Werac SAFETY 40 Parts list manual

Version 10.12.2019
Safety Light Grids and
Multibeam Safety Light Barriers
Technical Description

Version 10.12.2019
page 2  WERAC Elektronik GmbH
1 General
This instruction manual is a constituent part of the SAFETY 40 safety light grid. It must be
available to all personnel concerned with assembly, commissioning, and maintenance during
its entire life cycle.
If the instructions in this manual are not followed or only partly followed, accidents could occur.
Any warranty claims against WERAC Elektronik GmbH become null and void in this case.
Designated use:
The safety systems SAFETY 40 consist of the certified components control unit, transmitter and
receiver (see type name) and may be used only coherently. The connections between the
single components must be carried out with cables of the company WERAC.
The system SAFETY 40 is a electro-sensitive protective equipment of the type 4 according to
IEC 61496-1 which can be used depending on the implementation for the access security of
danger zones and safeguarding dangerous points on power-driven machinery in compliance
with the safety engineering requirements as stated in the standard EN 999/ ISO 13855 and the
standards of the corresponding machinery up to safety category 4 according to EN 954-1/
ISO 13849-1.
1.1 Overview of the product features
• SAFETY 40 series for applications according to performance level PL e, safety category 4 of
EN ISO 13849-1 (2008)
• resolution 14 mm (finger guard), 30 mm (finger guard) or 40 mm (hand guard)
• Width of guarded area with resolution 30 mm or 40 mm = 0 - 6 m or 3 – 10 m,
with 14 mm resolution = 0 - 6 m
• Variable length in 50 mm steps up to 1900 mm – maximum 190 lines
(with resolution 40 mm – 35 mm steps)
• Small robust aluminium profile 29 x 19 mm for the emitter and receiver
• Attachment optionally via the rail or on the end pieces
• Cascadable: 2 light grids can be driven with one control unit
• Control unit WGN 100 with an identical interface to the machine controller as the control
units of our multibeam safety light barriers
• Can be also used as a multibeam light barrier e.g. as an access safeguard
• available as combination light grid with 14/30 mm, 14/40 mm and 30/40 mm resolution
Additional functions of the control unit WGN 110:
• Additional inputs for bypassing the light grid
• Switchable reduced resolution for bypassing individual lines of the light grid
• Fixed blanking for permanent blanking of individual lines of the light grid
1.2 Approval
EC type-examination certificate No. HSM 06081:
DGUV test
Testing and Certification Body Lifting Gears, Safety Components and Machinery
Expert Committee for Woodworking and Metalworking
European notified body Identification number 0393
Kreuzstrasse 45
D-40210 Düsseldorf, Germany
1.3 Manufacturer
WERAC Elektronik GmbH Telefone: +49 7271/6136
Am Rodaugraben 2 Telefax: +49 7271/8932
D-76744 Wörth am Rhein Email: [email protected]

Version 10.12.2019
 WERAC Elektronik GmbH page 3
1.4 Version no.
This manual applies for the SAFETY 40 types WGN 100-2 and WGN 110-0 of version 2.71 of
23.05.2017.
1.5 Approval marks
2 Description of function
Our safety light grids consist of an emitter, a receiver and the WGN 100 or 110 control unit.
Control unit WGN 100/ WGN 110: The control unit must first of all be enabled via start enable
T1, T2. This takes place through sequential switching (see e.g. 5.1) by pressing the start
button. Provided that the light grid (LG) is not interrupted and without errors (the individual light
beams are scanned in sequence), output relays A and B are activated. At least one contact of
each relay (OSSD) is incorporated into the further processing of the sequential switching.
The start and restart lockout must be carried out by the sequential switching as described
under point 5. If one relay fails, the second one remains dropped, i.e. in a safe condition. The
switching status of the relays is indicated in the control unit and visually indicated for the user
in the emitter. The light grid is in the OFF state after power supply ON or a light barrier
interruption. This is indicated by the red LED. Provided that the light grid has not been
interrupted, the yellow LED is also lit. If the gain reserve of at least one light beam has
significantly decreased compared to the last alignment, the yellow LED blinks (the light grid
still functions). This is an indication for the user to clean the light grids (realignment may be
necessary). The alignment is described under point 6.10.
WGN 100/ WGN 110 – requirements to the external power supply:
For the supply voltage for the control units WGN 100 / WGN 110 a electrically insulated
protective extra low voltage (PELV or SELV) according to VDE0100, part 410 shall be used.
The external power supply shall guarantee that the voltage ratings defined for the WGN 100 /
WGN 110 devices are not exceeded, even in case of an error. PELV power supplies according
to EN 60204, chapter 6.4.2 fulfill these requirements.
Note: To calculate the PFH (Probability of dangerous failure per hour) of the safety function,
the PFH of the external power supply must be included as well.

Version 10.12.2019
page 4  WERAC Elektronik GmbH
3 Technical Data for the WGN 100-1 control unit
Standard to IEC EN 61496-1 Type 4
Performance Level PL e, Category 4 (EN ISO 13849-1, 2008)
PFH / TM 4,93 x 10-8 1/h / 20 years
Response time see section 6.5
Permissible operating temperature 0... +50°C / 32... +122°F
Stock temperature -25°C... +70°C / -18°F... +158°F
Supply voltage WGN 100-2 24 V AC ± 10% 48 – 62 Hz, 24 V DC ± 10%
Power consumption WGN 100-2 approx. 8 VA
Supply voltage WGN 110-0 24 V AC ± 10% 48 – 62 Hz, 24 V DC ± 10%
Power consumption WGN 110-0 approx. 12 VA
Output contacts:
max. switching voltage
max. switching current at 230 V~ (ind. load)
max. switching frequency
min. operating cycles
250 V~
2 A
2 /s
106 with contactor for 5.5 kW 3-phase motor
Switch-on delay after power supply ON ~ 4 s
Switch-on delay after test ON ≤ 70 ms
Housing Sheet-metal housing with Makrolon cover
Enclosure rating IP 20
Electrical connection Terminal plug, up to 2.5 mm²
RJ 45 connector (emitter and receiver)
Status display red, yellow, green
Start enable T1, T2 External voltage 10-50 V
Table 1
External connections control unit WGN 100 (see fig. 1)
connection A1-A2 (normally open contact) security output relay A - OSSD 1
connection A5-A6 (normally open contact) security output relay B - OSSD 2
connection A3-A4 (normally closed contact) e.g., message to PLC, rest contact query,
display red
connection A4-A7 (normally open contact) e.g., message to PLC, display green
connection T1, T2 start release of the sequential switching
connection 24V, 0V electricity supply with 24 V
Table 2
Additional external connections control unit WGN 110 (see fig. 2)
connection B1, B2 contact monitoring circuit 1
connection B3, B4 contact monitoring circuit 2
saftey category 4
contact pair 1
connection B5, B6 contact monitoring circuit 1
connection B7, B8 contact monitoring circuit 1
saftey category 4
contact pair 2
Table 3
The relay outputs are line voltage isolated from the light barriers; to IEC60664 -1 overvoltage
category III.
All emitters WGS4... and WLS4... and all receivers WGE4... and WLE4... can be connected.
The control unit is built only for the use inside of control cabinets. The Sheet-metal housing
can be snapped on to the TS 35 for mounting inside control cabinets. The control cabinet must
comply with degree of pollution 2 to IEC EN 60439-1 at least (This is normally IP 54). The
mounting rail TS 35 must be connected to the PE conductor.

Version 10.12.2019
 WERAC Elektronik GmbH page 5
Technical Data for the emitters and receivers
WGS 4.../WGE 4...
WLS 4.../WLE 4...
Standard to IEC EN 61496-1, -2 Type 4
Performance Level PL e, Category 4 (EN ISO 13849-1, 2008)
Infrared pulsed light (950 nm) bundled on ± 2°
Permissible operating temperature 0...+50 °C
Stock temperature -25...+70 °C
"Traffic light" display (see Table 5) red, yellow, green LED in the emitters
Power supply ON indicator yellow LED in the receiver
Housing Aluminium section tube 19 x 29 mm
Yellow (RAL 1021) powder-coated
Enclosure IP 65, pane of polycarbonate
System length 50 mm to 2000 mm (see section 8)
Height of guarded area see section 6.4
Resolution (WGS and WGE) 14, 30 or 40 mm
Width of guarded area: resolution 14 mm
res. 30 and 40 mm
0 - 6 m
0 - 6 m, 3 - 10 m with amplified emitters and
receivers
Multibeam light barrier see section 8.3
Electrical connection 165 mm round cable, 8 poles, screened
with connector M12 x 1 (socket connector)
Cascadable (see 6.6) max. 2 light grids
Maximum cable length from the control unit to
emitter or receiver
10 m with UL-listed cables
15 m with VDE 0472/ 804-cables
Table 4
4 Diagram of connections
The sequential switching has to conform the risk evaluation of the machinery. Our system
SAFETY 40 provides two output (normally open) contacts: relay A (A1-A2) and relay B (A5-A6)
as seen in figure 1. The output contacts have to be integrated into the sequential switching,
that the two signals are processed separately (e.g. in figure 2). If the cables run outside of a
housing, arrangements for the detection of a short circuit are needed (e.g. separate cables or
pulsed signals).
The sequential switching must provide the restart lockout and the start enable (T1, T2). The
switching should be specified in co-ordination with us. The plug connectors may only be
manipulated when they are off-circuit.
Note: To guarantee the electromagnetic compatibility it is required to bolt the M12 connectors
well.
Start enable 10-50V

0V 24V
L1 N
or
mains
outputs
S1
24V~
230V~
PTC fuse
2x 4K7
T1
T2 A2 A3 A4
A1
A
B
A7
A5
A6
transmitter receiver
RJ 45 RJ 45
transmitter (cascaded)
receiver (cascaded) receiver (standard)
transmitter (standard)
control unit WGN 100
Fig.1: Diagram of connections for a cascaded SAFETY 40 system

Version 10.12.2019
page 6  WERAC Elektronik GmbH
Fig.2: Diagram of connections for the external safety category 4 contacts
Attention:
In order to achieve the corresponding safety level, the external control of contact pairs 1 and 2
must also be carried out in accordance with Performance Level PL e, Category 4 in
accordance with EN ISO 13849-1.
5 Proposed wiring diagrams for the sequential switching
The contactors or relays actuated by the control unit must have positively driven contacts and
be suitable for industrial use.
IMPORTANT: When using plug-in auxiliary contacts, the positively driven operation must also
be available between the main contact set. It must also be checked whether disconnection of
the auxiliary block is detected by the controller. No further work on the machine may be
possible in such cases.
The spark suppression must always be connected via the contactor coil (by means of an RC
element or varistor).
5.1 Proposed wiring diagram for control unit WGN100, WGN 110 to Performance Level PL e,
Category 4 according to EN ISO 13849-1 on power-driven machinery (PDM) with start-up
test and restart lock
The control line for contactor A (terminals A1, A2), contactor B (terminals A5, A6) and the test
(T1, T2) must be laid in separate cables if the control unit and the contactors are spatially
separated. if both are located in the control cabinet, standard wiring is adequate. The user has
to provide a max. 2 A fuse for current-limiting measures to protect the output signal switching
devices (OSSD).
We will be pleased to supply you with other proposed wiring diagrams on inquiry.
0V
+24V
max. 2A
A1
T1
C
B
A
D
d c
b
a
T
d c
b
a
A2
A6
T2
WGN 100
WGN 110
reserve
b
d
a
c
x
max. 2A
b
d
a
c
z
max. 2A
b
d
a
c
y
max. 2A
d
c
b
a
A4
A3
A7
A5
Fig. 3: Proposed wiring diagrams for the sequential switching
Start enable 10-50V 
0V
24V
mains
outputs 24V
AC or DC
T1
T2
transmitter receiver
RJ 45 RJ 45
control unit WGN 110
A2
A3 A4
A1
A7
A5 A6
B2
B3 B4
B1
B7
B5 B6 B8
Input contact pair 1
Safety category 4
Input contact pair 2
Safety category 4

Version 10.12.2019
 WERAC Elektronik GmbH page 7
A, B, C and D = contactors or relays with positively driven contacts..
T = operating device (pushbutton) which has to be pressed for start-up (release of the starting
and the restart lockout). The identifying marking of the pushbutton must be located near this
component.
It must be impossible to press the pushbutton T from inside the danger area.
x, y = Two-channel implementation in the controller of the PDM for interruption of the
movement. Note: Performance Level PL e, category 4 according to EN ISO 13849-1.
z = Variant with only single-channel control of the PDM. Important: Maximum performance
level PL c, category 2 according to EN ISO 13849-1 is achieved in this case.
Note: The declaration of the performance level and category according to EN ISO 13849-1 is
only valid for the entirety of the shown elements. If additional contacts are needed, they must
be implemented according to the required safety category.
6 Applications and assembly instructions
The safety light grids (ESPE = Electro-Sensitive Protective Equipment, here with control units
WGN 100 or WGN 110) are used for the access protection of danger zones and
safeguarding hazardous points on power-driven machinery in compliance with the safety
engineering requirements as stated in this description, the standard EN 999 (ISO 13855) and
the type C standards of the corresponding machinery.
Operation e.g. in the following areas of operation is possible:
Operating machines for the chemicals, rubber and plastics industries as defined by VBG 22
Printing and paper converting machinery as defined by prEN 1010-1 to -5
Conveying equipment
Power driven windows, doors and gates as defined by BGR 232 (former ZH 1/494)
Storage facilities and equipment as defined by BGR 234 and EN 15095
Food processing machines as defined by EN 12852:2001 and/or BGV D18 (former VBG 77)
Robots
Textile machines as defined by VBG and DIN EN ISO 11 111
Packaging machines as defined by DIN EN 415-1 to -7 and/or BGV D17 (früher VBG 76)
The above individual applications were not an object of the EC type-test.
6.1 General remarks
The operating device for start-up (pushbutton T) must be installed in such a way that a good
overview of the danger area is provided from its operating position. Actuation of the operating
device from inside the danger area must be excluded.
The ESPE must be installed in such a way that the dangerous points can only be reached
through the guarded area.
6.2 Safeguarding hazardous points by means of a light grid
Safety distance
An adequate safety distance between the guarded area and the hazardous points must be
provided, so that if the guarded area is entered, the dangerous movement is interrupted before
the dangerous points can be reached.
S: Safety distance
H: Height of guarded area
Danger
area
S
H
Fig. 4: Safety distance

Version 10.12.2019
page 8  WERAC Elektronik GmbH
Extensive information concerning the safety distance is provided in the standard ISO 13855. If
type C standards are already in existence for the machinery, the specifications of these
standards must be used.
The subsequent shown formulas and demands are part of the standard ISO 13855:
S = K ∙ T + C
S = Safety distance [mm]
K = 2 m/s hand-arm speed
T = Stop time of machine and ESPE [ms]
C = Allowance depending on the resolution
The following applies for a resolution up to ≤ 40 mm:
C = 8 ∙ (R – 14 mm)
R = Resolution of the ESPE in mm (as a grid system)
C may be not less than 0
The calculation applies for all safety distances up to 500 mm. If S is < 100 mm, the minimum
value S = 100 mm must still be complied with. If S is > 500 mm, K = 1.6 m/s may be used. In
this case, S may not be less than 500 mm.
In general, the following applies from a resolution of > 40 mm:
C = 850 mm and K = 1.6 m/s
If children are present (non industrial area), the safety distance S must be increased by at
least 75 mm.
Example: A machine with a braking time of 100 ms is equipped with a light grid (ESPE) with a
resolution of 30 mm and a response time of 20 ms.
C = 8 ∙ (30 – 14 mm) = 128 mm
S = 2 m/s ∙ (100 ms +20 ms) + 128 mm = 240 mm + 128 mm = 368 mm
If a resolution of 14 mm is used in an otherwise identical machine, a safety distance S = 2 m/s
(100 ms +20 ms) + 0 mm = 240 mm results.
If the ESPE is used as finger, hand or arm protection, it must be mounted in such a way that
the guarded area cannot be reached over, reached under, reached around or stepped behind.
If this requirement cannot be met solely by the ESPE, additional protective devices such as
fixed covers must be provided.
Information in the operating manual of the machine
● Maximum machine stopping time
● Safety distance S
● Guarded area dimensions (height × max. width of guarded area of the light barriers)
● Test rod diameter
● Reaction time T (stop time of machine and ESPE)
6.3 Access security of danger zones
Two to four single beams are required for the access security of danger zones depending on
the risk evaluation. The beams are only considered to this extent that they are arranged
parallel to the floor, and that the beam is interrupted by the body of a person standing upright.

Version 10.12.2019
 WERAC Elektronik GmbH page 9
The following incomplete list is provided as a support for risk evaluation. Possibilities in which
access security with 2-4 single beams cannot be expected are listed:
● Crawling under the lowest beam
● Reaching over the topmost beam
● Reaching between two beams
● Climbing between two beams
Note: All possibilities of access into the danger zone should be considered in the risk
evaluation.
As specified in ISO 13855, the multibeam light barriers consist of 2, 3 or 4 light grid modules
(black with one line), each with a length of 35 mm and which are fitted in the section tube at
the desired distance by means of 1, 2 or 3 passive components (green).
If the result of the risk evaluation is such that protective devices have to be used with several
single beams, they must be positioned at a distance obtained using the formula below.
S = K ∙ T + C S = Safety distance [mm]
K = 1.6 m/s hand-arm speed
T = Stop time of machine and ESPE [ms]
C = 850 mm
Example: Access to a robot is protected by 3 light beams at 300, 700 and 1100mm. The
braking time of the robot is 100ms, the response time of the ESPE is 20ms.
S = K x T + C = 1.6 m/s x (100 ms + 20 ms) +850 mm =
S = 192 mm + 850 mm = 1042 mm
Minimum distance (S)
Receiver
Deflector mirror
Emitter
Danger zone
Fig. 5: Example for access security
SAFETY 40
1100
700
300
0
Height above the floor
Fig. 6: Example for the distances with multibeam light barriers
SAFETY 40
900
400
0
Height above the floor
SAFETY 40
900
600
300
0
Height above the floor
1200

Version 10.12.2019
page 10  WERAC Elektronik GmbH
Note: When using an access protection with two to four single beams the entry of a body or
body parts can not be detected absolutely.
Note: Multibeam light barriers are possible with other light barrier distances (e.g. 100 mm
resolution) for access protection by means of horizontally arranged light grids (see ISO 13855
Section), provided that they are permitted in type C standards of machines.
6.4 Height of guarded area
The height of guarded area SH is indicated on each product label and in the selection tables.
The guarded area stretches slightly beyond the ends of the light grid modules.
6.5 Response time of the light grids
The response time tR results from a basic time tRG (relay release time and self-checking) of
16 ms and a time tRL which is dependent on the number of lines = 0.16 ms per line.
When using a single, non-cascaded light grid the valid response time can be found on the
product label on the emitters and receivers.
In the case of cascades, the response time is dependent on the total number of lines in all light
grids. The following applies: tR cascade = tRG + tRL (total)
It is not valid to add the response times that are given on the product label. It is necessary to
use the above-quoted formula.
Example: Two light grids with 30 lines and 48 lines are required for the protection of an
automatic warehouse system. The response time is calculated as follows:
tR cascade = tRG + tRL(total) = 16 ms + (30 + 48) · 0.16 ms = 16 ms + 12.48 ms = 28.5 ms
SH = Height of guarded area
N = Number of lines
A = Resolution (14, 30 or 40 mm)
LD = Light beam diameter
4 mm at 14 mm resolution,
5 mm at 30 and 40 mm resolution
SH = (N + 1) x (A - LD) + LD
For a light grid with 14 mm resolution:
SH = (N + 1) x (14 - 4) mm + 4 mm
= (N + 1) x 11 mm + 4 mm
For a light grid with 30 mm resolution:
SH = (N + 1) x (30 - 5) mm + 5 mm
= (N + 1) x 25 mm + 5 mm
For a light grid with 40 mm resolution:
SH = (N + 1) x (40 - 5) mm + 5 mm
= (N + 1) x 35 mm + 5 mm
Fig. 7: Beam geometry for
resolution 14, 30 and 40 mm
Height of guarded area
30 mm
5 mm
25 mm
30 mm
Height of guarded area
14 mm
4 mm
10 mm
14 mm
10 mm
40 mm
40 mm
Height of guarded area
35 mm
5 mm

Version 10.12.2019
 WERAC Elektronik GmbH page 11
6.6 Cascadable systems
It is possible to connect up to two light grids one after another. The maximum number of 190
lines may not be exceeded in this case. The operator must be able to see all the areas
protected by the cascade when pressing the start button.
An example is the protection of the front and rear of a machine or a combination of vertical,
inclined and horizontal light grids.
The individual light grids can be directly connected to each other. An extension cable with a
length of 0.3 to 2 metres can also be intermediately connected.
The last system of the cascade corresponds to the standard design without a cable outlet. The
upstream light grids have a cable entry and cable outlet.
Note: If a guarded area is formed by more than one light grid, no insecure areas may be
located between the light grids. If necessary, additional measures such as
mechanical guards are implemented.
6.7 Deflector mirror
Special problems can be considered with a reduced width of guarded area by means of 1 or
max. 2 deflector mirrors.
6.8 Optical bypassing
To prevent optical bypassing, a minimum distance A of the optical axis to reflective surfaces
must be complied with. Read off the value in the diagram for your distance D between the
emitter and receiver to determine the minimum distance A.
6.9 Assembly of the emitters and receivers
The explanatory remarks on the safety distance and the mounting height in the previous
sections must be considered. All mounting positions are permissible, e.g. cable connection
from above or below. There are two possibilities for mounting:
6.9.1 Rail mounting
There are two seamless profiled grooves on the rear of the housing of the emitters and
receivers. The retainer blocks WHK1 can be positioned at any desired point and clamped in
place by means of an M4 grub screw. 2 retainer blocks are required up to a system length of
1200 mm. These are mounted approx. 100 mm from the edge. An additional retainer block is
required above 1200 mm to 2000 mm. This is mounted in the centre. We supply a suitable
Reflective surface
D
A

2° = 4° (=Typ4)
Fig. 9: Principle of optical bypassing
262
0
200
400
600
0 1 2 3 4 5 6 7 8 9
D in m
A in mm
SAFETY 40
131
Fig. 10: Minimum distance to reflective surfaces
Fig. 8: Cascadable systems

Version 10.12.2019
page 12  WERAC Elektronik GmbH
angle bracket WHW1 which can be used to adjust both axes.
The retainer block WHK1 has also a transverse hole for direct attachment if alignment is not
required.
For a more comfortable mounting please ask for our hinge bracket WSH 1.
6.9.2 End piece mounting
An even simpler attachment is possible by means of the mounting bracket WHW2. This allows
alignment in the axis of rotation. For reasons of stability, this attachment is only possible for
emitters and receivers up to a maximum system length of 800 mm.
Additional information:
The emitters and receivers should be mounted on a stable, level and, if required, vibration-
damped machine component.
The emitters and receivers must have the connection and the LED displays on the same side.
The status LED display has to be placed unhidden and visible for the user.
6.10 Alignment mode
The alignment procedure must be carried out by an authorised, skilled representative.
With each connection of a new light grid an additional alignment procedure is needed. The
LED display on the control unit can visualise that a new alignment procedure is required (see
table 6).
If cascades are added or modified the procedure is also needed.
Note: Whenever a light grid is connected or the configuration is varied (cascades, number of
lines) a procedure corresponding to chapter 7 is needed.
6.10.1 Alignment of the emitters and receivers
The procedure for alignment of the emitter and receiver elements is described in the following
section:
a) The emitters and receivers are mounted as described under 6.9. Ensure that the
longitudinal axes are aligned in parallel during the assembly. Use a spirit level for this
purpose. Care should also be taken that the axis of rotation is set as accurately as
possible.
b) Set DIP S1-1 and S1-2 to ON (alignment mode):
Switch on power supply.
c) Next determine the reception range of the receiver by rotating it around the longitudinal
axis. The yellow LED in the "traffic light" shines, when there is a sufficient light reserve on
all lines of the grid. The red LED is lit as soon as one single line is not receiving any light. If
none of the both LED is shining there is not enough light for operation of the light grid.
d) Place the receiver in the centre of the reception range and secure.
e) Follow the same procedure to adjust and attach the emitters.
f) Switch off DIP S1-1:
The control unit will now store the amplification reference values of the individual lines after
a waiting period of 5-7 seconds (intermission indicated by flickering red LED to get the
hand out of the guarded area). Once this procedure has been completed, the red LED
starts to blink.
Now, switch off Dip S1-2
g) Switch off the power supply to exit the alignment mode. After reconnection, the light grid
enters the stand-by mode (red and yellow LEDs are lit). It switches to green (OSSD = ON)
as soon as the start button is pressed and the light grid is not interrupted.
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6

Version 10.12.2019
 WERAC Elektronik GmbH page 13
Assignment of DIP-switch S1:
ON OFF
S1-1: Alignment mode Normal operation
S1-2: Set safety mode Normal operation
S1-3, S1-4, S1-5, S1-6 see Table 7
Table 5
Note: During the alignment mode the OSSDs are switched OFF.
LED status
red yell grn Meaning OSSD
Power ON, Initialising off
Error in system – Power OFF required off
no reception off
all lines receiving light, but without sufficient reserve off
all lines receiving light off
5–7 s pause before storing reference values off
Alignment mode
Alignment mode terminated
Number of lines and attenuation stored
Power OFF required in order to swap to normal mode
off
Power ON, Initialising off
Error in system – Power OFF required off
not ready or interrupted off
grid ready for activation (external restart lock enabled) off
grid ready for activation
Less light reserve in relation to calibrated reference off
light grid active and free
Less light reserve in relation to calibrated reference ein
Normal mode
light grid active and free ein
Red and yellow LED blink alternately:
Incorrect line number in memory
Alignment mode required
off
Special case
Red LED blinks and yellow LED flashes:
Default status restored (memory erased)
Alignment mode required
off
Table 5 on, off, blinking, flashing, flickering, error blinking
6.10.2 Alignment of cascades
First of all, the light grid directly connected to the control unit is adjusted as described under
6.10.1. In this regard, the output cables to the next light grid must be separated and
terminated with the termination plug WAC1.
The second light grid can now be connected and adjusted. It is possible to connect two light
grids in cascade in this way.

Version 10.12.2019
page 14  WERAC Elektronik GmbH
6.11 Definition of the different possible operating modes for the control unit WGN 110
6.11.1 WGN 110
Additional to its normal function as ESPE (mode 0) the control unit WGN 110 has three more
operating modes. The additional modes (mode 1, mode 2 and mode 3) allow to bypass the
light grid (LG) respectively reduced resolution or fixed blanking of lines of the light grid.
To use the modes 1 to 3 the control unit WGN 110 is equipped with two type 4 inputs,
according to PL e, contact pair 1 (B1/B2 and B3/B4) and for contact pair 2 (B5/B6 and B7/B8)
in each case to connect two floating normally open (NO) contacts e.g. for a two-channel safety
equipment.
The following operation modes are distinguished:
- Mode 0 Monitoring with the ESPE (like WGN 100)
- Mode 1 Mode 0 + Bypassing the LG with contact pair 1/ Bypassing the LG with contact
pair 2
- Mode 2 Mode 0 + Reduced resolution with contact pair 1/ Bypassing the LG with contact
pair 2
- Mode 3 Fixed Blanking + Bypassing the LG with contact pair 1/ Bypassing the LG with
contact pair 2
In mode 0 the control unit WGN 110 behaves exactly like the WGN 100. The additional inputs/
contacts are not evaluated.
Caution!
When using mode 2 it should be noted that the function ”bypassing the light grid” has a higher
priority than reduced resolution. E.g. if both contact pairs are activated the function bypassing
is selected. (Details can be found in chapter 6.11.6 and 6.11.7)
6.11.2 Bypassing the light grid (LG)
If an operating mode with bypassing the light grid was selected in the alignment mode, the
safety function of the light grid can be bypassed with contact pair 1 and 2 in mode 1 and 3
(bypassing the lightgrid or fixed blanking). In mode 2 the light grid can be bypassed only with
contact pair 2. To activate the bypassing both NO contacts of a contact pair must close within
one second. As long as the light grid is bypassed by the two NO contacts no monitoring of the
guarded area takes place, i.e. an interruption of the light grid will not be detected!
During mode 1, 2 and 3 the connected inputs/ contacts were monitored dynamically.
The use of the function “bypassing the light grid” is only allowed for applications were the risk
assessment showed that bypassing is permissible.
6.11.3 Reduced resolution (blanking of light beams)
If operating mode 2 was selected in the alignment mode, contact pair 1 can activate the
blanking of the teached-in lines. To activate the blanking mode both NO contacts of contact
pair 1 must close within one second.
As long as the blanking function is activated by the two NO contacts, only the remaining part
of the guarded area is monitored, i.e. an interruption of the light grid in the teached-in blanking
area will not be detected!
During mode 2 the connected inputs/ contacts were monitored dynamically by the control unit.
The blanked light beams are determined in an extra teach-in function within the alignment
mode. Then they are saved in the internal memory of the control unit.
The use of the function switched blanking is only allowed for applications were the risk
assessment showed that blanking is permissible.

Version 10.12.2019
 WERAC Elektronik GmbH page 15
6.11.4 Fixed Blanking (of selected light beams)
The Fixed Blanking function is used to monitor the light grid in areas that are not permanently
blanked. The blanked lines are also monitored for light reception. If light is received, it is
switched off immediately. These areas must be mechanically protected against unauthorised
access. If this mechanical protection is omitted, monitoring of the light curtain ensures that it is
switched off immediately and that safety remains intact. The bypassing function is also
available in the Fixed Blanking mode. This can be activated via contact pairs 1 and/or 2. A
detailed description of the bridging function can be found in chapter 6.11.6.
6.11.5 Teach-in of the safety modes
To change the operating mode the following procedure must be met:
In mode 0 as AOPD (electro-sensitive protective device) and for the WGN 100-2:
same procedure as described in chapter 6.10.1 (Alignment of transmitters and receivers).
In mode 1 as AOPD with additional bypassing function:
1. device in OFF state (supply voltage off)
2. set DIP switch S1-1 to the following position:
3. switch on the device
4. if necessary, align the light grid optimally as described under 6.10.1 (c) to (e)
5. switch OFF dip S1-1.
After a pause of 5-7s (to remove the hand from the protected area, this is indicated by the
flickering red LED), the control unit saves the mode and the reference values of the individual
lines in the read-only memory. When this process is completed, the red LED starts flashing.
To exit the adjustment mode, switch the power and then DIP S1-2 off.
6. After the power supply is switched on again, the light grid goes into waiting mode (red and
yellow LEDs light up). It switches to green (OSSD = ON) as soon as the start release is
activated and the light grid is free.
7. In normal operation in mode 1, the DIP switch is set:
In mode 2 as AOPD with additional function reduced resolution and bypassing:
1. device in OFF state (supply voltage off)
2. set DIP switch S1-1 to the following position:
3. switch on the device
4. if necessary, align the light grid optimally as described under 6.10.1 (c) to (e)
5. Close the two normally open contacts connected to contact pair 1. All LEDs switch off, the
red LED lights up when all lines are interrupted.
6. cover the lines to be blanked. If all lines to be blanked are correctly covered, the two NO
contacts must be opened. The lines to be blanked out for the reduced resolution are taught
in or accepted. Caution: At least one line must remain uncovered, else no line will be
specified as blanked! Now the yellow LED lights up again if the protective field is clear and
has reserve, the red LED if at least one line is interrupted and no LED if light is received
but not sufficient for safe operation.
7. Clear the light girds guarded area completely and check the optimum alignment once
again.
8. Switch off dip S1-1.
After a pause of 5-7s (to remove the hand from the protected area, this is indicated by the
flickering red LED), the control unit saves the mode, the lines to be blanked and the
reference values of the individual lines in the read-only memory. When this process is
completed, the red LED starts flashing. To exit the adjustment mode, the power supply and
then DIP S1-2 must be switched off.
9. After the power supply is switched on again, the light grid goes into waiting mode (red and
yellow LEDs light up). It switches to green (OSSD = ON) as soon as the start release is
activated and the light grid is free.
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6

Version 10.12.2019
page 16  WERAC Elektronik GmbH
10. After activating the reduced resolution function with contact pair 1, the test rod must be
used to test whether the taught-in lines to be blanked correspond to the desired ones. If
not, the complete teach-in procedure must be repeated until the configuration is correct.
11. In normal operation in mode 1, the DIP switch is set:
In mode 3 as AOPD with additional function fixed blanking and bypassing:
1. device in OFF state (supply voltage off)
2. set DIP switch S1-1 to the following position:
3. the areas to be permanently blanked must be interrupted or covered. Caution: At least one
line must remain free.
4. switch on the device
5. swivel the light grid over the entire reception area and align it centrally. The yellow LED
lights up. Now wait 30 seconds. Within this time the lines to be blanked are defined and
saved.
6. Switch off dip S1-1.
7. After a pause of 5-7s (to remove the hand from the protected area, this is indicated by the
flickering red LED), the control unit saves the mode, the lines to be blanked and the
reference values of the individual lines in the read-only memory. When this process is
completed, the red LED starts flashing. To exit the adjustment mode, the power supply and
then DIP S1-2 must be switched off.
After the power supply is switched on again, the light grid goes into waiting mode (red and
yellow LEDs light up). It switches to green (OSSD = ON) as soon as the start release is
activated and the light grid is free.
8. The guarded area must be tested in accordance with the given specifications.
9. In normal operation in mode 1, the DIP switch is set:
6.11.6 Activate the bypass function of the light grid
To activate the bypassing function of the light grid system in safety mode 1, 2 or 3 the
following sequence must be met:
Before a bypassing can be chosen and activated all contacts of the two type-4 contact pairs
must be open. Both contacts of a contact pair must close within a time slot of one second.
Only the contact pair which fulfills this requirement activates the overriding. The second
contact pair now cannot influence the bypassing but it is constantly checked if the contacts
also close within one second. If the time slot is exceeded, both contacts of the contact pair
must open again. As soon as one contact of the active contact pair opens, it is checked if the
second contact pair was closed correctly and a bypassing is requested. If so the bypassing
mode is passed to the other contact pair, if not the overriding is stopped and the light grid
guarantees the safety function.
The bypassing mode can be activated and deactivated both in OSSD off mode (when the light
grid is interrupted) and in normal mode when the light grid is unobstructed.
Caution, risk of injury
Particularly when using the bypassing in OSSD off mode it must be ensured by measures
defined through a risk assessment that an activation of the bypassing will cause no hazardous
situation.
I.e. only when hazards can be excluded by using other measures, e.g. a locked and monitored
rolling door and a restart lock, the use of the overriding mode is permitted.
6.11.7 Activate the reduced resolution mode
6.11.7.1 In normal mode
To activate the reduced resolution function of the light grid system in safety mode 2 the
following sequence must be met:
Before switched blanking can be chosen and activated both contacts of the type-4 contact pair
1 must be open. Both contacts of a contact pair must close within a time slot of one second.
Only if the contact pair fulfills this requirement reduced resolution is activated.
The second contact pair is constantly checked if the contacts also close within one second. If
so the system switches to the bypassing mode. This takes place because the overriding has a
higher priority than the reduced resolution mode. I.e. if both contact pairs close correctly
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6
Dip S1 on
off
1 2 3 4 5 6

Version 10.12.2019
 WERAC Elektronik GmbH page 17
during safety mode 2, always bypassing is activated. This particularity must be considered in
the risk assessment. See also the safety guidelines at the end of chapter 6.11.5.
As soon as one contact of the active contact pair opens, it is checked if the second contact
pair was closed correctly and another safety mode is requested. If so the safety mode is
passed to the one related to the other contact pair, if not the current mode is stopped and the
light grid guarantees the safety function.
The reduced resolution mode can be activated and deactivated both in OSSD off mode (when
the light grid is interrupted) and in normal mode when the light grid is unobstructed. The
blanking function will only effect the light grid in normal mode.
6.11.7.2 After power ON
A special function is included in the reduced resolution mode after power ON. After system
start and the system self-tests the mode reduced resolution is activated directly if the function
is selected, i.e. both contacts of contact pair 1 are closed/ switched ON.
Once the reduced resolution is activated the same monitoring sequences and operations are
carried out as described in 6.11.7.1.
Caution, risk of injury
When using the switched reduced resolution, in particular the special function after power on it
must be ensured that an accumulation of faults does not lead to a loss of the safety function
for reaching the performance level PL e, category 4 in accordance with EN ISO 13849-1. For
this reason, appropriate measures must be taken on the application side, which may also
include fault exclusions (e.g. at the switches).
Caution, risk of injury
When using the function reduced resolution the lines specified for bypassing were no longer
evaluated, when contact pair 1 is closed. The guarded area then is reduced by the blanked
lines. In the bypassed areas no monitoring takes place. I.e. only when hazards in the blanked
areas can be excluded by using other measures, e.g. a locked and monitored rolling door and
a restart lock, the use of reduced resolution is permitted.
Caution, risk of injury
When using both functions (blanking and bypassing) in mode 2 it must be ensured that the
different priorities of the functions were considered in the risk assessment and the passing
from one function to the other does not generate a hazardous situation.
6.11.8 Operation with Fixed Blanking
If mode 3 has been defined in the teach-in procedure, fixed blanking is permanently active.
This means that the selected lines are always blanked and must be interrupted at all times to
enable the OSSDs.
Caution, risk of injury
When using both functions (fixed blanking and bypassing) it must be ensured that the different
priorities of the functions were considered in the risk assessment and the passing from one
function to the other does not generate a hazardous situation.
7 Commissioning and regular inspections
The commissioning engineer must have all the requisite information on the machine and the
mounted ESPE (ESPE = electro-sensitive protective device, in this case SAFETY 40 safety
light curtain with WGN 100 or WGN 110 control unit) available. The inspection must extend to
the perfect interaction of the ESPE with the controller of the power-driven machinery and the
setup in compliance with these safety regulations. With all inspections always check the safety
guidelines of the machine manufacturer (e.g. the manufacturer of the presses).

Version 10.12.2019
page 18  WERAC Elektronik GmbH
A distinction is made between:
a) Inspections before the initial start-up and after changes (Acceptance inspection)
Before the initial start-up of the ESPE and after changes at the ESPE or at other
components/ units involved in the safety function an inspection should be done by an
authorized and qualified person.
Changes are considered as all modifications to the switching, the controller, the
configuration or the programming of the ESPE and other components that can have an
effect on the safety function.
These inspections should determine that the requirements to the power-driven machinery
(e.g. the press) with using the ESPE are fulfilled and the faultless working of all
components that are involved to the safety function of the ESPE. Furthermore the manner
of use and the mounting of the ESPE must be checked.
In case of presses also the after-running time must be considered with the inspection.
b) Regular inspections
Regular inspections provide a systematically testing guard against to prevent flaws (e.g.
with changes or manipulations) of the safety equipment of the machinery/ installation after
the start-up. As defined in § 3 Para. 3 of the Ordinance on Industrial Safety and Health
(BetrSichV) nature, scope and times for regular inspections must be determined by the
user for the specific work equipment. Furthermore the qualifications and requirements (e.g.
technical expert or professional) for the designated person must be determined.
According to technical regulations for safety in the work place (TRBS 1201) for presses a
testing period of „as the need arises and at least once a year“ has proven.
This inspection includes, inter alia safety check to guarantee impeccable operation the
faultless working of the ESPE, the condition of the parts, the appropriate installation of the
ESPE and the interaction of the ESPE and the control of the press (see BGI 724, chapter
6.3.2.1)
Furthermore the inspection must include, that the maximum permissible value for the after-
running time of the press in not exceeded.
For all inspections the governmental Standard Operating Procedures, the type C standards,
the rules and information of the Institution for Statutory Accident Insurance and Prevention
(BG) allocated to the individual machines shall be noticed.
The inspection results must be
documented in a report, which must
be signed by the inspector. The
report must be kept at the site of
installation of the power-driven
machinery.
Fig. 11:
Checking the guarded
area by means of a
test rod
The red LED must
light as long as the
test rod is moved
inside the guarded
area.
The green LED must
light when the test rod
is removed.
SAFETY 40
SAFETY 40

Version 10.12.2019
 WERAC Elektronik GmbH page 19
8 Type designation code for light grids and multibeam light barriers
Our light grids can be divided into three groups: standard light grids, combination light grids
and multibeam light barriers. The light grids with 14 mm and 30 mm resolution are composed
of light barrier modules with a length of 50 mm. The system length is calculated from the
number of 50 mm modules. This length only includes the active elements (without head pieces
and LED display).
As a result of the modular design, it is possible to produce light grids at each 50 mm step of
the system length (35 mm modules for resolution 40 mm). This provides high flexibility for our
customers.
The following sections show the type designation code and examples to determine the order
number of the light grid variants.
You can determine the unspecified intermediate types and data in the general sense. Their
height of guarded area and number of lines can be determined as described in section 6.5 and
the response time as described in 6.4. The overall length is calculated from the system length
plus 38 mm.
8.1 Type designation code for standard light grid with 14, 30 and 40 mm resolution
W G x x x x x x x x x – 0
Examples for emitters, standard design with 14 mm resolution
System
length Type designation code Overall length in mm
Height of guarded
area in mm No. of lines Response time tR in ms
50 WGS 4005A014-0 88 64 5 16.8
100 WGS 4010A014-0 138 114 10 17.6
600 WGS 4060A014-0 638 614 60 25.6
1900 WGS 4190A014-0 1938 1914 190 46.4
Table 8
Examples for emitters, standard design with 30 mm resolution
50 WGS 4005A030-0 88 80 2 16.32
100 WGS 4010A030-0 138 130 4 16.64
600 WGS 4060A030-0 638 630 24 19.84
2000 WGS 4200A030-0 2038 2030 80 28.8
Table 9
Examples for emitters, standard design with 40 mm resolution
70 WGS 4007A040-0 108 110 2 16.32
175 WGS 4017A040-0 213 215 5 16.80
630 WGS 4063A040-0 668 670 18 18.88
1995 WGS 4199A040-0 2033 2035 57 25.12
Table 10
14
= Resolution 14 mm
30 = Resolution 30 mm
40
=
Resolution
40 mm
Emitter =
S
Receiver = E
SAFETY 40 = 4
0 = Standard light grid
System length 50 – 2000 mm
e.g. 50 mm = 005
700 mm = 070
1500 mm = 150
Variants:
A = Standard design (NA), width of guarded area 0-6 m,
without cascade output
B = Additional cascade output, width of guarded area 0-6 m
C = NA with increased width of guarded area (woga):
3-10 m (only 30 an 40 mm resolution)
D = Increased woga 3-10 m and cascade output
(only 30 and 40 mm resolution)
Change index
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...
... ... ... ... ... ...

Version 10.12.2019
page 20  WERAC Elektronik GmbH
8.2 Combination light grid with 14/30 mm or 14/40 mm resolution
In the case of the combination light grid, modules with a 30 mm or 40 mm resolution and
modules with a 14 mm resolution are fitted in an aluminium profile. The combination light grid
is especially suitable for machines in which several danger spots have to be safeguarded. For
the use of combination light grids all safety distances (including the vertical position) shall be
taken into account.
The different resolutions are marked on both sides of the section tube. The 14 mm resolution
can be identified by the optical system (interconnected lenses) and a red range marking with
yellow inscription “14 mm”.
When using combination light grids, the respective range must be checked with the two test
rods for 14 mm and 30 mm and/or 40 mm.
Application example:
There are two danger spots in a miniload
storage/retrieval machine: firstly the lift shaft at a
distance S1 with a shearing hazard and secondly the
unloading station (distance S214 and S230) with a
crushing hazard. A light grid with a combined
resolution of 14 mm and 30 mm allows both danger
spots to be safeguarded in very effective manner.
Calculation of the minimum value for S214 and S230:
If the machine has a braking time of 80 ms and the
combination light grid a response time tR = 24.1 ms,
a safety distance
S214 = 2 m/s · (80 + 24,1) ms = 208.2 mm
results at a 14 mm resolution (see Section 6.2)
and S230 = 336,2 mm at a 30 mm resolution.
The dimension for the height of the section with a
14 mm resolution is calculated as follows:
   
mm2642S2SH 2
14
2
3014 
On account of the 50 mm module sections, the following is obtained: H14 = 300 mm.
A more accurate determination of H14 is possible. Because of a diagonal entry through the
30 mm light grid the resolution is increased. Thus H14 can possibly be chosen smaller. For
more information please contact us.
Note: This calculation depends on the application which the safety light grid is used for and is
not a part of the EC-type-test.
Also a combination light grid with 14/40 mm is possible. Then the 14 mm resolution has just an
additional, not safety relevant use. In this case the height of the 14 mm part can be only 50 or
100 mm.
The type designation code for the combination light grids is the same except for the three
points marked with "Yyy". These three reference numbers change as follows:
W G x x x x x x Y y y Z z z z - 0
Fig. 12: Application example
Miniload storage/retrieval machine
600
mm
H14=
300
mm
S214
Unloader
Vertical
movement
(Lift)
S1
S230
1
= res. 14 mm at cable entry, remain 30 mm
2 = res. 14 mm at casc. output, remain 30 mm
3 = res. 14 mm at cable entry, remain 40 mm
4 = res. 14 mm at casc. output, remain 40 mm
5 = res. 30 mm at cable entry, remain 40 mm
6 = res. 30 mm at casc. output, remain 40 mm
Height of light grid component with bigger res.
e.g. 20 = 200 mm
35 = 350 mm
Length of the filler element
in mm
e.g. 105 = 105 mm
I
= filler element cable entry
O = filler element at cascade
output