Ix075C1 780 45 12,0
SG4-30Ix090C1 930 54 14,0
SG4-30Ix105C1 1080 63 16,0
SG4-30Ix120C1 1230 72 18,5
SG4-30Ix135C1 1380 81 20,4
SG4-30Ix150C1 1530 90 23,4
SG4-30Ix165C1 1680 99 25,8
SG4-30Ix180C1 1830 108 27,0