8 008 616/17-07-02 · GO/SM · Printed in Germany (07.02) · We reserve the right to make changes
Safety Switches
P r o d u c t
C a t a l o g u e
GB 9.02 PK
Kat_Sicher_Umschlag_en 28.08.2002 11:39 Uhr Seite 1
Kat_Umschlag_U2_U3_en 27.08.2002 14:14 Uhr Seite 1
© 2002 SICK AG
Kat_Sicherheit_en 27.08.2002 13:31 Uhr Seite 1
We l c o m e t o t h e
experts in safety
te chnology.
We a r e p r e s e n t
wherever you
need us.
Safety photoelectric light
switches, safety light grids
and curtains, laser scanners
and safety switches ensure
effective prevention of accidents and protection for personnel in automated production and logistics processes.
Many years’ experience with
numerous industrial applications have resulted in revolutionary safety products that
have set standards in many
industries. SICK comprehensive expertise in planning,
implementation and operation
make it the number one in
this area.
Our sales and service bases
on six continents guarantee
that wherever you are in the
world we are not far away.
SICK subsidiaries and agencies are active in the world’s
most important markets in
line with our philosophy “think
global, act local”. SICK consultant engineers maintain
close contact with customers
and users on-site, ensuring
that new solutions can be
found for any problems that
occur. Solutions that are
based on the particular tasks
and their specific requirements. Maximum customer
satisfaction is the challenge
that we set ourselves every
day.
SICK electro-mechanical
safety switches provide you
with an alternative to optoelectronic solutions. They are
equipped with all the quality
features typical of SICK products. A wide range of
sophisticated interlock systems, with many variants, is
available to meet the most
varied of requirements and
operating conditions.
On the pages that follow you
will find detailed information
on all the data, technical
details, dimensions, technical
drawings and examples of
applications. In short: everything that you need for your
safety planning. See for yourself which is the most suitable interlock solution for you
and which best meets your
budgetary requirements.
Company headquarters
Subsidiaries
Associated companies
Agencies
Sales offices
Kat_Sicherheit_en 27.08.2002 13:31 Uhr Seite 2
Which interlock solution do
you require?
The following selection
guide provides an
overview of basic problem
definitions and suggests
particular solutions. Clear
page references simplify
use of the catalogue.
You are looking for a
simple, compact interlock solution with a high
degree of variability
... safety locking
devices?
Detailed information can be found
on pages 11–16
... safety switch
with actuator?
Detailed information can be found
on pages 17–28.
You are looking for a
solution that can withstand extreme conditions
such as heat, shock or
vibration
.... safety locking
devices?
Detailed information can be found
on pages 37–46/
75–82.
... safety switch
with actuator?
Detailed information can be found
on pages 47–66/
83–88/95–111.
2
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:31 Uhr Seite 3
Contents
The most modern interlock technology for application flexibility
Designed for practicality
Switch to safety and efficiency. SICK safety switches
6
7
8
Light duty safety locking devices
i10 Lock safety locking devices series
i14 Lock safety locking devices series
i10 and i 14 Lock series ordering table
11
12
14
16
Light duty safety switches with actuator
i10 Lock safety switch series
i11 mini safety switch series
i12 Lock safety switch series
i16 Lock safety switch series
i17 Lock safety switch series
i10, i11 mini, i12, i16 and i17 series ordering tables
17
18
20
22
24
26
28
Light duty accessories
iE10 and iE10 Lock series accessories
iE14 series accessories
iE11 series accessories
iE12, iE16, iE17 series accessories
iE10, iE11, iE12, iE16 and iE17 series ordering tables
29
30
32
33
34
35
Heavy duty safety locking devices
i100 Lock safety locking device series
i100 Lock safety locking device series
i100 Lock safety locking device series
i100 Lock safety locking device series
i100 Lock series ordering table
(head on left – cable entry)
(head on right – cable entry)
(head on left – device plug)
(head on right – device plug)
37
38
40
42
44
46
Heavy duty without solenoid release
Construction – function – details
i100 R1 safety switches series
i100 R2 safety switches series
i100 P1 safety switches series
i100 P2 safety switches series
i100 S1 safety switches series
i100 S2 safety switches series
i110 H safety switches series
i110 S safety switches series
i100 and i110 series ordering table
47
48
50
52
54
56
58
60
62
64
66
Heavy duty accessories
Actuator accessories
iE110 accessories
Plug accessories
IE100 and iE110 series ordering table
67
68
70
71
72
Contents continue on page 5
3
3
Kat_Sicherheit_en 27.08.2002 13:31 Uhr Seite 4
Are you looking for an
interlock solution that
meets strict hygiene
regulations?
Are you looking for a
solution for large, heavy
doors with alignment
errors?
... with solenoid
release?
Detailed information can be found
on pages 11–13.
Detailed information can be found
on
pages 95–111.
... with solenoid
release?
Detailed information can be found
on pages 75–82.
... without solenoid
release?
Detailed information can be found
on pages 83–88/
95–111.
Are you looking for a
solution for a complex
locking situation?
... with solenoid
release?
Detailed information can be found
on pages 75–82.
... without solenoid
release?
Detailed information can be found
on pages 83–88.
Do you require operating
or service personnel to
be granted authorised
access to the machine?
Are you looking for a
locking solution for robot
cells with rapid and
frequent access?
... with solenoid
release?
Detailed information can be found
on pages 75–82.
... without solenoid
release?
Detailed information can be found
on pages 83–88.
... with solenoid
release?
Detailed information can be found
on pages 89–93.
... without solenoid
release?
Detailed information can be found
on pages 89–93.
4
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Are you looking for a
solution with a secure
enable/service mode?
Detailed information can be found
on
pages 113–118.
Are you looking for relevant regulations and
standards?
Detailed information can be found
on pages 119–125.
Kat_Sicherheit_en 27.08.2002 13:32 Uhr Seite 5
Contents
Ultra heavy duty with solenoid release
Function – details – options
i1002 Lock safety locking device series
i1001 Lock safety locking device series
Ordering table
75
76
78
80
82
Ultra heavy duty without solenoid release
i1001 safety switches series
i1002 safety switches series
Ordering table
Modular options
83
84
86
88
89
Ultra heavy duty accessories
Ordering table
91
91
Non-contact safety sensors
RE300 Non-contact safety sensor
T4000 Non-contact safety sensor
T4000 Compact Non-contact safety sensor
T4000 und T4000 Compact ordering table
95
96
100
106
111
Safety operating units
Safety operating units
E100 Safety operating units
i110 RP rope-operated emergency stop switch
i110 RP accessories
E100 and i110 RP ordering table
113
114
115
116
117
118
Norms and standards
Risk analysis – control categories
Control categories
Regulations – norms – recommendations
Colour coding
Definition of terms
Switching elements
Safety switches – categories
3 stage/dual channel
119
120
122
123
125
126
127
128
5
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:33 Uhr Seite 6
A guarantee d future from an
e x p e r i e n c e d c o m p a n y.
Th e m o s t m o d e r n
i n t e r l o ck t e c h n o logy for application
flexibility
Safety components offer a
great deal. But only a few
manufacturers build them in
such a way that they can fulfil
both today’s practical
demands and those of the
future. In order to ensure that
our safety switches can do
the job properly, we have put
more into them than just
SICK’s well-known quality and
reliability. Namely, the experience and knowledge gained
from thousands of applications in the most varied of
industries. SICK’s presence
on Europe’s leading safety
committees guarantees that
SICK is always at the forefront of safety technology.
Those who choose to go with
SICK can profit from this
extensive knowledge.
We e n s u re s a f e
a c c e s s b y p ro v i d i n g
a suit able interlock
for every application.
Extremely harsh environmental conditions, external effects
such as shocks and vibration,
and frequent operation are
demands that SICK safety
switches can easily handle.
They remain alert and on duty
throughout the hard industrial
day-to-day grind: accurate
opening and closing is consistently assured. From the technical point of view, the switches belong to the most mature
of all the systems. At the
same time they are truly hightech.
6
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:34 Uhr Seite 7
D e s i g n e d f o r p r a c t i c a l i t y.
It’s safe to say:
e ve n m o re p o s s i b i l ities.
SICK’s modern interlock
expertise opens countless
new possibilities for complete
safety. Their flexibility for use
in new applications has been
considerably improved as a
result of improved equipment,
stronger housings and the
use of modern switching
technology. You are aware of
the complex demands that
you make of an interlock, and
you assess the duties that
the door interlock has to perform in everyday usage. Our
aim is to find an interlock
solution that is individually
tailored to suit your plant or
machine.
SICK safety switches are
available in light duty, heavy
duty, ultra heavy duty and
non-contact versions.
Wh i ch i n t e r l o ck
s o l u t i o n d o yo u
r e q u i re ?
i 10 / i 10 L o ck / i 14 L o ck /
i 11 m i n i / i 12 / i 16 / i 17
i100 /
i100 Lock/i110
i 10 0 0 / i 10 0 0 L o ck
T4000/
R E300
E 100
Frequency of
operation
low – average
high
very high
high
low
Environmental
conditions
normal
shock
vibration
heat
extreme loads
alignment errors
vibration, heat
complex locking situations
aggressive
heat
vibration
shock
heat
deformation
Lock
single
double
treble
–
–
Encoding
via key
via key
via key
electronic
–
Function
opening/closing, locking
opening /
closing, locking
opening /closing, locking,
with key /enable functions
opening /
closing
3 stage manual
enabling
function
Advantages at a glance:
●
●
●
●
small sizes
safety categories 2–4
all environmental conditions
high IP enclosure ratings
(up to IP 67)
● great versatility
● large variety of fittings
● approval according to BG,
BIA, CSA, SAQ, SUVA, TÜV,
UL
7
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:35 Uhr Seite 8
Switch to s afety and efficiency.
Safety switches by S I C K .
Li g h t d u t y
Heavy duty
i 10 0 / i 10 0 L o ck / i 110
metal series
i 10 L o ck / i 14 L o ck / i 10 / i 11 m i n i /
i 12 / i 16 / i 17 p l a s t i c s e r i e s
This versatile line of switches
have a high-quality, recyclable
plastic housing that is the
most compact and the lightest of their class. Here you
will find reliable safety based
on sophisticated technology
– SICK qualities precisely.
4 lateral approach directions
in addition to one from above
are quickly and easily adjusted. The small interlock width
allows trouble-free mounting
on small profiles.
But the i10/i10 Lock/i11 mini
series’ small and light structure is not their only attribute.
Their robust, versatile technology is also outstanding.
Switching elements with two
to four switching members
provide flexible connection.
From now on you only need
one interlock for a variety of
applications.
Advantages at a glance:
● can be mounted on
30–40 mm profiles
● 4 lateral approach directions
● 1 approach direction from
above
● compact housing
● easy connection
● variable switching members
● approvals: BG, CSA, SAQ,
SUVA, TÜV, UL
● with locking (i10 Lock)
● up to 3 cable entries
Sophisticated technology forms
the basis for the greatest reliability and precision – independent of external influences.
Here too, SICK’s safety
switches again demonstrate
their excellence. The i100
series was developed for the
harshest conditions in
mechanical engineering and
plant construction. This line
has metal housings, and the
high-quality materials used for
the plunger, driving mechanism and seals
guarantee a long life.
A C-rail ensures absolute protection against manipulation.
i100 metal switches are available in category 1 (switching
member and actuator form
one unit) and category 2
(switching member and
actuator do not form a unit).
8
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Versatile convertibility of the
approach direction, actuator
entry direction and switching
direction mean that the
switches are components
that can be used anywhere
for protecting people and
machines.
Advantages at a glance:
● Light-metal die-cast housing
● Position switch according
to EN 50041
● Safety categories 1–4
● Variable approach direction
● Variable actuator entry
direction
● Switching direction
left /right
● Indicator light
Kat_Sicherheit_en 27.08.2002 13:36 Uhr Seite 9
Ultra heavy duty
i 10 0 0 / i 10 0 0 L o ck
high-end series
The modular solution for extreme demands.
This safety system offers suitable modules for
every application.
The inclusion of an “arresting key” allows you
to employ new configurations in your safety
facilities.
Advantages at a glance:
●
●
●
●
●
●
●
●
●
unique modular concept
great variety of configurations
self-adjusting of alignment errors
conforms to the norms EN 954-1,
EN 1088, EN 292 and EN 1050
trapped-key transfer system
encodable with locking and without key
with differing access rights (general and
section keys)
cannot be forced open
simple mounting
IP 67 enclosure rating
Safety sensors
Safety operating units
T4000/ R E300
series
E 100/i110 RP safety
operating units
With the T 4000 safety sensors you remain
independent of external influences, and therefore most effectively protect your plant from
manipulation.
The T 4000 switch operates with an electronic,
uniquely encoded actuator. This technology
has been successfully used in the automobile
industry for years to prevent car thefts. T 4000
switches are the ideal solution wherever exact
door alignment is impossible, machine vibration, or for heavy and large doors. Actuators
without batteries also guarantee continuous,
service-free operation.
Employed as hand-operated
command unit these switches
allow the operation of machines and plant in hazardous
areas. In the “manual operation” operating mode, the
function of protective systems
is cancelled under certain
conditions. This allows access
to hazardous areas so that
programming, adjustment and
commissioning work may be
carried out.
Advantages at a glance:
● Ideal where there are strict hygiene regulations (e.g. in the catering industry)
● For imprecise door alignment
● When there is a lot of vibration
● For large and heavy doors
● High security against manipulation
● Fulfils control category 3 to EN 954-1
9
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:36 Uhr Seite 10
10
Kat_Sicherheit_en 27.08.2002 13:37 Uhr Seite 11
Li g h t d u t y w i t h
s a f e t y l o ck i n g d e v i c e s
A door interlock with a robust,
compact housing, its in-line design
providing a versatile solution to
many applications.
Necessary wherever the machine
stop time is greater than the
access time.
Light duty with s afety locking devices
Use
11
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:37 Uhr Seite 12
Safety Locking Devices
Housing:
Connection:
Switching elements:
Series i10 Lock
Reinforced thermoplastic
Type i10...1
Cable entry PG 13.5
Type i10...2
Plug connector SR 11
Typ i10...3
Cable entry M 20
4 contacts
Door contact
Explosive area zone 2
Switching element
Dimensional drawing Type i10...1 und i10...3
Travel
23
for M 5 > 35 mm
ISO 1207 (DIN 84)
ISO 4762 (DIN 912)
Actuator inserted
locked
unlocked
Dependent action contact
element, 2 positively driven NC
contacts + 1 NO + 1 NC as door
contact
Actuator
removed
Mechanical unlocking
mechanism
Mechanical unlocking
screw
23
Please order actuator
separately.
(See page 30)
Locking methods
i10 Lock M...:
i10 Lock E...:
Dimension drawing Type i10 Lock...2
Please order actuator
and plug connector separately.
(See page 71)
Actuator inserted, mechanically locked, unlocking
by applying voltage.
Locking by applying
voltage.
fitted
fitted
Mechanical unlocking mechanism
Safety locking devices can be unlocked by
means of the mechanical unlocking
mechanism in the event of power failure,
for example. The mechanical unlocking
mechanism has to be sealed to prevent
manipulation (for example with sealing
lacquer).
Changing the approach direction
Warning
The complete safety locking devices must be replaced in the event of faults.
Installation notes
The safety locking device and actuator must be assembled for installation purposes. The
actuator must be positively connected with the mounting surface, e.g. by using safety
screws or by welding, riveting, pinning. The safety locking device must not be used as an
end stop.
12
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. Manufacturer setting is
approach direction A.
A
Kat_Sicherheit_en 27.08.2002 13:37 Uhr Seite 13
Safety Locking Devices
Series i10 Lock
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Retaining force in locked condition
Switching element
Contact elements
Switching principle
Rated insulation voltage
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type i10...1
Connection type i10...2
Connection type i10...3
Wire cross-section max., i10...1
Short-circuit protection (control circuit fuse)
Weight
Solenoid:
Solenoid operating voltage
On time
Power absorbed
Value
Reinforced thermoplastic
IP 65
optional
106 switching cycles
– 20 to + 55
20
1200
23
2 NC
+ 1 NO + 1 NC as door contact
Dependent action contact element
i10...1, Ui = 250
i10...2, Ui = 50
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Screw terminal, PG 13.5
Plug connector SR 11, cable diameter 8–10 mm
Screw terminal, M 20
1.5
slow 10 / fast 20
approx. 0.5
Value
24 V DC / 110 V AC / 230 V AC (for all – 15 % / + 10 %)
100
8
Insertion depth (necessary minimum travel
+ permissible overtravel)
Approach direction side (h)
Approach direction from top (v)
Unit
°C
m/min
N
V
V
mA
mm2
A
kg
Unit
%
W
Standard Actuator
28 + 2
29.5 + 1.5
mm
mm
Pin assignment type i10 Lock...2
View from connection side
10
9
23
7
5
3
1
41
33
42
34
21
22
11
12
8
6
4
2
Positively driven NC contacts
NO
Positively driven NC contacts
1 NC as door contact
13
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:37 Uhr Seite 14
Safety Locking Devices
Housing:
Connection:
Switching elements:
Series i14 Lock
Glass-reinforced polyester
Cable entry M 20
3 contacts
Dimensional drawing Type i14
Switching element
21
30
2 positively driven NC contacts
+ 1 NO
3 positively driven NC contacts
Actuator inserted
locked
unlocked
Actuator
removed
21
30
Locking methods
i14 Lock M...:
Please order actuator
separately.
(See page 32)
Warning
If signs of damage or wear are detected, replace the complete locking device and actuator. Do not replace individual components or assemblies!
The actuator is physically
locked in position by the
force of the actuator
spring. Unlock the actuator
by applying voltage to the
solenoid.
Solenoid operating voltage
24 V DC –15 ... +10 %
110 V AC –15 ... +10 %
230 V AC –15 ... +10 %
LED display
The safety device can be opened; the
electro-magnetic solenoid is activated.
Installation notes
The safety locking device and actuator must be assembled for installation purposes. The
safety locking device and the actuator must not be used as a stop. The actuator must
be fixed to the safety device such that it cannot become detached. It must be fixed using, for example, one-way screws, rivets or be fixed by means of welding. The unused
actuator slot must be covered and sealed using the cover supplied.
Change actuator entry direction
After loosening the fixing screws, the actuator
head can be twisted around to the desired
direction.
14
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Mechanical unlocking mechanism
In the event of malfunctions, solenoid
latching can be deactivated using a resistor screwdriver, irrespective of the state of
the electro-magnetic solenoid.
Kat_Sicherheit_en 27.08.2002 13:37 Uhr Seite 15
Safety Locking Devices
Series i14 Lock
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Max. approach speed
Max. actuation force
Retaining force in locked condition
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Min. switching voltage
Min. switching current at 5 V DC
Wire cross-section
Short-circuit protection
(control circuit fuse EN 60269)
Solenoid operating voltage
On time
Power consumption
Indication
Value
Glass-reinforced polyester
IP 65
106 switching cycles
– 10 ... + 60
optional
M 20
160
12
1200
mm/s
N
N
2/1 or 3/0
2500
V
250
AC 15/AC: 2 A (250 V), 5 A (100 V)
DC 13/DC: 0.5 A (250 V), 2 A (24 V)
5
5
1 x 1.5
Slow-blow 10/10
24 V DC, 110 V AC, 230 V AC
100
Typically 7
Solenoid energised
Unit
°C
V
V DC
mA
mm2
A
%
W
15
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 16
Safety Locking Devices
Series i10 Lock and i14 Lock
O rd e r i n g t a b l e i 10 L o ck
Type
i10i10i10i10i10i10i10i10i10i10i10i10-
Solenoid release
mechanical electrical
M
E
M
E
M
E
M
E
M
E
M
E
Switching element:
S a f e t y L o ck i n g D e v i c e
24 V DC
024
024
Solenoid voltage
110 V AC 230 V AC
Connector
110
110
230
230
024
024
0
0
2
2
23
23
23
23
i14i14i14i14i14i14-
Part no.
6 012 135
6 012 136
6 021 037
6 021 036
6 012 137
6 012 138
6 012 139
6 012 140
6 022 580
6 022 585
6 022 582
6 022 586
23 – 2 positively driven NC contacts + 1 NO + 1 NC as door contact as standard.
O rd e r i n g t a b l e i 14 L o ck
Type
Type of connection
PG 13.5 SR 11 M 20
1
1
1
1
1
1
2
2
3
3
3
3
Solenoid release
mechanical
M
M
M
M
M
M
S a f e t y L o ck i n g D e v i c e
24 V DC
0
0
Solenoid voltage
110 V AC 230 V AC
1
1
2
2
Connector
NO
NC
2
1
3
0
2
1
3
0
2
1
3
0
16
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Type of connection
M 20
3
3
3
3
3
3
Part no.
6 025 060
6 025 062
6 025 064
6 025 066
6 025 068
6 025 070
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 17
Li g h t d u t y
s a f e t y s w i t ch w i t h
actuator
Safety switch with strong plastic
housings and small dimensions.
Use
Light duty safety switch with actuator
Highly versatile, ideal for small
door openings.
17
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 18
Safety Switches
Housing:
Connection:
Switching elements:
Series i10
Reinforced thermoplastic
Cable entry
2 contacts
Explosive area zone 2
Dimensional drawing Type i10
Fixing to EN 50047
Switching elements
11
Travel
20
Travel
Dependent action contact element, 1 positively driven NC +
1 NO contact
Dependent action contact element, 2 positively driven NC
.
.
Actuator
inserted
Actuator
removed
11
20
Please order actuator
separately.
(See page 30)
Installation notes
The safety switch and actuator must be
assembled for installation purposes. The
actuator must be positively connected
with the mounting surface, e.g. by using
safety screws or by welding, riveting,
pinning. The safety switch must not be
used as an end stop.
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. Manufacturer setting is
approach direction A.
A
18
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 19
Safety Switches
Series i10
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Switching element
Contact elements
Switching principle
Rated voltage
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Retaining force
Wire cross-section max.
Short-circuit protection (control circuit fuse)
Weight
Value
Reinforced thermoplastic
IP 67
optional
106 switching cycles
– 20 to + 80
20
Unit
°C
m/min
11
20
+ 1 NO
2 NC
Dependent action contact element
NP 1: Ui = 400
AC-15 Ue 230 V Ie 4 A / DC-13 Ue 24 V Ie 4 A
24
30
Silver alloy
Screw terminal
10
1.5
slow 6 / fast 10
approx. 0.1
N
mm2
A
kg
Standard Actuator
28 + 2
29.5 + 1.5
mm
mm
1 NC
Insertion depth1)
Approach direction side (h)
Approach direction from top (v)
1) Necessary minimum travel and permissible overtravel
V
V
mA
19
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Safety Switches
Housing:
Connection:
Switching elements:
Series i11 mini
Reinforced Thermoplastic
Cable entry
...10... with 1 positively driven NC contact
...21... with 3 contacts
Explosive area zone 2
Approvals pending
Dimensional drawing S 103
Switching elements
Travel
Travel
...10... gold flashed, dependent action
contact element,
1 positively driven NC contact
...21... gold flashed, dependent action
contact element,
2 positively driven NC contacts,
+ 1 NO
Actuator
inserted
Actuator
removed
v
h
Please order actuator
separately.
(See page 33)
Standard
Dimensional drawing S 211
21
22
21
22
...10...
31
21
13
32
22
14
31
21
13
32
22
14
...21...
Installation notes
Travel
Travel
The safety switch and actuator must be
assembled for installation purposes. The
actuator must be positively connected
with the mounting surface, e.g. by using
safety screws or by welding, riveting,
pinning. The safety switch must not be
used as an end stop.
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. Manufacturer setting is
approach direction A.
Warning
(3x)
The complete safety switch must be
replaced in the event of damage or wear.
Please order actuator
separately.
(See page 33)
Standard
20
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 21
Safety Switches
Series i11 mini
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Switching element
Contact elements
Switching principle
Rated voltage
Utilization category IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Cable entry
Actuation force
Retaining force
Wire cross-section max.
Short-circuit protection (control circuit fuse)
Weight
Insertion depth
Necessary minimum travel
Permissible overtravel
Value
Reinforced thermoplastic
IP 67
optional
106 switching cycles
– 20 to + 80
20
...10...
...21...
1 NC
2 NC
+ 1 NO
Dependent action contact element
Ui = 250
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Screw terminal
1 x M 16
3 x PG 9
approx. 6
approx. 10
1.5
slow 10 / fast 20
approx. 0.08
approx. 0.1
Value
20
4
Unit
°C
m/min
V
V
mA
N
N
mm2
A
kg
Unit
mm
mm
Minimum door radius
21
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Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 22
Safety Switches
Housing:
Connection:
Switching elements:
Series i12
Glass-reinforced polyester
Cable entry M 16
SA103 with 1 contact
SA113 with 2 contacts
SA213 with 3 contacts
Dimensional drawing SA103 and SA113
TÜV
Switching elements
10
11
21
1 positively driven NC contact
1 positively driven NC contact
1 NO
2 positively driven NC contact
1 NO
Actuator
inserted
Actuator
removed
10
Please order actuator
separately.
(See page 34)
11
Dimensional drawing SA213
21
Installation notes
The safety switch and actuator must be
assembled for installation purposes. The
safety switch and the actuator must not
be used as a stop. The actuator must be
fixed to the safety device such that it cannot become detached. It must be fixed
using, for example, one-way screws, rivets
or be fixed by means of welding. The unused actuator slot must be covered and
sealed using the cover supplied.
Change actuator entry direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. Manufacturer setting is
actuator entry direction A.
Please order actuator
separately.
(See page 34)
Warning
22
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
If signs of damage or wear are detected,
replace the complete switch and actuator.
Do not replace individual components or
assemblies!
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 23
Safety Switches
Series i12
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Approach speed (maximum)
Actuation force (minimum)
Frequency of use (maximum)
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Switching voltage (minimum)
Switching current (minimum) at 5 V DC
Wire cross-section
Short-circuit protection
(control circuit fuse EN 60269)
Value
Glass-reinforced polyester
IP 67
1 x 106 switching cycles
– 20 ... + 80
Optional
1 x M 16
160
6
1
2/1 or 1/1 or 1/0
Unit
°C
mm/s
N
cycle/s
2500
V
250
AC 15/3 A (240 V), 6 A (120 V)
DC 13/1.1 A (250 V), 2.2 A (125 V)
5
5
1 x 1.5
Slow-blow 10/10
V
V DC
mA
mm2
A
23
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Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 24
Safety Switches
Housing:
Connection:
Switching elements:
Series i16
Glass-reinforced polybutylene terephthalate (PBT)
Cable entry M 20
With 2 contacts
Dimensional drawing
TÜV
Switching elements
20
11
2 positively driven NC contact
1 positively driven NC contact,
1 NO
Actuator
inserted
Actuator
removed
20
Please order actuator
separately.
(See page 34)
11
Installation notes
The safety switch and actuator must be
assembled for installation purposes. The
safety switch and the actuator must not
be used as a stop. The actuator must be
fixed to the safety device such that it cannot become detached. It must be fixed
using, for example, one-way screws, rivets
or be fixed by means of welding. The unused actuator slot must be covered and
sealed using the cover supplied.
Change actuator entry direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. Manufacturer setting is
actuator entry direction A.
Warning
If signs of damage or wear are detected,
replace the complete switch and actuator.
Do not replace individual components or
assemblies!
24
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 25
Safety Switches
Series i16
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Approach speed (maximum)
Actuation force (minimum)
Frequency of use (maximum)
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Switching voltage (minimum)
Switching current (minimum) at 5 V DC
Wire cross-section
Short-circuit protection
(control circuit fuse EN 60269)
Value
Glass-reinforced polybutylene terephthalate (PBT)
IP 67
1 x 106 switching cycles
– 20 ... + 80
Optional
3 x M 20
160
30
2
2/1 or 1/1
Unit
°C
mm/s
N
cycles/s
2500
V
250
AC 15/AC: 2 A (250 V), 5 A (100 V)
DC 13/DC: 0.5 A (250 V), 2 A (24 V)
5
5
1 x 1.5
Slow-blow 10/10
V
V DC
mA
mm2
A
25
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Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 26
Safety Switches
Housing:
Connection:
Switching elements:
Series i17
Glass-reinforced polyester
Cable entry M 20
With 3 contacts
Dimensional drawing
TÜV
Switching elements
2 positively driven NC contact, 1 NO
Actuator
inserted
Please order actuator
separately.
(See page 34)
Actuator
removed
Installation notes
The safety switch and actuator must be
assembled for installation purposes. The
safety switch and the actuator must not
be used as a stop. The actuator must be
fixed to the safety device such that it cannot become detached. It must be fixed
using, for example, one-way screws, rivets
or be fixed by means of welding. The unused actuator slot must be covered and
sealed using the cover supplied.
Change actuator entry direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. Manufacturer setting is
actuator entry direction A.
Warning
If signs of damage or wear are detected,
replace the complete switch and actuator.
Do not replace individual components or
assemblies!
26
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 27
Safety Switches
Series i17
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Approach speed (maximum)
Actuation force (minimum)
Frequency of use (maximum)
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Switching voltage (minimum)
Switching current (minimum) at 5 V DC
Wire cross-section
Short-circuit protection
(control circuit fuse EN 60269)
Value
Glass-reinforced polyester
IP 67
1 x 106 switching cycles
– 20 ... + 80
Optional
3 x M 20
1
12
2
2/1
Unit
°C
m/s
N
cycles/s
2500
V
250
AC 15/AC: 2 A (250 V), 5 A (100 V)
DC 13/DC: 0.5 A (250 V), 2 A (24 V)
5
5
1 x 1.5
Slow-blow 10/10
V
V DC
mA
mm2
A
27
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Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 28
Safety Switches
Series i10, i11 mini , i12, i16 and i17
O rd e r i n g t a b l e i 10
Type
i10i10-
Mounting
EN 50 047
A
A
S a f e t y S w i t ch e s
Dual Pole Switch
NC
1
2
NO
1
0
Connector
M 20
3
3
NO
1
0
1
Connector
PG 9
M 16
1
3
3
NO
0
1
1
Connector
M 16
3
3
3
NO
0
1
1
Connector
M 20
3
3
3
O rd e r i n g t a b l e i 11 m i n i
Type
i11i11i11-
Variant
S
S
S
i12i12i12-
Variant
SA
SA
SB
i16i16i17-
Variant
SA
SA
SA
Part no.
6 012 162
6 022 584
6 022 583
S a f e t y S w i t ch e s
Dual Pole Switch
NC
1
1
2
O rd e r i n g t a b l e i 16 / i 17
Type
6 022 530
6 022 529
S a f e t y S w i t ch e s
Dual Pole Switch
NC
2
1
2
O rd e r i n g t a b l e i 12
Type
Part no.
Part no.
6 025 056
6 025 057
6 025 059
S a f e t y S w i t ch e s
Dual Pole Switch
NC
2
1
2
28
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Part no.
6 025 063
6 025 065
6 025 067
Kat_Sicherheit_en 27.08.2002 13:40 Uhr Seite 29
Li g h t d u t y
accessories
Accessories for SICK light duty
series of Safety switches.
Use
Light duty accessories
Can be used for any application
when employed in combination
with various approach directions.
29
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Accessories
Series i10 and i10 Lock
Actuators
Bent actuator iE10-A1
Straight actuator iE10-S1
Part no. 5 306 535
(2 safety screws included)
Min. door radius 1000 mm
Part no. 5 306 527
(2 safety screws included)
Min. door radius 1000 mm
Radius actuator iE10-R1
for top and bottom hung doors
Part no. 5 306 528
(2 safety screws included)
Min. door radius 90 mm
Adjustment
screw
Adjustment
screw
Radius actuator iE10-R2
for right and left hand hung doors
Part no. 5 306 529
(2 safety screws included)
Min. door radius 100 mm
Adjustment
screw
30
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Adjustment
screw
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 31
Accessories
Series i10 and i10 Lock
Straight actuator iE10-S2
Actuators
flexibly
Part no. 5 306 530
(2 safety screws included)
Min. door radius 1000 mm
Lockout bar iE10-S3
Part no. 5 306 536
The locking bar can be inserted into the safety switch in place of
the actuator when the safety guard is in the open condition and
can be secured to prevent its removal by standard commercially
available padlocks (max. 2 pcs.).
This guarantees reliable protection for persons who have to
enter potentially hazardous areas.
Lock iE10-K1, iE10-K2
Lock:
- various systems of closing:
- uniform system of closing:
iE10-K1, Part no. 5 308 269
iE10-K2, Part no. 5 308 270
Blade
locked
Marker
Mechanical unlocking
mechanism
(Nominal position)
Safety screw
unlocked
31
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Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 32
Accessories
Straight actuator iE14-S1
Part no. 5 311 133
32
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Series iE14 Lock
Actuators
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 33
Accessories
Series iE11
Straight actuator iE11-S1
Bent actuator iE11-A1
Part no. 5 306 537
(2 safety screws M 4 x 14 included)
Straight actuator iE11-S2
Part no. 5 306 538
(2 safety screws M 4 x 14 included)
flexibly in longitudinal direction
Part no. 5 306 539
(2 safety screws M 4 x 14 included)
Straight actuator iE11-S3
Bent actuator iE11-A1
flexibly
Part no. 5 306 541
(2 safety screws M 4 x 14 included)
flexibly in cross direction
Part no. 5 306 540
(2 safety screws M 4 x 14 included)
.
.
33
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Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 34
Accessories
Straight actuator iE12-S1
Part no. 5 311 131
Series iE12, iE16 and iE17
Straight actuator iE12-F1
flexibly
Part no. 5 311 132
2 SLOTS FOR
M 4 SCREWS
Straight actuator iE16-S1
Part no. 5 311 128
Straight actuator iE16-F1
Part no. 5 311 129
Straight actuator iE17-S1
Part no. 5 311 130
34
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
flexibly
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 35
Accessories
Series iE10, iE11, iE12, iE14, iE16 and iE17
O rd e r i n g t a b l e i E 1 0
Type
Actuator Type
straight
A c t u a t o r f o r i 10 L o ck a n d i 10
straight,
flexibly
iE 10iE 10iE 10iE 10iE 10iE 10-
S1
Type
Lock
various systems of closing
K1
iE10iE10-
angled
A1
R1
R2
S3
Part no.
uniform system of closing
iE 11iE 11iE 11iE 11iE 11-
5 308 269
5 308 270
K2
Actuator Type
straight
A c t u a t o r f o r S a f e t y s w i t ch i 11 m i n i
Part no.
straight, flexibly
in line
angled
iE12iE12-
transversal
S2
S3
A1
A2
Actuator Type
straight
S1
iE14-
Part no.
straight, flexibly
5 311 131
5 311 132
F1
A c t u a t o r f o r i 14
Actuator Type
straight
S1
Part no.
5 311 133
O rd e r i n g t a b l e i E 16 / i E 17
Type
iE16iE16iE17-
Actuator Type
straight
S1
A c t u a t o r f o r i 16 / i 17
Part no.
straight, flexibly
5 311 128
5 311 129
5 311 130
F1
S1
O rd e r i n g t a b l e
Type
SSR 11, cable receptacle
ASR 11, cable receptacle
Device plug
Cable gland M 16
Cable gland M 20
Cable gland PG 13.5
5 306 537
5 306 539
5 306 540
5 306 538
5 306 541
A c t u a t o r f o r i 12
O rd e r i n g t a b l e i E 14
Type
angled, flexibly
S1
O rd e r i n g t a b l e i E 12
Type
Part no.
5 306 527
5 306 530
5 306 535
5 306 528
5 306 529
5 306 536
S2
O rd e r i n g t a b l e i E 1 1
Type
Lockout
Bar
Radius: door hinged
up/down left side/right side
Cable gland/plug for
i 10 , i 10 L o ck i 10 0 u n d i 10 0 L o ck
straight
angled
for safety switch
für
Number of pins
11 + PE
11 + PE
11 + PE
11 + PE
Part no.
6 020 757
6 020 758
6 020 759
5 309 163
5 309 164
5 305 811
35
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Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 36
36
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 37
Heavy duty
s a f e t y l o ck i n g d e v i c e
Robust, highly reliable metal interlocks for frequent operation and
extreme environmental conditions.
For safeguarding machines with
run-on conditions.
Use
Heavy duty s afety locking device
Always required whenever the stop
time of the machine is greater
than the access time.
37
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Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 38
Safety Locking Device
Series i100 Lock (head on left – cable entry)
with monitored solenoid release
Housing:
Anodized die-cast light alloy
Actuator head:
Left
Connection:
Cable entry PG 13.5
Switching elements:
2 contacts
Explosive area zone 2
Dimensional drawing
Switching elements
b
Mechanical
unlocking
mechanism
a
11 gold flashed, slow-action interlock
1 positively driven NC + 1 NO contact
(See page 100 for further details)
Locking methods
M: Actuator inserted, mechanically locked,
unlocking by applying voltage.
E: Locking by applying voltage.
Solenoid operating voltages
24 V AC/DC – 15 % to + 10 %
110 V AC – 15 % to + 10 %
230 V AC – 15 % to + 10 %
LED function display
Safety Locking Device i100 Lock
Made in Germany
Please order actuator
separately.
(See page 67)
The function display makes it possible to
check the respective operating state of
the safety locking device.
a) Pre-travel:
The actuator is in the guide, but does not initiate switching operation.
Only Green:
Only Red:
b) Switching operation complete:
The actuator must be inserted up to this point to ensure reliable switching.
The actuator must be withdrawn at least to point a for switching off.
Warning
Safety circuit closed
Key unlocked,
safety circuit open.
The LED voltage corresponds to the solenoid operating voltage. Please specify other operating voltages in the safety and
monitoring circuit.
Installation notes
The complete safety locking devices must be replaced in the event of damage or wear.
D
E (C)
Standard
The safety locking device and actuator
must be assembled for installation purposes. The actuator must be positively
connected with the mounting surface, e.g.
by using safety screws or by welding, riveting, pinning. The safety locking device
must not be used as an end stop.
(See page 98 for further information)
Mechanical unlocking mechanism
.
Safety locking devices with mechanical
locking can be unlocked by means of the
mechanical unlocking mechanism in the
event of power failure, for example. The
mechanical unlocking mechanism can be
sealed to prevent manipulation (lead seal
set supplied).
B
Changing the approach direction
D
E (C)
A
B
38
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. The working illustration
is as shown (approach direction E).
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 39
Safety Locking Device
Series i100 Lock (head on left – cable entry)
Te c h n i c a l d a t a
Parameter
Housing material
Color of housing cover
Environmental protection IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Actuating force
Retaining force in locked condition
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Cable cross section max.
Short-circuit protection (control circuit fuse)
Weight (incl. solenoid)
Value
Anodized die-cast light alloy
black
IP 67
optional
2 x 106 switching cycles
– 25 to + 80
20
35
1000
2 x 11
1 NO + 1 NC
Slow-action
4.0
250
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Screw terminal
1.5
slow 10 / fast 20
approx. 1.07
Solenoid
Solenoid operating voltage 1)
ON time
Connected load
1) Other operating voltages available to order
Value
24 / 110 / 230
100
7
Switching diagram
Unit
°C
m/min
N
N
kV
V
V
mA
mm2
A
kg
Unit
V
%
W
Circuit diagram (to be connected by the user)
Safety guard open
Solenoid
GN
Depicted:
Safety guard closed
Actuator locked
RD
SK =
ÜK =
Safety circuit
Monitoring circuit
Safety guard closed
Terminal 1 to 6 of PCB
terminal strip are shown by .
Solenoid
GN
RD
Line 2: Safety guard open
Line 3: Safety guard closed and locked
Line 4: Safety guard to unlock
(e.g. release of Zero Speed Indicator)
Line 6: Unlocked (released for opening)
GN
RD
39
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 40
Safety Locking Device
Series i100 Lock (head on right – cable entry)
with monitored solenoid release
Housing:
Anodized die-cast light alloy
Actuator head:
Right
Connection:
Cable entry PG 13.5
Switching elements:
2 contacts
Explosive area zone 2
Dimensional drawing
Switching elements
Mechanical
unlocking
mechanism
11 gold flashed, slow-action interlock
1 positively driven NC + 1 NO contact
(See page 100 for further details)
b
a
Locking methods
M: Actuator inserted, mechanically locked,
unlocking by applying voltage.
E: Locking by applying voltage.
Solenoid operating voltages
24 V AC/DC – 15 % to + 10 %
110 V AC – 15 % to + 10 %
230 V AC – 15 % to + 10 %
LED function display
i100 Lock Safety Locking Device
Made in Germany
Please order actuator
separately.
(See page 67)
a) Pre-travel:
The actuator is in the guide, but does not initiate switching operation.
b) Switching operation complete:
The actuator must be inserted up to this point to ensure reliable switching.
The actuator must be withdrawn at least to point a for switching off.
Warning
The function display makes it possible to
check the respective operating state of
the safety locking device.
Only Green:
Only Red:
Safety circuit closed
Key unlocked,
safety circuit open.
The LED voltage corresponds to the solenoid operating voltage. Please specify other operating voltages in the safety and
monitoring circuit.
Installation notes
The complete safety locking devices must be replaced in the event of damage or wear.
D
E (A)
Standard
The safety locking device and actuator
must be assembled for installation purposes. The actuator must be positively
connected with the mounting surface, e.g.
by using safety screws or by welding, riveting, pinning. The safety locking device
must not be used as an end stop.
(See page 98 for further information)
Mechanical unlocking mechanism
Safety locking devices with mechanical
locking can be unlocked by means of the
mechanical unlocking mechanism in the
event of power failure, for example. The
mechanical unlocking mechanism can be
sealed to prevent manipulation (lead seal
set supplied).
B
Changing the approach direction
C
D
B
E (A)
40
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. The working illustration
is as shown (Approach direction E).
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 41
Safety Locking Device
Series i100 Lock (head on right – cable entry)
Te c h n i c a l d a t a
Parameter
Housing material
Color of housing cover
Environmental protection IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Actuating force
Retaining force in locked condition
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Cable cross section max.
Short circuit protection (control circuit fuse)
Weight (incl. solenoid)
Value
Anodized die-cast light alloy
black
IP 67
optional
2 x 106 switching cycles
– 25 to + 80
20
35
1000
2 x 11
1 NO + 1 NC
each
Slow-action
4.0
250
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Screw terminal
1.5
slow 10 / fast 20
approx. 1.07
Solenoid
Solenoid operating voltage1)
ON time
Connected load
1) Other operating voltages available to order
Value
24 / 110 / 230
100
7
Switching diagram
Unit
°C
m/min
N
N
kV
V
V
mA
mm2
A
kg
Unit
V
%
W
Circuit diagram (to be connected by the user)
Safety guard open
Solenoid
GN
Depicted:
Safety guard closed
Actuator locked
RD
SK =
ÜK =
Safety circuit
Monitoring circuit
Safety guard closed
Terminal 1 to 6 of PCB
terminal strip are shown by .
Solenoid
GN
RD
Line 2: Safety guard open
Line 3: Safety guard closed and locked
Line 4: Safety guard to unlock
(e.g. release of Zero Speed Indicator)
Line 6: Unlocked (released for opening)
GN
RD
41
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Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 42
Safety Locking Device
Series i100 Lock (head on left – plug connector)
with monitored solenoid release
Housing:
Anodized die-cast light alloy
Actuator head:
Left
Connection:
Plug connector SR 11 (see page 56)
Switching elements:
2 contacts
Dimensional drawing
Switching elements
b
Mechanical
unlocking
mechanism
a
11 gold flashed, slow-action interlock
1 positively driven NC + 1 NO contact
(See page 100 for further details)
Locking methods
M: Actuator inserted, mechanically locked,
unlocking by applying voltage.
E: Locking by applying voltage.
Solenoid operating voltages
24 V AC/DC – 15 % to + 10 %
LED function display
i100 Lock Safety Locking Device
Made in Germany
The function display makes it possible to
check the respective operating state of
the safety locking device.
Please order actuator
separately.
(See page 67)
Only Green:
dependent on wiring:
Power on / actuator unlocked
customer specific
a) Pre-travel:
The actuator is in the guide, but does not initiate switching operation.
Only Red:
b) Switching operation complete:
The actuator must be inserted up to this point to ensure reliable switching.
The actuator must be withdrawn at least to point a for switching off.
The LED voltage corresponds to the solenoid operating voltage. Please specify other operating voltages in the safety and
monitoring circuit.
Warning
Installation notes
The complete safety locking devices must be replaced in the event of damage or wear.
The safety locking device and actuator
must be assembled for installation purposes. The actuator must be positively
connected with the mounting surface, e.g.
by using safety screws or by welding, riveting, pinning. The safety locking device
must not be used as an end stop.
(See page 98 for further information)
fitted
fitted
Dimensions plug connector connection SR 11
Mechanical unlocking mechanism
Safety locking devices with mechanical
locking can be unlocked by means of the
mechanical unlocking mechanism in the
event of power failure, for example. The
mechanical unlocking mechanism can be
sealed to prevent manipulation (lead seal
set supplied).
D
E (C)
Standard
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. The working illustration
is as shown (Approach direction E).
.
B
42
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 43
Safety Locking Device
Series i100 Lock (head on left – plug connector)
Te c h n i c a l d a t a
Parameter
Housing material
Color of housing cover
Environmental protection IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Actuating force
Retaining force in locked condition
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Short-circuit protection (control circuit fuse)
Weight (incl. solenoid)
Value
Anodized die-cast light alloy
black
IP 65
optional
2 x 106 switching cycles
– 25 to + 80
20
35
1000
2 x 11
1 NO + 1 NC
Slow-action
4.0
50
AC-15 Ue 50 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Plug connector 11 + PE (DIN 43651)
slow 10 / fast 20
approx. 1.14
Solenoid
Solenoid operating voltage1)
ON time
Connected load
1) Other operating voltages available to order
Value
24 / 110 / 230
100
7
Switching diagram
Unit
°C
m/min
N
N
V
V
mA
A
kg
Unit
V
%
W
Circuit diagram (internally wired)
Safety guard open
Solenoid
GN
Depicted:
Safety guard closed
Actuator locked
RD
SK =
ÜK =
Safety circuit
Monitoring circuit
Safety guard closed
Terminal 1 to 6 of PCB
terminal strip are shown by .
Solenoid
GN
RD
GN
RD
43
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 44
Safety Locking Device
Series i100 Lock (head on right - plug connector)
with monitored solenoid release
Housing:
Anodized die-cast light alloy
Actuator head:
Right
Connection:
Plug connector SR 11 (see page 56)
Switching elements:
2 contacts
Dimensional drawing
Switching elements
11 gold flashed, slow-action interlock
1 positively driven NC + 1 NO contact
(See page 100 for further details)
b
Mechanical
unlocking
mechanism
a
Locking methods
M: Actuator inserted, mechanically locked,
unlocking by applying voltage.
E: Locking by applying voltage.
Solenoid operating voltages
24 V AC/DC – 15 % to + 10 %
LED function display
i100 Lock Safety Locking Device
Made in Germany
Please order actuator
separately.
(See page 67)
The function display makes it possible to
check the respective operating state of
the safety locking device.
Only Green:
dependent on wiring:
Power on / actuator unlocked
customer specific
a) Pre-travel:
The actuator is in the guide, but does not initiate switching operation.
Only Red:
b) Switching operation complete:
The actuator must be inserted up to this point to ensure reliable switching.
The actuator must be withdrawn at least to point a for switching off.
The LED voltage corresponds to the solenoid operating voltage. Please specify other operating voltages in the safety and
monitoring circuit.
Warning
Installation notes
The complete safety locking devices must be replaced in the event of damage or wear.
The safety locking device and actuator
must be assembled for installation purposes. The actuator must be positively
connected with the mounting surface, e.g.
by using safety screws or by welding, riveting, pinning. The safety locking device
must not be used as an end stop.
(See page 98 for further information)
fitted
fitted
Dimensions plug connector connection SR 11
Mechanical unlocking mechanism
Safety locking devices with mechanical
locking can be unlocked by means of the
mechanical unlocking mechanism in the
event of power failure, for example. The
mechanical unlocking mechanism can be
sealed to prevent manipulation (lead seal
set supplied).
D
Changing the approach direction
E (A)
Standard
B
44
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. The working illustration
is as shown (Approach direction E).
Kat_Sicherheit_en 27.08.2002 13:41 Uhr Seite 45
Safety Locking Device
Series i100 Lock (head on left – plug connector)
Te c h n i c a l d a t a
Parameter
Housing material
Color of housing cover
Environmental protection IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Actuating force
Retaining force in locked condition
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Short-circuit protection (control circuit fuse)
Weight (incl. solenoid)
Value
Anodized die-cast light alloy
black
IP 65
optional
2 x 106 switching cycles
– 25 to + 80
20
35
1000
2 x 11
1 NO + 1 NC
Slow-action
4.0
50
AC-15 Ue 50 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Plug connector 11 + PE (DIN 43651)
slow 10 / fast 20
approx. 1.14
Solenoid
Solenoid operating voltage1)
ON time
Connected load
1) Other operating voltages available to order
Value
24
100
7
Switching diagram
Unit
°C
m/min
N
N
kV
V
V
mA
A
kg
Unit
V
%
W
Circuit diagram (internally wired)
Safety guard open
Solenoid
GN
Depicted:
Safety guard closed
Actuator locked
RD
SK =
ÜK =
Safety circuit
Monitoring circuit
Safety guard closed
Terminal 1 to 6 of PCB
terminal strip are shown by .
Solenoid
GN
RD
GN
RD
45
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Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 46
Safety Locking Device
O rd e r i n g t a b l e
Type
Locking
Actuating Head Solenoid Voltage
Switching
mech. electr. right
left
24 V DC 110 V AC 230 V AC element
i100M
R
024
i100E
R
024
i100M
L
024
i100E
L
024
i100M
R
230
i100E
R
230
i100M
L
230
i100E
L
230
i100M
R
024
i100E
R
024
i100M
L
024
i100E
L
024
i100M
L
110
i100E
L
110
i100M
R
110
i100E
R
110
i100M
R
0
11
Ordering example: i100-, electrical locking, solenoid voltage 024 V AC, connector SR11
Type i100-EL0242; Cat. No. 6 012 126
46
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Series i100 Lock
S a f e t y L o ck i n g D e v i c e
Connector
PG 13,5 SR 11
1
1
1
1
1
1
1
1
2
2
2
2
1
1
1
1
Part no.
M 20
3
6 012 121
6 012 122
6 012 117
6 012 118
6 012 123
6 012 124
6 012 119
6 012 120
6 012 127
6 012 128
6 012 125
6 012 126
6 021 907
6 021 908
6 021 909
6 021 910
6 022 595
Heavy duty without
s o l e n o i d re l e a s e
Robust, highly reliable metal interlock for frequent operation and
extreme environmental conditions.
A large variety of construction
designs to suit all applications.
Use
Used whenever the access time is
greater than the machine’s stop
time.
Heavy duty without solenoid release
Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 47
47
8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved
Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 48
Design – Function – Det ails
Applications
The safety switches in this series are used for protection of
personnel, machines and production goods throughout the whole
field of mechanical and plant engineering thanks to their design
concept and high degree of flexibility.
A fully-developed design, the use of top quality materials and
SICK-production know-how guarantee problem-free operation of
these devices under even the most stringent conditions. Two
different types are available.
Design
The safety switches of this series possess an anodized
die-cast light alloy housing. They are characterized by a high level
of operating reliability, high strength and corrosion resistance.
Reliability and function are assured over and beyond the guaranteed service life by the use of top quality materials for the plungers, drive mechanisms and seals.
Function
Position switches
In accordance with EN 50041 with safety function
Type series i100
This series is characterized by positive interaction of all actuating
elements in the functional sequence of the interlocks. This guarantees that the switching element responsible for the safety
function positively disconnects circuits even in the event of contact welding, for example.
Flexibility
These safety switches are universal components for the whole
field of mechanical and plant engineering thanks to the many
conversion possibilities:
approach directions (4 x 90°)
actuator directions (4 x 90°) for roller-lever
mechanism
switching directions left /right /two-way.
Refer to the adjacent page for further information.
LED display
Safety locking devices can be equipped with a function display
(LED) if required. This is available for the voltage ranges
12–60 V
110 V
230 V
± 15 %
± 15 %
AC/DC
AC
AC
A built-in electronic controller guarantees constantly high
luminosity independently of the applied voltage.
48
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 49
Position switches to EN 50041
Type series i100
Actuator and approach direction
R = Roller lever
steel
P = Roller plunger
Plunger Rotation – Actuator
Horizontal repositioning 4 x 90°
Roller lever
Straight actuator
Vertical conversion 4 x 90° (form fitted)
or infinitely adjustable through 360° (no positive fixing)
Convertible – switching direction
left /right
switching
(standard setting)
right-hand
switching
left-hand
switching
49
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Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 50
Safety Switches
Type:
Housing:
Connection:
Actuator:
Switching elements:
Series i100 R1
Basic housing EN 50041
Anodized die-cast light alloy
Cable entry M 20
Roller lever (Steel)
4 contacts
Dimensional drawing
(cable entry)
Explosive area zone 2
Switching elements
31 gold flashed, slow-action switch
3 positively driven NC + 1 NO contact
Positive
o pe
Installation notes
nin
g
tra
ve
l
The radial cam distance shown in the
dimensional drawing must be observed in
order to obtain the correct air gap.
Actuator elements such as the radial cam
approach guide must be mounted on the
interlock in accordance with VDI 2854,
i.e. riveted, welded, or otherwise secured
to prevent detachment.
Conversion possibilities
Horizontal and vertical 4 x 90°.
Switching direction: right hand, left hand or
left /right switching.
(See page 128 for further details)
Warning
The complete safety switch should be replaced in the event of damage or wear.
Actuator travel diagrams
Contacts
open
closed
31
50
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
not-activated
activated at 45°
Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 51
Safety Switches
Series i100 R1
(cable entry)
Te c h n i c a l d a t a
Parameter
Value
Housing material
Anodized die-cast light alloy
Environmental protection to IEC 529
IP 67
Mounting position
optional
Mechanical service life
30 x 106 switching cycles
Ambient temperature
– 25 to + 80
Actuator
Steel Roller lever
Approach speed max.1)
60
Approach speed min.
0.1
Pretravel up to switching point
see actuator travel diagram
Travel to isolating distance
45
Actuating force
10
Switching element
31
Contact elements
3 NC
+ 1 NO
Switching principle
Slow-action
Rated impulse withstand voltage Uimp
4.0
Closing time
<4
Bounce time
<3
Rated insulation voltage Ui
250
Utilization category to IEC 947-5-1
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
Switching voltage min.
12
Switching current min. at 24 V
10
Contact material
Silver alloy, gold flashed
Connection type
Screw terminal
Cablecross-section max.
2 x 1.5
Short-circuit protection (control circuit fuse)
slow 10 / 20 fast
Weight
approx. 0.3
1) The approach speed is valid for a trip dog approach angle of 30°; it may be exceeded if the approach angle is reduced.
Unit
°C
m/min
m/min
°
N
kV
ms
ms
V
V
mA
mm2
A
kg
51
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Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 52
Safety Switches
Type:
Housing:
Connection:
Actuator:
Switching elements:
Series i100 R2
(plug connector)
Basic housing EN 50041
Anodized die-cast light alloy
Plug connector SR 11 (see page 56)
Roller lever (Steel)
4 contacts
Dimensional drawing
Switching elements
31 gold flashed, slow-action interlock
3 positively driven NC + 1 NO contact
P o s i ti v e
o pe
nin
g
tra
ve
l
Installation notes
The trip dog distance as shown in the
dimension diagram must be observed in
order to obtain the isolating distance.
Actuating elements such as trip dogs
must be installed with a positive connection in accordance with VDI 2854, e.g.
riveted, welded or otherwise secured to
prevent detachment.
Conversion possibilities
fitted
fitted
Horizontal and vertical 4 x 90°.
Switching direction: right hand, left hand or
left /right switching.
(See page 128 for further details)
Warning
The complete safety switch should be replaced in the event of damage or wear.
Actuator travel diagrams
Contacts
open
closed
31
52
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
not-activated
activated at 45°
Kat_Sicherheit_en 27.08.2002 13:43 Uhr Seite 53
Safety Switches
Series i100 R2
(plug connector)
Te c h n i c a l d a t a
Parameter
Value
Housing material
Anodized die-cast light alloy
Environmental protection to IEC 529
IP 65
Mounting position
optional
Mechanical service life
30 x 106 switching cycles
Ambient temperature
– 25 to + 80
Actuator
Steel
Roller material
Steel
Approach speed max.1)
60
Approach speed min.
0.1
Pretravel up to switching point
see actuator travel diagram
Travel to isolating distance
45
Actuating force
10
Switching element
31
Contact elements
3 NC
+ 1 NO
Switching principle
Slow-action
Rated impulse withstand voltage Uimp
4.0
Closing time
<4
Bounce time
<3
Rated insulation voltage Ui
50
Utilization category to IEC 947-5-1
AC-15 Ue 50 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
Switching voltage min.
12
Switching current min. at 24 V
10
Contact material
Silver alloy, gold flashed
Connection type
Plug connector 11 + PE (DIN 43651)
Short-circuit protection (control circuit fuse)
slow 10 / 20 fast
Weight
approx. 0.35
1) The approach speed is valid for a trip dog approach angle of 30°; it may be exceeded if the approach angle is reduced.
Unit
°C
m/min
m/min
°
N
kV
ms
ms
V
V
mA
A
kg
53
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Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 54
Safety Switches
Type:
Housing:
Connection:
Actuator:
Switching elements:
Series i100 P1
Basic housing EN 50041
Anodized die-cast light alloy
Cable entry M 20
RS (plunger with large steel roller)
4 contacts
(cable entry)
Explosive area zone 2
Switching elements
31 gold flashed, slow action interlock
3 captive NC contacts + 1 NO contact
Installation notes
Free position
Opening point
Positive opening travel
Dimensional drawing
The trip dog distance as shown in the
dimension diagram must be observed in
order to obtain the isolating distance.
Actuating elements such as trip dogs
must be installed with a positive connection in accordance with VDI 2854, e.g.
riveted, welded or otherwise secured to
prevent detachment.
Conversion possibilities
Horizontal 4 x 90°.
(See page 128 for further details)
Warning
The complete safety switch should be replaced in the event of damage or wear.
Plunger types / Actuator travel
not-activated
Free position
RS = Steel roller
Form C (EN 50041)
31
End position
Contacts
open
closed
54
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
activated at 5 mm
Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 55
Safety Switches
Series i100 P1
(cable entry)
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Mounting position
Mechanical service life
Ambient temperature
Plunger design
Plunger type
Design to EN 50041-type
Approach speed max.
Approach speed min.
Pretravel up to switching point
Forced opening after switching point
Actuating force
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Closing time
Bounce time
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Cablecross-section max.
Short-circuit protection (control circuit fuse)
Weight
Value
Anodized die-cast light alloy
IP 67
optional
30 x 106 switching cycles
– 25 to + 80
Maintenance-free
RS
C1
20
0.01
see actuator travel diagram
≥ 0.8
15
31
3 NC
+ 1 NO
Slow-action
4.0
<4
<3
250
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Screw terminal
2 x 1.5
slow 10 / 20 fast
approx. 0.3
Unit
°C
m/min
m/min
mm
N
kV
ms
ms
V
V
mA
mm2
A
kg
55
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Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 56
Safety Switches
Type:
Housing:
Connection:
Actuator:
Switching elements:
Series i100 P2
(plug connector)
Basic housing EN 50041
Anodized die-cast light alloy
Plug connector SR 11 (see page 56)
Plunger with large steel roller
2 contacts
Switching elements
Free position
31 Slow-action switch
3 positively driven NC + 1 NO contact
Opening point
Positive opening travel
Dimensional drawing
Installation notes
The trip dog distance as shown in the
dimension diagram must be observed in
order to obtain the isolating distance.
Actuating elements such as trip dogs
must be installed with a positive connection in accordance with VDI 2854, e.g.
riveted, welded or otherwise secured to
prevent detachment.
Conversion possibilities
fitted
fitted
Horizontal 4 x 90°.
(See page 128 for further details)
Warning
The complete safety switch should be replaced in the event of damage or wear.
Plunger types / Actuator travel
not-activated
Free position
Steel roller
Form C (EN 50041)
31
End position
Contacts
open
closed
56
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
activated at 5 mm
Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 57
Safety Switches
Series i100 P2
(plug connector)
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Mounting position
Mechanical service life
Ambient temperature
Plunger design
Plunger type
Design to EN 50041-type
Approach speed max.
Approach speed min.
Pretravel up to switching point
Forced opening after switching point
Actuating force
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Closing time
Bounce time
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Short-circuit protection (control circuit fuse)
Weight
Value
Anodized die-cast light alloy
IP 67
optional
30 x 106 switching cycles
– 25 to + 80
Maintenance-free
Steel Roller
C1
20
0.01
2
≥ 0.8
15
31
3 NC
+ 1 NO
Slow-action
4.0
<4
<3
50
AC-15 Ue 50 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Plug connector 11 + PE (DIN 43651)
slow 10 / 20 fast
approx. 0.35
Unit
°C
m/min
m/min
mm
mm
N
kV
ms
ms
V
V
mA
A
kg
Pin assignment type i100 P2
View from connection side
57
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Safety Switches
Type:
Housing:
Connection:
Switching elements:
Series i100 S1 (cable entry)
Basic housing EN 50041
Anodized die-cast light alloy
Cable entry M 20
4 contacts
Dimensional drawing
Explosive area zone 2
Switching elements
31 gold flashed, slow-action interlock
3 positively driven NC + 1 NO contact
b
a
Actuator removed
Actuator inserted
Installation notes
The safety switch and actuator must be
assembled for installation purposes. The
actuator must be positively connected
with the mounting surface, e.g. by using
safety screws or by welding, riveting,
pinning. The safety switch must not be
used as an end stop.
Please order actuator
separately.
(See page 67)
a) Pre-travel:
The actuator is in the guide, but does not initiate switching operation.
b) Switching operation complete:
The actuator must be inserted up to this point to ensure reliable switching.
The actuator must be withdrawn at least to point a for switching off.
Warning
The complete safety switch should be replaced in the event of damage or wear.
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© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. The working illustration
is as shown (approach direction E).
D
E (A)
C
B
Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 59
Safety Switches
Series i100 S1 (cable entry)
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Actuating force
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Rated insulation voltage Ui
Utilisation category acc. to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Cablecross-section max.
Short-circuit protection (control circuit fuse)
Weight
Value
Anodized die-cast light alloy
IP 67
optional
2 x 106 switching cycles
– 25 to + 80
20
35
31
3 NC
+ 1 NO
Slow-action
4.0
250
AC-15 Ue 230 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Screw terminal
1.5
slow 10 / 20 fast
approx. 0.3
Unit
°C
m/min
N
kV
V
V
mA
mm2
A
kg
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Safety Switches
Type:
Housing:
Connection:
Switching elements:
Series i100 S2
(plug connector)
Basic housing EN 50041
Anodized die-cast light alloy
Plug connector SR 11 (see page 56)
4 contacts
Dimensional drawing
Switching elements
31 gold flashed, slow-action interlock
3 positively driven NC + 1 NO contact
b
a
Actuator removed
Actuator inserted
Installation notes
The safety switch and actuator must be
assembled for installation purposes. The
actuator must be positively connected
with the mounting surface, e.g. by using
safety screws or by welding, riveting,
pinning. The safety switch must not be
used as an end stop.
Please order actuator
separately.
(See page 67)
a) Pre-travel:
The actuator is in the guide, but does not initiate switching operation.
b) Switching operation complete:
The actuator must be inserted up to this point to ensure reliable switching.
The actuator must be withdrawn at least to point a for switching off.
Changing the approach direction
The actuator head can be turned to the
desired approach direction after undoing
the fixing screws. The working illustration
is as shown (approach direction E).
Warning
The complete safety switch should be replaced in the event of damage or wear.
fitted
fitted
Dimensions plug connector connection SR 11
60
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
D
E (A)
C
B
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Safety Switches
Series i100 S2
(plug connector)
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Mounting position
Mechanical service life
Ambient temperature
Approach speed max.
Actuating force
Switching element
Contact elements
Switching principle
Rated impulse withstand voltage Uimp
Rated insulation voltage Ui
Utilization category to IEC 947-5-1
Switching voltage min.
Switching current min. at 24 V
Contact material
Connection type
Short-circuit protection (control circuit fuse)
Weight
Value
Anodized die-cast light alloy
IP 65
optional
2 x 106 switching cycles
– 25 to + 80
20
35
31
3 NC
+ 1 NO
Slow-action
4.0
50
AC-15 Ue 50 V Ie 6 A / DC-13 Ue 24 V Ie 6 A
12
10
Silver alloy, gold flashed
Plug connector 11 + PE (DIN 43651)
slow 10 / 20 fast
approx. 0.35
Unit
°C
m/min
N
kV
V
V
mA
A
kg
Pin assignment type i100 S2
View from connection side
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Safety Switches
Housing:
Connection:
Switching elements:
Series i110 H
Die-cast light alloy
Cable entry M 20
With 3 contacts
Dimensional drawing
Switching elements
2 positively driven NC, 1 NO
Installation notes
The safety switch is fitted to engage with
safety doors pivoted on hinges. The safety
switch must not be used as a mechanical
stop. The safety switch and the switch
cam must be adequately secured against
positional movement and be engaged with
each another in an interlocking manner.
Adjusting the switching angle
The switch activation angle can be set in
the range 5 ° ... 11 ° (after functionally
testing, the safety switch and the switch
cam must be pinned together to ensure
integrity).
Warning
If signs of damage or wear are detected,
the complete switch must be replaced.
Do not replace individual components or
assemblies!
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Safety Switches
Series i110 H
Te c h n i c a l d a t a
Parameter
Housing material
Shaft material
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Approach speed (maximum)
Switching angle
Frequency of use (maximum)
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Switching voltage (minimum)
Switching current (minimum) at 5 V DC
Wire cross-section
Short-circuit protection
(control circuit fuse EN 60269)
Weight
Value
Die-cast light alloy
Stainless steel
IP 66
1 x 106 switching cycles
– 25 ... + 80
Optional
1 x M 20
160
5° ... 11° adjustable
1
2/1
Unit
°C
mm/s
cycle/s
2500
V
250
AC 15/AC: 2 A (250 V), 5 A (100 V)
DC 13/DC: 0.4 A (250 V), 2 A (24 V)
5
5
1 x 1.5
T6
V
0.42
V DC
mA
mm2
kg
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Safety Switches
Housing:
Connection:
Switching elements:
Series i110 S
Die-cast zinc, varnished
Cable entry M 20
With 4 contacts
Dimensional drawing
Switching elements
31 3 positively driven NC contacts, 1 NO
22 2 positively driven NC contacts, 2 NO
Actuator inserted
Actuator removed
Installation notes
Please order actuator
separately.
(See page 72)
During installation the safety switch and
the actuator must be engaged. The safety
switch and the actuator must not be used
as a stop. The actuator must be fitted to
the safety device in such a manner as to
prevent it becoming detached. It must be
fixed using, for example, one way screws,
rivets or be fixed by means of welding.
The unused actuator slot must be covered
and sealed using the cover supplied.
Change actuator entry direction
After loosening the 4 fixing screws, the
actuator head can be twisted around to
the desired direction.
Warning
If signs of damage or wear are detected,
replace the complete switch and actuator.
Do not replace individual components or
assemblies!
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Safety Switches
Series i110 S
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Approach speed (maximum)
Actuating force (minimum)
Frequency of use (maximum)
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Switching voltage (minimum)
Switching current (minimum) at 5 V DC
Wire cross-section
Short-circuit protection
(control circuit fuse EN60269)
Weight
Value
Die-cast zinc, varnished
IP 67
1 x 106 switching cycles
– 20 ... + 80
Optional
1 x M 20
1
12
2
3/1 or 2/2
Unit
°C
m/s
N
cycles/s
2500
V
250
AC 15/AC: 2 A (250 V), 5 A (100 V)
DC 13/DC: 0.5 A (250 V), 2 A (24 V)
5
5
1 x 1.5
Slow-blow 10/10
V
V DC
mA
mm2
A
0.52
kg
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Safety Switches
Series i100 and i110
O rd e r i n g t a b l e i 10 0
Type
i100i100i100i100i100i100-
Actuator
Roller
Lever
R
Roller Plunger
S a f e t y S w i t ch e s
Separate
Actuator Key
P
S
Switching element
NC
NO
Connector
M 20
3
3
3
3
3
3
1
1
1
R
Part no.
SR 11
2
2
2
P
S
6 022 588
6 022 589
6 022 590
6 012 131
6 012 132
6 012 133
Switching elements: 3 NO contacts /1 NC contact as standard.
O rd e r i n g t a b l e i 11 0
Type
i110i110i110-
Actuator
Hinge
HA
Separate Actuator Key
SA
SA
S a f e t y S w i t ch e s
Switching element
NC
NO
2
1
3
1
2
2
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© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Connector
M 20
3
3
3
Part no.
6 025 072
6 025 073
6 025 074
Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 67
Heavy duty
accessories
A wide range of accessories for all
SICK heavy duty safety switch series.
Use
Heavy duty accessories
To be used in conjunction with variable actuator directions for almost
all applications.
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Actuators for Safety Switches
SICK category 2 safety switches can be operated only with an
actuator which is specifically intended for the interlock in question.
This actuator initiates an exactly defined functional sequence in
the safety switch. This guarantees optimum protection against
unintentional actuation and manipulation.
Part no. 5 306 498
Category 2
The actuator comprises a laminated spring steel core coated
with abrasion-resistant plastic to guarantee maximum reliability
combined with minimum wear.
Two straight actuators and four hinged actuators are available
to meet the needs of an extremely wide variety of applications.
Part no.
5 306 526
Part no. 5 306 497
Part no.
5 306 500
The actuators must be fitted on their mounting surface by means
of a positive connection in accordance with the applicable regulations (e.g. VDI 2854), i.e. they must be welded, riveted or otherwise secured to prevent them from being detached.
The actuator and safety switch must be assembled together for
installation in order to ensure reliable operation.
Standard actuator
Part no.
5 306 499
Actuators must not be used as guides or end stops in conjunction with safety switches. Safety guard bolts must be used if this
task cannot be solved by design measures.
SICK safety guard bolts are available for all safety switches of
the type series i100 and i100 Lock.
Straight actuator iE100-S1
with 4 mm overtravel, door radius min. 1000 mm,
with two safety screws for each actuator
Part no. 5 306 497
Unit 1 pc.
Installation example: Sliding cover
.
.
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Actuators for Safety Switches
Hinged actuator
Category 2
Hinged actuator iE 100-R 1
with 2 safety screws
for each actuator
Part no. 5 306 498
Unit 1 pc.
.
Hinged actuator
Door hung on left
Installation example (top view)
Hinged actuator iE 100-R 2
with 2 safety screws
for each actuator
Part no. 5 306 499
Unit 1 pc.
Door hung on right
Installation example (top view)
Hinged actuator
Hinged actuator iE 100-R 3
with 2 safety screws
for each actuator
Part no. 5 306 500
Unit 1 pc.
Safety flap hung at bottom
Installation example
.
Hinged actuator
with 2 safety screws
for each actuator
Part no. 5 306 526
Unit 1 pc.
Hinged actuator iE 100-R 4
Safety flap hung at top
Installation example
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Accessories
Straight actuator iE110-S1
with 2 safety screws
for each actuator
Part no. 5 311 134
Unit 1 pc.
Series iE110
Bent actuator iE110-F1
with 2 safety screws
for each actuator
Part no. 5 311 135
Unit 1 pc.
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© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
flexibel
Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 71
Accessories
Conne ctors
Connectors
Safety switches are available with plug
connectors for certain applications, e.g.
where fast replacement is important. Alternatively, connectors can be retrofitted by
the user.
SICK offers a range of high quality connectors:
Plastic encapsulated (DIN 43651, 6 and 11 poles)
Te c h n i c a l d a t a
Parameter
Housing material
Number of pins
Nominal voltage (11 + PE)
Enclosure rating acc. to IEC 529
Type of connection
O rd e r i n g t a b l e
Value
plastic
12 (11 + PE)
50 V ~/=
IP 65 (fitted)
crimp contacts 0.5 ... 1.5 mm2
Cable gland/plug for
i 10 , i 10 L o ck , i 10 0 a n d i 10 0 L o ck
Type
SSR 11, cable receptacle
ASR 11, cable receptacle
Device plug
Cable gland M 16
Cable gland M 20
Cable gland PG 13.5
straight
angled
for safety switch
für
Number of pins
11 + PE
11 + PE
11 + PE
11 + PE
Part no.
6 020 757
6 020 758
6 020 759
5 309 163
5 309 164
5 305 811
Lockout bar
Part no. 5 603 534
.
The locking insert can be inserted in the
safety switch instead of the actuator when
the safety guard is in open condition and
can then be secured to prevent removal
by standard commercially available padlocks (max. 3 pcs.).
This guarantees reliable protection for
persons who have to enter potentially
hazardous areas.
.
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Accessories
Conne ctors – Lockout bar
O rd e r i n g t a b l e i E 1 0 0
Type
iE100iE100iE100iE100iE100iE100-
Actuator Type
straight
A c t u a t o r f o r i 10 0 L o ck a n d i 10 0
Radius: door hinged
left side
right side
Lockout
Bar
lower side
Part no.
upper side
S1
R1
R2
R3
R4
S2
5 306 497
5 306 498
5 306 499
5 306 500
5 306 526
5 306 534
Type iE 100-S 2; Part No. 5 306 543
O rd e r i n g t a b l e i E 11 0
Type
iE110iE110-
Actuator Type
straight
S1
A c t u a t o r f o r i 11 0
Part no.
straight, flexibly
F1
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5 311 134
5 311 135
Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 73
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Ultra heavy duty
which interlock solution do you require?
The modular construction of the highend ultra heavy duty series provides numerous solutions for the most varied of
safeguarding systems. The system can
be adapted or expanded at any time.
The following selection guide lists possible requirements and challenges and
helps in your selection of the most suitable solution modules.
Are you looking for a
solution with solenoid
release?
75–82
The machine can only be
started from inside with an
access key.
You will find detailed
information on page
You will find detailed
information on pages
Are you looking for a
solution without
solenoid release?
83–94
You will find detailed
information on pages
80–85
Are you looking for a
solution with access
function?
Access to the machine is
only granted to those with
a key.
You will find detailed
information on page
Do you need a status
indicator visible from
a distance?
You will find detailed
information on page
Are you looking for a
solution with integrated
restart function?
The door can only be opened
or closed deliberately. The
accidental closing of the
door does not trigger a
machine start.
You will find detailed
information on pages
Are you looking for a
solution with enable
function?
89
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© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
89
89
Ultra heavy duty with
s o l e n o i d re l e a s e
Maximum reliability with dualchannel safety switching with and
unique modular construction.
Use
Ultra heavy duty with solenoid release
Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 75
Always necessary when the
access time is less than the
machine stop time.
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Function – det ails – options
Applications
These extremely robust electro-mechanical safety switches provide unique modular solutions for safety applications. They allow
simple selection of the components required for safeguarding
work processes and machines.
LED indicators
All safety switches in this series have an LED status indicator. It
provides a visual check of the current state of the device.
Construction
The safety switches of this series are extremely robust thanks to
their housing made of zinc alloy and stainless steel components.
Their reliability has been tested for more than 1,000,000
switching actions.
Their simple modular construction allows optimal function-oriented use in any applications.
Function
The gate is closed and voltage applied when the machine is in
operation. If access is required, the actuator is simply separated
from the unit by the opening of the gate and the switching contact is forced open via positive mechanical operation. A red LED
indicator lamp lights up at this moment. Despite its simple operating principle this series provides double safety: for the machine
operator and for the machine.
Flexibility
Apart from their modular construction, these safety switches also
offer integrated flexibility for protecting personell and machinery:
Variable approach directions
(4 x 90°)
Variable handle position (only for devices with a handle)
(8 x 45°)
Alignment error tolerance tongue – only for devices with a
tongue (automatic adjustment ± 12 mm)
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Function – det ails – options
Turning the head
Actuator alignment error tolerance
Turning the handle
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Safety Locking Device
Housing:
Connection:
Contacts:
i1002 Lock
Cast housing in zinc alloy with polyester coating
PG 13.5 threaded
4 x NC + 2 x NO
Dimensional drawing
Approvals applied for
Function / LED indicators
When the machine is in operation, the
device securely traps the actuator on the
movable gate: a solenoid operated mechanism holds it firmly in place. In order to
open gates in the protective fence the
machine operator must first switch off the
machine at the control panel. The internal
solenoid is activated only when the
machine has come to a complete stop.
At this moment, a yellow indicator light
signals that the actuator can be released.
After release a red indicator light signals
that access is allowed.
Installation
The machine’s protective fence must be
drilled for mounting on the front or back.
The main unit is normally mounted on a
static part of the fence with the actuator
on the entrance gates. The actuator can
be mounted with any orientation on a sliding or hinged gate. The safety locking
device must not be used as an end stop.
Changing the approach direction
Control voltages
Solenoid Plunger
M 4 x 30
drop
screws
24 V AC/DC ± 10 %
110 V AC/DC ± 10 %
230 V AC/DC ± 10 %
Manual unlocking mechanism
Head Plunger
opening
Earthing Point
Unscrew the cover.
Loosen and remove both M 4 x 30 screws.
Hold plunger down with a small screwdriver (see arrow in the above diagram). Remove
head.
Re-insert screws; ensure that the head is correctly fixed. Replace cover.
Please note
The complete safety locking device must be replaced in the event of damage or wear.
78
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Safety locking devices with manual solenoid release can be operated by means
of a manual mechanism in the event of,
for example, a power failure. The solenoid
release can only be freed using the
encoded key supplied. Unlocking can also
be used in conjunction with the lockout
bar.
Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 79
Safety Locking Device
i1002 Lock
Te c h n i c a l d a t a
Parameter
Housing material
Coating
Colour
Enclosure rating
Actuator turning moment
Retaining power, locked
Max. approach speed
Mechanical service life
Max. frequency of use
Ambient temperature
Max. cross-section of cables
Connection
Switching conformity
Switching contacts
Contact type
Switching current
Switching voltage
Insulating gap
Contact material
Utilisation category
Operating voltages
Insulation resistance
Rated impulse voltage
Coil magnet nominal power
Coil current at 24 V DC nominal voltage
Coil magnet
– operating voltages
– voltage tolerance
Accessories available
Value
zinc alloy and stainless steel
powder-coated polyester
black /yellow and stainless steel
IP 67 (DIN 40 0050)
5
2 500
20
> 106 switching cycles
7 200
– 5 to + 40
2.5
vibration-proof snap-on binding block
DIN VDE 0660 part 206 & IEC 947-5-1
4 x NC + 2 x NO
captive opening
max. 10 A
max. 230 V AC
2 x 2 mm per switching contact
90 % silver and 10 % nickel
AC 15 or DC 13
24 V AC/DC, 110 V AC or 230 V AC
20
2 500
12
500
Unit
Nm
N
m/min
/h
°C
mm2
MΩ
V AC
W
mA
24 V AC/DC, 110 V AC or 230 V AC
85 % to 110 % of nominal value
Circuit diagram
Adapter for safety key
Adapter for access key
Option housing
Blocking clip
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Safety Locking Device
Housing:
Connection:
Contacts:
i1001 Lock
Cast housing in zinc alloy with polyester coating
PG 13.5 threaded
2 x NC + 1 x NO
Dimensional drawing
Function / LED indicators
When the machine is in operation, the
device securely traps the handle and the
gate is firmly locked: a solenoid operated
mechanism prevents the handle from being pulled out. In order to open gates in
the protective fence the machine operator
must first switch off the machine at the
control panel. The internal solenoid is activated only when the machine has come
to a complete stop. At this moment, a yellow indicator light signals that the handle
can be removed. After removal a red indicator light signals that access is allowed.
Installation
The machine’s protective fence must be
drilled for mounting on the front or back.
The main unit is normally mounted on a
static part of the fence with the actuator
on the entrance gates. The actuator can
be mounted with any orientation on a sliding or hinged gate. The safety locking
device must not be used as an end stop.
Changing the approach direction
Control voltages
Solenoid Plunger
24 V AC/DC ± 10 %
110 V AC/DC ± 10 %
230 V AC/DC ± 10 %
M 4 x 30
drop
screws
Mechanical unlocking mechanism
Head Plunger
opening
Earthing Point
Unscrew the cover.
Loosen and remove both M 4 x 30 screws.
Hold plunger down with thin screwdriver (see arrow in the above diagram). Remove
head.
Re-insert screws; ensure that the head is correctly fixed. Replace cover.
Please note
The complete safety locking device must be replaced in the event of damage or wear.
80
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Safety locking devices with mechanical
solenoid release can be released by
means of the unlocking mechanism in the
event of, for example, a power failure. The
solenoid release can only be freed using
the encoded key supplied. Unlocking can
also be used in conjunction with the lockout bar.
Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 81
Safety Locking Device
i1001 Lock
Te c h n i c a l d a t a
Parameter
Housing material
Coating
Colour
Enclosure rating
Actuator turning moment
Retaining power, locked
Max. approach speed
Mechanical service life
Max. frequency of use
Ambient temperature
Max. cross-section of cables
Connection
Switching conformity
Switching contacts
Contact type
Switching current
Switching voltage
Insulating gap
Contact material
Utilisation category
Operating voltages
Insulation resistance
Rated impulse voltage
Coil magnet nominal power
Coil current at 24 V DC nominal voltage
Coil magnet duty cycle
Coil magnet
– operating voltages
– voltage tolerance
Accessories available
Value
zinc alloy and stainless steel
powder-coated polyester
black / yellow and stainless steel
IP 67 (DIN 40 0050)
5
2 500
20
> 106 switching cycles
7 200
– 5 to + 40
2.5
vibration-proof snap-on binding block
DIN VDE 0660 part 206 & IEC 947-5-1
4 x NC + 2 x NO
captive opening
max. 10 A
max. 230 V AC
2 x 2 mm per switching contact
90 % silver and 10 % nickel
AC 15 or DC 13
24 V AC/DC, 110 V AC or 230 V AC
20
2 500
12
500
100
Unit
Nm
N
m/min
/h
°C
mm2
MΩ
V AC
W
mA
%
24 V AC/DC, 110 V AC or 230 V AC
85 % to 110 % of nominal value
Circuit diagram
Adapter for safety key
Adapter for lockout bar
Optional housings
Bridging key switch
Blocking clip
Emergency-off switch
81
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Safety Locking Device
i1001 Lock/i1002 Lock
O rd e r i n g t a b l e
Type
i1001 Lock
S a f e t y L o ck i n g D e v i c e
Solenoid voltage
24 V AC/DC
24
Part no.
110 V AC
230 V AC
110
230
i1002 Lock
24
110
230
Ordering note: actuator supplied with delivery
82
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
6 021 013
6 021 014
6 021 015
6 021 007
6 021 008
6 021 009
Ultra heavy duty
without solenoid
release
This highly robust and reliable safety switch offers a dual-channel
safety circuit and unique modular
construction.
Use
This series provides optimal protection for applications whose
access time is greater than the
plant or machine stop time.
Ultra heavy duty without solenoid release
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Safety Switches
Housing:
Connection:
Contacts:
i1001
Cast housing in zinc alloy with polyester coating
PG 13.5 threaded
2 x NC + 1 x NO
Ex-Zone 2
Dimensional drawing
Please note
The complete safety switch must be
replaced in the event of damage or wear.
Installation
The machine’s protective fence must be
drilled for mounting on the front or back.
The main unit is normally mounted on a
static part of the fence with the actuator
on the entrance gates. The actuator can
be mounted with any orientation on a sliding or hinged gate. The safety switch must
not be used as an end stop.
Control voltages
24 V AC/DC ± 10 %
110 V AC/DC ± 10 %
230 V AC/DC ± 10 %
Accessories available
Adapter for safety key
Adapter for access key
Lockout bar
Changing the approach direction
Unscrew the cover.
Loosen and remove both M 4 x 30 screws and remove head from the side.
Reposition head and base. A pre-tensioned piston prevents the head from moving all
the way back. Use a small screwdriver to release the piston tension so that the head
can be returned to its original depth.
Replace cover screws. Ensure that the head is correctly fixed before replacing the
cover.
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Safety Switches
i1001
Te c h n i c a l d a t a
Parameter
Housing material
Coating
Colour
Enclosure rating
Actuator turning moment
Retaining power, locked
Max. approach speed
Mechanical service life
Max. frequency of use
Ambient temperature
Max. cross-section of cables
Connection
Switching conformity
Switching contacts
Contact type
Switching current
Switching voltage
Insulating gap
Contact material
Utilisation category
Operating voltages
Insulation resistance
Rated impulse voltage
Value
zinc alloy and stainless steel
powder-coated polyester
black /yellow and stainless steel
IP 67 (DIN 40 0050)
5
2 500
20
>106 switching cycles
7 200
– 5 to + 40
2.5
vibration-proof snap-on binding block
DIN VDE 0660 part 206 & IEC 947-5-1
2 x NC + 1 x NO
captive opening
max. 10 A
max. 230 V AC
2 x 2 mm per switching contact
90 % silver and 10 % nickel
AC 15 or DC 13
24 V AC/DC, 110 V AC or 230 V AC
20
2 500
Unit
Nm
N
m/min
/h
°C
mm2
MΩ
V AC
Circuit diagram
85
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Safety Switches
Housing:
Connection:
Contacts:
i1002
Cast housing in zinc alloy with polyester coating
PG 13.5 threaded
2 x NC + 1 x NO
Ex-Zone 2
Dimensional drawing
Please note
The complete safety switch must be
replaced in the event of damage or wear.
Installation
The machine’s protective fence must be
drilled for mounting on the front or back.
The main unit is normally mounted on a
static part of the fence with the actuator
on the entrance gates. The actuator can
be mounted with any orientation on a sliding or hinged gate. The safety switch must
not be used as an end stop.
Control voltages
24 V AC/DC ± 10 %
110 V AC/DC ± 10 %
230 V AC/DC ± 10 %
Accessories available
Adapter for safety key
Adapter for access key
Lockout bar
Changing the approach direction
Unscrew the cover.
Loosen and remove both M 4 x 30 screws and remove head from the side.
Reposition head. A pre-tensioned piston prevents the head from moving all the way
back. Use a small screwdriver to release the piston tension so that the head can be
returned to its original depth.
Replace cover screws. Ensure that the head is correctly fixed before replacing the
cover.
86
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Safety Switches
i1002
Te c h n i c a l d a t a
Parameter
Housing material
Coating
Colour
Enclosure rating
Actuator turning moment
Retaining power, locked
Max. approach speed
Mechanical service life
Max. frequency of use
Ambient temperature
Max. cross-section of cables
Connection
Switching conformity
Switching contacts
Contact type
Switching current
Switching voltage
Insulating gap
Contact material
Utilisation category
Operating voltages
Insulation resistance
Rated impulse voltage
Value
zinc alloy and stainless steel
powder-coated polyester
black /yellow and stainless steel
IP 67 (DIN 40 0050)
5
2 500
20
>106 switching cycles
7 200
– 5 to + 40
2.5
vibration-proof snap-on binding block
DIN VDE 0660 part 206 & IEC 947-5-1
2 x NC + 1 x NO
captive opening
max. 10 A
max. 230 V AC
2 x 2 mm per switching contact
90 % silver and 10 % nickel
AC 15 or DC 13
24 V AC/DC, 110 V AC or 230 V AC
20
2 500
Unit
Nm
N
m/min
/h
°C
mm2
MΩ
V AC
Circuit diagram
87
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Safety Switches
i1001/i1002
O rd e r i n g t a b l e
Type
i1001
S a f e t y s w i t ch e s
Voltage
24 V AC/DC
24
Part no.
110 V AC
230 V AC
110
230
i1002
24
110
230
Ordering note: actuator supplied with delivery
88
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
6 021 016
6 021 017
6 021 018
6 021 010
6 021 011
6 021 012
Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 89
Modular options
Each basic unit can be supplemented by various optional housings: key module, emergency-off
module, and control lamp module.
Use
Modular options
Simple adaptation of the basic
system to individual applications.
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Options
Safety key adapter
Housings
Housings are available in three different designs. Each of them
can accept the solenoid controlled elements: the key switch,
press button and indicator lamp.
They offer great flexibility, e.g. for the stop functions. They are
simply mounted below the particular unit.
Located between the unit’s head and its housing. The key is
securely held in the unit and the gate is kept closed. Access is
only possible when the key has been turned and removed.
For use with
i1001
i1001 Lock
i1002
i1002 Lock
Key switch iE 1000 ES
contact set 2 x NO + 2 x NC for connections into the machine’s
stop circuit.
Push button iE 1000 ER
provides signals that are connected into the machine’s control
system (e.g. stop command).
Indicator lamp iE 1000 ML
improves the visibility of the LED indicator lights
For use with i1001 / i1001 Lock / i1002 /i1002 Lock
Access key adapter
Lockout bars
Lockout bar
for actuator
The adapter is identical to the above-mentioned safety key –
except for its function. The gate is locked if there is no key in
the adapter; the gate can only be opened when a key has been
inserted and moved (access permission).
For use with
i1001
i1001 Lock
i1002
i1002 Lock
Lockout bar
for actuator handle
As soon as they have been attached to the head and fixed into
their operating position, gates can no longer be closed and therefore no machine start is possible without deliberate actuation.
For use with
90
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
i1001
i1001 Lock
i1002
i1002 Lock
Kat_Sicherheit_en 27.08.2002 14:04 Uhr Seite 91
Options
Emergency-stop / Restart button
Accessories
Ordering table
Type
Part no.
iE 1002
S3
Lockout bar
R1
Lockout bar
3 mm/1/40
Inbus safety screws
5 308 317
Key for emergency unlocking i1001
Actuator
iE 1002
iE 1001
Accessories
S2
R1
5 308 312
5 308 313
5 308 320
5 308 315
5 308 316
Actuator iE 1002 S 2
Actuator iE 1001 R 1
Lockout bars iE 1002 S 3
Lockout bars iE 1002 R 1
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Ordering table
Type
iE 1000
Coding
1
2
SK 1
SK 2
Safety key adapters
Part no.
3
4
5
SK 3
SK 4
SK 5
Ordering table
Type
iE 1000
Coding
1
2
ES 1
ES 2
Enabling unit
Part no.
3
4
5
ES 3
ES 4
ES 5
Ordering table
Type
Key
Coding
1
2
SK 1
SK 2
Key
3
4
5
SK 4
SK 5
Ordering table
iE 1000
Coding
1
2
AK 1
AK 2
Part no.
3
4
5
AK 4
AK 5
Ordering table
Key
Coding
1
2
AK 1
AK 2
Part no.
3
4
5
AK 4
AK 5
5 308 686
5 308 687
5 308 688
5 308 689
5 308 690
Emergency-stop/Restart unit
Type
iE 1000
5 308 302
5 308 303
5 308 304
5 308 305
5 308 306
Key
AK 3
Ordering table
5 308 307
5 308 308
5 308 309
5 308 310
5 308 311
Access key adapters
AK 3
Type
6 021 019
6 021 020
6 021 021
6 021 022
6 021 023
Part no.
SK 3
Type
5 308 297
5 308 298
5 308 299
5 308 300
5 308 301
Part no.
ER
6 021 024
Ordering note: key supplied with delivery
92
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Ordering table
Status/indicator light unit
Type
iE 1000
Part no.
ML
6 021 025
Ordering note: key supplied with delivery
Head unit 1002
Head unit 1001
2
6
3
7
1
5
4
Access key adapter AK or
8
Safety key adapter SK
Basic unit Lock or Basic unit Standard
1
Basic unit Lock + Head unit 1002
2
Basic unit Lock + AK or SK + Head unit 1002
3
Basic unit Lock + AK or SK + Head unit 1001
4
Basic unit Lock + Head unit 1001
5
Basic unit Standard + Head unit 1002
6
Basic unit Standard + AK or SK + Head unit 1002
7
Basic unit Standard + AK or SK + Head unit 1001
8
Basic unit Standard + Head unit 1001
93
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94
Non-contact Safety
Sensors
Non-contact safety sensors with
an electronically coded actuator
for various applications.
Use
The ideal interlock for large and
heavy doors (also those with imprecise alignment), for increased
demands regarding hygiene as
well as when extreme vibrations
are present. Conforms to control
category 3 to EN 954-1.
Non - cont act Safety Sensors
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Non - cont act Safety Sensor
R E300
TÜV
Advantages
Integrated safety switch
Broad physical tolerances possible for door guidance
Integrated restart inhibit
Compact design of the actuator and sensing head
Two redundant built in relay outputs having internally
monitored contacts
➡ Control category 3 in accordance with EN 954
Flush installation in door architrave
Description of the system
The coded electronic safety sensor – RE300 – supplied by SICK
comprises three components:
The sensor is attached to the static part of the safety device,
and is connected to the analyser by way of a four-core cable.
Magnetic coded actuator
Sensor
Evaluator unit
The actuator is fixed to the door of the safety device. Upon closing the safety device the actuator is guided towards the sensor.
On reaching the activation zone the sensor is activated. As a result, the safety contacts in the evaluator unit close.
Operating voltage either 24 V DC, 110 V AC or 230 V AC.
Operating mode “without contactor monitoring and reset”
requires a jumper to be inserted between X1 and X2.
The non-contact safety sensor works with a magnetic coded actuator. The great advantage of the system lies in the proximity
method of operation of the actuator and sensor, which provide
the user with maintenance free operation of over many years.
96
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Non - cont act Safety Sensor
R E300
Connection and block diagram
24 V AC/DC
blu
yel
2 1 A1 +
31 13 23
3 4 A2 --- X1 X2 32 14 24
grn
red
KA
KB
KA
KB
KA
KB
GND
PE
110 V AC or
230 V AC
blu
yel
2 1 A1 +
31 13 23
3 4 A2 --- X1 X2 32 14 24
grn
red
KA
KB
N
PE
Typical operating range RE300
Sensor – actuator distance (mm)
15
OFF
5
ON
– 15
–4
0 mm
4
15
Misalignment tolerance on the sides (mm)
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Non - cont act Safety Sensor
R E300
Evaluation unit
Dimensional drawing
Te c h n i c a l d a t a
Parameter
Control category to EN 954-1
PDF-class to EN 60947-5-3
Housing material
Environmental protection to IEC 60529
Weight
Protection class
Ambient temperature (operation)
Outputs
Sensor connection
Sensor cable resistance max.
Mechanical service life
Utilization category
Switching voltage/switching current max.
Max. switching capacity
Min. switching current/switching voltage
Output fuse
Operating voltage ± 10 %
Max. consumed power
Rated impulse withstand voltage Uimp
Max. wire cross-section
Release delay max.
Shock-proof to IEC 68-2-27
Vibration-proof to IEC 68-2-6
Indicators
1)
2)
Value
3
PDF-S
Polycarbonate
IP 20
590
To EN 50178, VDE 0110
– 10 ... + 55
2 safety outputs (NO contacts) 13/14 and 23/24,
1 auxiliary output (NC contact) 31/32
Terminals 1/2/3/4
75
1 x 106 switching cycles
AC-15, DC-13
AC: 4 A/250 V AC
DC: 2 A/30 V DC
1000 VA for COS φ = 1
10 mA/10 V AC/DC
5 A max. quick-acting for AC, 3 A max. quick-acting for DC
+/–: 24 V AC/DC PELV1)
A1/A2: 110 V AC or 230 V AC2)
< 4 VA (AC)
4
1 x 2.5
25
30 g/11 ms
10 ... 55 Hz, amplitude 0.35 mm ± 15 %)
LED OUTPUT, green = safety contacts 13/14 and 23/24 closed,
LED POWER, green = Power ON
PELV-earthed protective extra-low voltage. When using terminals +/–,
terminal –/PE must be connected to the protective earth
conductor PE
When using the 110 V AC or 230 V AC operating voltage, protective
earth conductor PE must be connected to the –/PE terminal
98
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Unit
g
°C
Ω
kV
mm2
ms
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Non - cont act Safety Sensor
R E300
Sensor and actuator
Dimensional drawing
Sensor
Actuator
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 60529
Weight
Temperature
Shock-proof to IEC 68-2-27
Vibration-proof to IEC 68-2-6
Operating range
Min. approach speed
Max. cable length
Value
Moulded ABS
IP 67
100 g each
Operation: – 10 ... + 55
Storage: – 25 ... + 70
30 g/11 ms
10 ... 55 Hz (amplitude 0.35 mm ± 15 %)
Son 5 mm, Soff 15 mm
> 17
Overall resistance < 75 Ω
Unit
°C
°C
mm/s
Safety sensor mounted on hinged door (example)
99
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Non - cont act Safety Sensor
T4000
Explosive area zone 2
Advantages
Unambiguous encoded actuator (unique)
➡ proof against manipulation
Integrated safety switching device
Two redundant relay outputs with internal monitored contacts
➡ Control Category 3 to EN 954
Error diagnosis possible
Self-testing without opening of the protective system
Large mechanical tolerances for door alignment possible
Small actuator and reading head construction shape
Flush mounting in the door panelling
Can be mounted behind metal
System description
The non-contact safety sensor T4000 consists of three components:
Coded actuator
Read head
Evaluation unit
Each actuator supplied features a unique electronic code and is
thus unique to the system used. The code of an actuator cannot
be reprogrammed.
The read head is mounted on the stationary part of the safety
guard and is connected to the evaluation unit via a two-core,
screened cable.
The actuator mounted on the safety guard is moved towards
the read head when the door is closed. When the switch-on
distance is reached, power is supplied to the actuator via the
inductive read head and the data can be transferred.
The bit pattern read in is compared with the stored code in the
evaluation unit. If the data corresponds, the relay outputs are
enabled and the Enable output (semiconductor output) is also
set to HIGH.
The evaluation unit reverts to safe state regardless of the
particular error owing to dynamic sensing of the actuator and
the redundant-diversity design of the safety circuitry.
When the safety guard is open, the normally open contacts
deactivate the safety circuit and the Enable output (OUT) is
switched to Low. The status of the normally open contacts is
monitored internally via positive-action normally closed contacts.
In the event of an internal error in the evaluation unit, the safety
circuit is also deactivated and the diagnostic output (ERROR)
is set to High. The ERROR LED then lights red.
Note: The dwell time of an actuator inside and outside the
operating range must be at least 0.5 seconds. Otherwise,
the evaluation unit reverts to Error status and the ERROR LED
lights red. The evaluation unit can be reset to Operating state
by disconnecting the power supply.
Function test (self-test)
On electromechanical safety switches or solenoid interlocks, the
function test can be conducted by cyclically opening the safety
guard.
As of control category 2, a function test of the entire safety
system must be conducted in accordance with EN 60204-1:
1997 (Chapter 9.4.2.4) on start-up or at stipulated intervals.
It is not necessary to test the internal function of the non-contact safety sensor T 4000 since the device monitors itself in real
time:
Welding of an output contact is detected by the unit at the latest
the next time the safety guard opens. A cross-fault of the relay
output lead is not detected by the unit. Moreover, the entire
safety circuit can be tested without opening the safety guard.
Opening of the safety guard is simulated for this purpose by
applying 24 V DC to the test input.
The relay outputs are deactivated, thus allowing testing of the
entire safety circuit. The diagnostic output ERR is also set to
HIGH by the evaluation unit as a monitoring function.
When the test input is reset, the evaluation unit resets the
diagnostic output ERR back to LOW, the red LED goes out
and the relay outputs are activated again.
This allows a self-test to be conducted on the safety system
without opening the safety guard.
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Non - cont act Safety Sensor
T4000
Connection and block diagram
T4000 evaluation unit
Operating voltage
+ 24 V 0 V
DC
Screen terminal
Brown
White
H2
H1
24 V
Sensing
head
SH
0V
DDSP
TST input not connected:
Operation without testing
TST
Transponder
CPU-B
CPU-A
KA
Coded
actuator
DDSP:
Double Dynamic Safety Path
with error monitoring of the actuator,
of the sensing head and of the cable to
the sensing head
KB
10 kΩ
10 kΩ
OUT
ERR
TST
OUT
ERR
GND
H1/ H 2
13 / 14
23 / 24
GND
13
14
23
24
Test input (STATE)
Enable output
Diagnostic output (ERROR)
0V
Connection, sensing head
Connection, NO contact 1, Enable safety relay
Connection, NO contact 2, Enable safety relay
Typical operating range T4000
Note safe switch-off
distance sar = 23 mm;
relay outputs are safely
deactivated.
Output state
m
Actuator
Hysteresis
ON
s
Sensing head
Distance s [mm]
OFF
OFF
8
Switch-off
distance
6
Hysteresis
4
Switch-on
distance Sao
Sao
Distance s
2
ON
-8
-6
-4
0
2
-2
Centre offset m [mm]
4
6
8
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Non - cont act Safety Sensor
T4000
Evaluation unit
Dimensional drawing
22.5
H1
H2
114
SH
24V 0V
99
STATE
OUT
ERROR
TST OUT ERR GND
13
Te c h n i c a l d a t a
14
23
24
matching standard
top-hat rail 35 mm
Parameter
Value
typical
Plastic PA 6.6
114.5 x 99 x 22.5
0.25
–
–
IP 20
35 mm top-hat rail to DIN 46277
Enclosurerating III, degree of contamination 2
1 read head per evaluation unit
plug-in screw-type terminals
–
min.
Housing material
Dimensions
Mass
Ambient temperature at Uop = 24 V DC
Storage temperature
Enclosure
Mounting
Enclosure rating
Number of read heads
Type of connection
Connection terminals
Operating voltage Uop
(stabilised, residual ripple < 5 %)
Electrical consumption (with relay energized)
Safety outputs
Switching voltage (relay outputs)1)
Switching current 0.1 ... 60 V
Switching current 10 ... 24 V
Output fusing
Utilisation category to EN 60 947-5-2
Control category to EN 954
Classification to IEC/EN 60 947-5-3
Rated insulation voltage
Rated impulse withstand voltage Uimp
Resistance to vibration
Mechanical switching operations (relays)
Operating delay as of state change
Risk period2)
Time delay before availability3)
Dwell time
Alarm outputs (diagnostic ERR, Enable OUT,
semiconductor output, p-switching)3)
– Output voltage
– Load rating
Test input LOW
HIGH
EMC protection requirements
LED indicators
0
– 25
0.14
21
1
1
–
–
–
–
0.5
24
150
2 safety relays, each with one NO contact
0.8 x Uop
–
0
15
STATE
(see System status table; Page 85)
2)
102
+ 55
+ 70
mm
kg
°C
°C
2.5
mm2
27
V DC
mA
–
300
–
4000
6.3 A quick-action
AC-12 60 V 300 mA 50 Hz/DC-12 60 V 300 mA
AC-140 30 V 2 A 50 Hz/DC-13 30 V 4 A
3
PDF-M
–
63
–
1.5
in accordance with EN 60 947-5-2
10 x 106
–
180
–
180
3
–
–
OUT
ERROR
1)
Unit
max.
If switching currents of > 300 mA are used then low current switching, < 10 mA, will be impaired due to possible damage to the gold
plated contacts.
The risk period is the maximum switch-off delay after occurrence of
an error. Welding of one of the relay outputs is only detected after
Uop
–
–
20
–
2
–
Uop
to EC 60947-5-3
LED green
Normal mode
blinking:
Teach-in operation
LED yellow
Actuator detected
LED red:
Test input activated
Internal circuitry error
Invalid Teach-in operation
3)
4)
mA
mA
V
kV
ms
ms
s
s
V DC
mA
V DC
V DC
opening of the safety guard.
When the operating voltage is switched on, the relay outputs are
electrically isolated during the initialisation period, and the door
alarm contact set to LOW.
Non-short-circuit-proof
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Non - cont act Safety Sensor
T4000
Sensing head
Dimensional drawing
42
12
25
T4000-DNA..
Ø8
Ø 4.5
"l"
Made in Germany
32 ± 0.1
4.6
Two safety screws included
in scope of delivery.
Te c h n i c a l d a t a
Parameter
Value
min.
typical
max.
Fortron, glass-reinforced thermoplastic material; fully encapsulated
42 x 25 x 12
0.3
– 25
–
+ 70
IP 67
any
inductive
2
Unit
Housing material
Dimensions
mm
Mass (including 10 m cable)
kg
Ambient temperature
°C
Enclosure
Installation position
Mode of operation
Dynamic data transfer to evaluation unit
kbit/s
Operating range
in the case of centre offset m = 0
5
6
–
– Switch-on distance Sao1)
– Differential hysteresis
–
2
–
mm
– Safe switch-off distance Sar
in the case of centre offset m = 0 mm1)
–
–
23
Power supply
via evaluation unit
Connection
permanently sealed connection cable, with wire end ferrules or plug
Line length
See Ordering / Type table; other lengths on request
1) These values apply to non-flush and flush installation of the read head and of the actuator in aluminium. Moreover, these values
apply only in conjunction with actuator T4000-KBA
Notes on installation
The connection cable of the read head may not be
lengthened.
The alarm outputs and connection terminals for read head
are non-short-circuit-proof
The safety guard must be designed so that there is no risk
up to a distance Sar (safe switch-off distance).
Note: The relay outputs are safely deactivated, even in the
case of an internal component failure, at the safe switch-off
distance Sar = 23 mm.
Actuator and read head must be mounted so that:
– the distance between the front faces is equal or less than
the switch-on distance 0.8 x Sao (see Technical data) with
the safety guard closed;
– they are not used as a mechanical stop;
– there must be a gap between the edge and the metal
housing when flush-mounted;
– they are connected keyed to the safety guard; e.g. by using
the enclosed safety screws;
103
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Non - cont act Safety Sensor
T4000
Actuator
Dimensional drawing
Two safety screws M 4 x 14
included in scope of delivery
Te c h n i c a l d a t a
Parameter
Housing material
Dimensions
Mass
Ambient temperature
Enclosure
Installation position
Power supply
Dwell time within the switch-off distance
Value
min.
typical
max.
Fortron, glass-reinforced thermoplastic material, fully encapsulated
40 x 25 x 12
0.01
– 25
–
+ 70
IP 67
sensing face opposite read head
inductive via read head
0.5
–
–
Unit
mm
kg
°C
s
Notes on installation
The safety guard must be designed so that there is no risk up
to the distance Sar (safe switch-off distance).
Actuator and read head must be mounted so that:
– the distance between the front faces is equal or less than
the switch-on distance 0.8 x Sao (see Technical data) with
the safety guard closed;
– they are not used as a mechanical stop;
– there must be a gap between the edge and the metal
housing when flush-mounted;
– they are connected keyed to the safety guard; e.g. by using
the enclosed safety screws;
104
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Non - cont act Safety Sensor
T4000
Teach-in function for actuator
Before the system forms a functional unit, the actuator must be
assigned to the evaluation unit with the Teach-in function.
During the Teach-in operation, the relay outputs and the alarm
output are set to LOW, i.e. the system is in safe state.
4. The operating voltage on the evaluation unit must then be disconnected for min. 10 seconds in order to activate the new
taught code of the actuator in the evaluation unit.
Teach-in function for first actuator (condition as delivered):
Note:
It is not possible to teach the same actuator on the same
evaluation unit more than once.
The number of valid teach-in operations on one evaluation
unit is limited to max. 8.
The evaluation unit can be operated only with the last
actuator taught.
A Teach-in operation is invalid if:
➡ the Teach-in operation is aborted before the green LED
go out
➡ The supply voltage has been disconnected during the
Teach-in operation
1. Apply the operating voltage to the evaluation unit
➡ Fast blinking (approx. 4 Hz) of the green LED
2. Move the actuator towards the read head
(note distance < Sao)
➡ Teach-in operation commences; slow blinking (approx.
1 Hz) of the green LED
3. Teach-in operation complete (after 60 seconds)
➡ Green LED goes out
4. The operating voltage applied to the evaluation unit must then
be disconnected for min. 10 seconds in order to activate the
taught code of the actuator in the evaluation unit.
Teach-in function for a new actuator:
Important:
1. Apply the operating voltage to the evaluation unit
2. Move the new actuator towards the read head
(note distance < Sao)
➡ Teach-in operation commences; green LED blinks (approx.
1 Hz)
3. Teach-in operation complete (after 60 seconds)
➡ Green LED goes out, new code is saved and old code is
deactivated.
The system automatically reverts to Teach-in mode even after
the 8th Teach-in operation or if an “old” actuator is moved
against the read head. In both cases, a Teach-in operation
lasting 60 seconds is initiated but the last actuator code
remains active in memory (see Status table); no new code is
taught.
System status table
PLC
Output
TST
OUT
(alarm signal)
ERR
STATE (green)
OUT (yellow)
ERR (red)
closed
open
on
off
N
N
1
0
0
0
1
1
1
0
0
0
Normal operation, door closed
Normal operation, door open
open
off
N
0
0
blinks
constantly
at 4 Hz
0
0
Initial commissioning on delivery
Ready for first Teach-In operation
closed
off
N
0
0
blinks 60 sec
at
approx. 1 Hz
0
0
Teach-In operation
closed
off
N
0
0
closed
0
0
Positive acknowledgement for successful
Teach-In operation. The unit must be
switched back on again for normal operation
X
off
X
0
0
3
0
0
X
off
X
0
0
2
0
0
X
off
X
0
0
1
0
0
X
off
X
0
0
0
0
0
Indication after 1st to 5th Teach-In operation
Indication of the number of Teach-In operations
still allowed after the 6th Teach-In operation
Indication of the number of Teach-In operations
still allowed after the 7th Teach-In operation
Device is now unable to perform a further
Teach-In operation
Error indication
X
X
off
off
N
N
0
0
1
1
0
0
0
0
1
1
Device-internal component failure
Actuator in response range less than 0.5 sec
Operating error
closed
closed
off
off
N
N
0
0
1
1
1
2
0
0
1
1
closed
off
N
0
1
Brief blink
sequences
repeated
after 1 sec
3
0
1
Illegal 9th Teach-In operation
Illegal Teach-In operation of an old actuator
Negative acknowledgement for Teach-In operation.
Actuator
open
off
1
0
1
1
0
1
closed
off
1
0
1
1
0
1
Normal operation
Commissioning
Status display
Test mode
N
0
1
X
=
=
=
=
0 Volt or not connected
0 Volt
24 Volt
0 or 24 Volt
resp. door open or closed
One-Off
blink
sequence
after
power-off
Number of
blink pulses
Relays KA, KB
(Safety circuit)
LED Indicator
Actuator /
Door position
Input
Status
External device test for “OPEN” and
function ERR output with door closed
1 = on
0 = off
105
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Non - cont act Safety Sensor
T4000 Compact
Advantages
Uniquely encoded actuator
➡ secure against manipulation
Integrated safety switching unit
Two redundant solide state outputs (safety outputs),
internally monitored
➡ control category 3 according to EN 954
Large mechanical tolerances for door alignment possible
Small actuator
Flush mounting in the door panelling
Compact unit, consisting of read head with evaluation unit,
reducing the risk of connection errors during installation
Error diagnosis possible
Construction and function
Construction
The non contact safety interlock T4000 Compact consists of two
parts:
Coded actuator
Read head with evaluation unit (Safety electronics)
Each delivered actuator is electronically coded (programme cannot be changed) and therefore unique to the installed system.
Function
The safety interlock with integrated evaluation unit and read
head is attached to the fixed part of the safety guard.
When the actuator is moved nearer to the read head than the
switch-on distance, power is supplied to the actuator via the inductive read head and the data can be transferred. The read-in
pattern is compared with the code stored in the evaluation unit.
If the two sets of data match,
the safety outputs (LA, LB) will be released and
the door signal output (OUT) is set to HIGH.
When the safety guard is opened, the safety outputs disconnect
the safety circuit and the door signal output (OUT) is switched to
LOW. The status of the safety outputs is monitored internally by
means of two microprocessors.
If an internal error occurs in the evaluation unit, the safety circuit
is disconnected and the red OUT/ERROR LED lights up.
Change actuator entry direction
Evaluation unit
The sensing face of the read head can be set to 5 different positions. It is identified by the SICK logo. The centre of the circle
also corresponds to the centre of the read head.
Read head
1. Remove the clamping unit by unscrewing the screws (1) from
the read head.
2. Pull the read head from the dovetail slot of the housing and tilt
by 90° (arrow A). Move the sensing face of the read head to
the desired position by rotating in the direction indicated by
arrow B.
3. Reassamble the read head by performing the above steps in
the reverse order.
Sensing face
A
B
1
Clamping unit
106
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Non - cont act Safety Sensor
T4000 Compact
Connection and block diagram
Actuator
Safety Guard
closed
(actuator identified)
open
(actuator out of
operating range)
Actuator
Read head
Read head
Read head with
evaluation unit
T 4000-2 DNAC
Shield spring
The shield of the connecting
cable is internally connected to
the shield spring of the device
Connection
M 12x1
8-pin,
shielded
Safety PLC
with static/dynamic signals
Test clock 1
Clocked output
Safety input
Test clock 2
Clocked output
Safety input
Input
Door contact
Safety Outputs
Typical operating range T4000 Compact
Safe switch-off distance
sar = 40 mm must be
observed, relay outputs
are safely deactivated.
Switch-on
distance Sao
Actuator and sensing head must be mounted in such a
way that a minimum distance of 3 mm is observed if
the actuator moves laterally.
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107
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Non - cont act Safety Sensor
T4000 Compact
D e t e c t o r w i t h re l a y c o n t ro l u n i t
Dimensional drawing
sensing face
(SICK logo)
40
40
40
OUT/
ER RO
45
STATE
7.3
118
60
5.3
M 12
30
11
15
Te c h n i c a l d a t a
Parameter
Value
typical
max.
Plasitc PBT V0 GF20
118 x 40 x 40
0.4
0
–
+55
– 25
–
+70
IP 67, protection class II, degree of contamination 2
optional
M 12 plug, 8-pin, shielded 1)
Unit
min.
Housing material
Dimensions
Weight
Ambient temperature at UB = 24 V DC
Storage temperature
Enclosure
Installation position
Type of connection
Operating voltage UB (reverse voltage proof,
stabilised, residual ripple < 5 %)
Current consumption
Operating voltage for load U(+LA) / U(+LB)
Safety outputs LA and LB
Output voltage U(LA) / U(LB) 2)
HIGH
HIGH
LOW U(LA) / U(LB)
Switching current
External fusing U (+LA) / U (+LB)
Utilisation category to EN 60 947-5-2
Classification to IEC/EN 60 947-5-3
Door signal output OUT
Output voltage
Load rating
Control category according EN 954
Rated insulation voltage Ui
Rated impulse withstand voltage Uimp
Resistance to vibration
Operating delay as of state change
Risk period 3)
Start-up delay time 4)
Dwell time 5)
EMC protection requirements
LED indicators
(see System status table; Page 90)
1)
2)
3)
18
18
24
80
–
solide state outputs, p-switching,
short circuit proof, electrically decoupled
U(+LA) – 1.4 V
U(+LB) – 1.4 V
0
1
27
27
–
U(+LA)
–
U(+LB)
–
1
–
400
400 quick action
DC-13 24V 400 mA
PDF-S
solid state output, p-switching, short circuit proof
0.8 x UB
–
UB
–
–
20
3
–
–
30
–
–
1.5
according to EN 60 947-5-2
–
–
180
–
–
180
3
0,5
–
–
according to IEC 60 947-5-3
STATE
LED green
Normal mode
blinking:
Teach-in operation
OUT
LED yellow
Actuator detected
ERROR
LED red:
Test input activated
Internal circuitry error
Invalid Teach-in operation
Use insulated cables only.
Values do not take cable length into consideration.
The risk period is the maximum switch-off delay following the failure
of an internal component. Component failure of a transistor output
is not detected until the safety guard is opened.
4)
5)
mm
kg
°C
°C
V DC
mA
V DC
V DC
mA
mA
mA
V
kV
ms
ms
s
s
When the operating voltage is switched on, the solide state outputs
are switched off and the signal contacts set to LOW potential during
the start-up delay.
The dwell time is the period for which the actuator must remain inside or outside the operating range.
108
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Non - cont act Safety Sensor
T4000 Compact
Actuator
Dimensional drawing
Two safety screws M 4 x 14
included with each actuator
Te c h n i c a l d a t a
Parameter
Housing material
Dimensions
Weight
Ambient temperature
Enclosure rating
Installation position
Power supply
Dwell time remaining inside the operating range
Value
min.
typical
max.
Fortron, glass-reinforced thermoplastic material, fully encapsulated
42 x 25 x 12
0.01
–25
–
+70
IP 67
sensing face opposite read head
inductive via read head
0,5
–
–
Unit
mm
kg
°C
s
Notes on installation
The safety guard must be designed so that there is no risk up
to the distance Sar (= 40 mm, safe switch-off distance).
Actuator and read head must be mounted so that :
– the distance between the front faces is equal or less than
the switch-on distance 0.8 x Sa0 (see Technical data) with
the safety guard close
– they are not used as a mechanical stop
– there must be a gap between the edge and the metal housing when flush-mounted
– they are mounted to the safety guard securely; e. g. using
the enclosed safety screws
109
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Non - cont act Safety Sensor
T4000 Compact
Teach-in function for actuators
The actuator must be assigned to the evaluation unit with the
teach-in function before the system forms a functional unit.
During the teach-in operation, the safety outputs and the door signal output OUT are set to LOW, i. e. the system is in the safe state.
4. The operating voltage on the evaluation unit must then be disconnected for a minimum of 10 seconds to activate the actuator code taught in the evaluation unit.
Note:
Teach-in function for first actuator (condition as delivered):
It is not possible to teach the same actuator on the same
evaluation unit more than once.
The number of valid teach-in operations on one evaluation
unit is limited to a maximum of 8.
The evaluation unit can be operated only with the last actuator
taught.
A teach-in operation is invalid if:
➡ the teach-in operation is aborted before the green LED
goes out
➡ the supply voltage has been disconnected during the
teach-in operation.
When the evaluation unit is switched on (connection of operating voltage), the STATE LED signals the number of teach-in operations that are still possible (see System status table).
1. Apply the operating voltage to the evaluation unit
➡ Fast blinking (approx. 4 Hz) of the green LED
2. Move the actuator towards the read head
(note distance < Sao)
➡ Teach-in operation commences; slow blinking (approx.
1 Hz) of the green LED
3. Teach-in operation complete (after 60 seconds)
➡ Green LED goes out
4. The operating voltage applied to the evaluation unit must then
be disconnected for a minimum of 10 seconds to activate the
actuator code taught in the evaluation unit.
Teach-in function for a new actuator
1. Apply the operating voltage to the evaluation unit
2. Move the new actuator towards the read head (
note distance < Sao)
➡ Teach-in operation commences; green LED blinks
(approx. 1 Hz)
3. Teach-in operation complete (after 60 seconds)
➡ Green LED goes out, new code is saved and old code is
deactivated
Important:
The system automatically reverts to teach-in mode even after
the 8th teach-in operation or if an “old” actuator is moved
against the read head. In both cases, a teach-in operation lasting 60 seconds is initiated, but the last actuator code remains
active in memory (see Status table); no new code is taught.
System status table
PLC
Output
STATE (green)
OUT/ERROR
(yellow)
OUT/ERROR
(red)
closed
open
on
off
1
0
1
1
1
0
0
0
Normal operation, door closed
Normal operation, door open
open
off
0
blinks
constantly
at 4 Hz
0
0
Initial commissioning on delivery
Ready for first Teach-in operation
closed
off
0
blinks 60 sec
at approx. 1 Hz
0
0
Teach-in operation
closed
off
0
0
0
0
Positive acknowledgement for successful
Teach-in operation. The unit must be
switched back on again for normal operation
X
off
0
3
0
0
X
off
0
2
0
0
X
off
0
1
0
0
X
off
0
0
0
0
X
off
0
0
0
1
closed
closed
off
off
0
0
1
2
0
0
1
1
closed
off
0
Brief blink
sequences
repeated
after 1 sec
3
0
1
One-Off
blink
sequence
after
power-off
Number of
blink pulses
OUT
(alarm signal)
Status display
Safety outputs
LA and LB
Commissioning
Actuator /
Door position
Normal operation
LED Indicator
Error indication
Operating error
110
0 = 0 Volt
1 = 24 Volt
X = 0 or 24 Volt
resp. door open or
closed
1 = on
0 = off
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Status
Indication after 1st to 5th Teach-in operation
Indication of the number of Teach-in operations
still allowed after the 6th Teach-in operation
Indication of the number of Teach-in operations
still allowed after the 7th Teach-in operation
Device is now unable to perform a further
Teach-In operation
Device-internal component failure or
actuator in response range less than 0.5 sec
or short-circuit/external voltage at safety
output LA/LB
Illegal 9th Teach-in operation
Illegal Teach-in operation of an old actuator
Negative acknowledgement for Teach-in operation.
Actuator was held in front of read head for less
than 60 sec.
Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 111
Non - cont act Safety Sensor
R E300/
T4000/T4000 Compact
O rd e r i n g t a b l e f o r R E 3 0 0
Non-contact Safety Sensor
Relais control unit
RE300-RA2
Part no.
6 025 082
Type
Cable Length
3m
03P
Detector (reading head and actuator) RE300-DA
Part no.
6 025 080
Spare part: Actuating Key
RE300-KA
Part no.
5 311 140
O rd e r i n g t a b l e f o r T 4 0 0 0
Non-contact Safety Sensor
Type
Actuating key T4000-1 KBA
Detector
Part no.
5 306 531
Cable Length
5m
10 m
05 P
10 P
T4000 DNA
T4000 DNA
T4000 DNA
T4000 DNA
Plug
15 P
C
Detector with plug
T4000 DNA
T4000 DNA
T4000 DNA
Cable Length
20 m
25 m
20
25
Plug
6 012 144
6 012 145
6 012 146
6 021 912
Part no.
50 m
50
C
C
C
Relay control unit
Relais T4000-1 RBA 01
Accessories:
Part no.
15 m
6 021 913
6 021 914
6 021 915
Part no.
6 012 147
Safety srews T4000, 20 pieces
Part no. 5 309 170
O rd e r i n g t a b l e f o r T 4 0 0 0 C o m p a c t
Non-contact Safety Sensor
Type
Actuating key T4000-1 KBA
Part no.
5 306 531
Detector with relay control unit
T4000-2 DRNAC
Part no.
6 022 052
Detector with female connector
M 12, 8-pin, straigth
T4000-2 DRNAC
T4000-2 DRNAC
T4000-2 DRNAC
T4000-2 DRNAC
Cable Length
5m
10 m
5
10
Part no.
15 m
30 m
15
30
6 020 993
6 022 152
6 022 153
6 022 242
111
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112
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Safety operating
units
Use
When these switches are used as
hand-operated command units
they allow work to be carried out
within the hazardous zones of
machines and plant.
Safety Operating Units
Confirmation switch E100 for carrying out programming, set-up or
commissioning work and the ropeoperated emergency stop switch
i110-RP.
113
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Safety Operating Units
General
E100
Function
Safety operating units are manually operated control devices
which are intended for use by persons working in danger areas
of machines and installations.
The functional sequence of SICK safety operating units meets
the requirements for 2-stage and 3-stage safety operating units
in accordance with EN 775 and VDI 2854.
In “Manual mode”, the protective effect of movable safety guards
may be disabled under certain conditions.
Functional sequence of 3-stage safety operating units:
Authorized personnel can then enter dangerous areas with the
safety operating unit, subject to observance of certain preconditions, in order to perform programming, setup work, testing or
service work, for example.
Safety operating units can perform their task properly only if safe
handling is possible for long periods, e.g. during observation of
production sequences, without the operator becoming tired.
Besides an absolute safe function we put specific attention to a
perfect and balanced ergonomics of the SICK safety operating
units, in order to being able offering a product which can be operated pleasantly in order to reduce readiness for manipulation.
Stage 1:
OFF function
(actuating element not pressed)
Stage 2:
Enabling function
(actuating element pressed to center position)
Stage 3:
OFF function with positive opening operation
(actuating element pressed down fully past the
center position)
A patented switch mechanism prevents the enabling function
from being activated when the switch returns from stage 3 to
stage 1.
The exact functional sequence is shown in the switching
diagrams of the respective safety operating units.
Design
All SICK safety operating units have a robust plastic housing offering a high degree of protection. The fully-developed design is
characterized by the following features:
perfect ergonomics
light weight
easily switched from hand to hand
light and stable action point
redundant make circuits
reliable line monitoring for cross shorts
tamper resistant
The hand versions are available with three different cable types,
namely 5 m or 10 m straight cable or 5 m coiled cable, and also
as a kit.
The patented cables of the safety operating units possess individually shielded conductors to permit effective cross-short monitoring. The shields must be connected with the PE system of the
machine or installation.
If the cables are then crushed, for example, short circuits will be
detected and the control switched off immediately by tripping of
the short-circuit protective device. This eliminates the need for an
additional evaluation device for line monitoring.
Application
Safety operating units are used in automated production installations, for example, which are operated in “Manual mode” in
accordance with the regulation EN775 and VDI 2854. This operating mode must be defined by means of lockable selector
switches as stipulated in EN 60204 T1 (DIN VDE 0113 T1).
Safety guards are partially disabled in this mode. For this reason,
the person working in the dangerous area with the safety operating unit must be able to recognize dangerous conditions in good
time and initiate corresponding counter-measures.
Important:
Commands for dangerous operations must not be initiated with
the safety operating unit alone. A “second, conscious” start instruction is necessary for this purpose. Each person to be in the
dangerous area has to have an own safety operating unit.
Approvals
SICK safety operating units have the following approvals:
BIA, Germany
SUVA, Switzerland
SAQ, Sweden
TÜV
as well as approval by the automotive industry.
114
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Safety Operating Units
E 100 (3-stage / dual channel)
Dimensional drawing
Explosive area zone 2
Te c h n i c a l d a t a
Parameter
Housing material
Environmental protection to IEC 529
Ambient temperature
Switching elements
Switching principle
Utilization category to IEC 947-5-1
Connection
Fuse
Weight
Value
Plastic
IP 67/IP 65
– 5 to + 60
see ordering table version IV and V
Slow-action Switch
AC-15 Ue 230 V Ie 4 A / DC-13 Ue 24 V Ie 3 A
cable 8 x 0.34 mm2
F6
approx. 1.1
Unit
°C
A
kg
2 NO
2 positively driven NC contacts
Positively driven NC contacts
Pressure point
Pressure point
Contacts
open
closed
Contacts
Fixing bracket for type E 100
open
closed
Material: Aluminium coated
Height: 30 mm
115
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Rope - operate d Emergency Stop Switch
Housing:
Connection:
Switching elements:
i110 R P
Die-cast zinc, varnished
Cable entry M 20
With 4 contacts
Dimensional drawing
TÜV
Switching elements
rope
stack
rope
tensioned
rope pulled
Installation notes
Fit the Emergency Stop switch in such a
manner that in all directions on activating
the cable the machine is reliably switched
off, and the switch engages the OFF position. The activation cable must cover the
entire operational zone. On pressing the
Reset button, the entire length of the
cable must be in view. In the case of long
lengths of cable use tension springs.
Where the cable is diverted around corners, fit 1 statically fixed diverter roller in
each instance on both sides of the corner.
Warning
If signs of damage or wear are detected,
the complete switch must be replaced.
Do not replace individual components or
assemblies.
116
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Rope - operate d Emergency Stop Switch
i110 R P
Te c h n i c a l d a t a
Parameter
Housing material
Eye nut
Environmental protection to IEC 60529
Mechanical service life
Ambient temperature (operation)
Mounting position
Connection type
Actuating force (minimum)
Frequency of use (maximum)
Contact elements positively guided
NC contacts/NO contacts
Rated impulse withstand voltage Uimp
Contacts referred to housing
Rated insulation voltage Ui
Utilisation category to IEC 60947-5-1
Value
Die-cast zinc, varnished
Stainless steel
IP 66
1 x 106 switching cycles
– 25 ... + 80
optional
1 x M 20
> 125 N (300 mm deflection)
1
3/1 or 2/2
2500
250
AC 15/AC: 2 A (250 V), 5 A (100 V)
DC 13/DC: 0.4 A (250 V), 2 A (24 V)
5
5
1 x 1.5
T6
Switching voltage (minimum)
Switching current (minimum) at 5 V DC
Wire cross-section
Short-circuit protection (control circuit fuse)
Accessories
Unit
°C
cycle/s
V
V
V DC
mA
mm2
Series iE110 RP
Pull cable set
Part no. 5 311 136, 5 311 137, 5 311 138, 5 311 139
117
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Safety Operating Units
E 100 and i110 R P
O rd e r i n g t a b l e E 10 0
Type
E100E100E100E100E100-
Design
Type
standard
A
A
A
B
B
Stage
Model
3-stage
2
2
2
2
2
Safety Operating Units
Internal
Connection
single
A
A
A
A
A
Dual Pole Switch
NC
2
2
2
2
2
NO
2
2
2
2
2
Cable
Type
straight spiral
S
S
W
S
S
O rd e r i n g t a b l e
Cable
Length
5 m 10 m
05
10
05
05
10
Safety Operating Units
Variant
Pull Cable
RP
RP
Dual Pole Switch
NC
NO
3
1
2
2
Connector
M 20
3
3
O rd e r i n g t a b l e
Type
iE110iE110iE110iE110-
6 012 141
6 021 916
6 021 917
6 022 879
6 022 880
Part no.
5 308 209
O rd e r i n g t a b l e i 11 0 R P
i110i110-
A
A
A
A
A
Part no.
F i x i n g b r a ck e t E 10 0
Type
Aluminium
Type
Connec.
without
Pull Cable
P
P
P
P
Part no.
6 025 076
6 025 077
C a b l e S e t s i 11 0 R P
Length
5m
05
Part no.
10 m
20 m
30 m
10
20
30
O rd e r i n g t a b l e
Type
iE110-PTS
118
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
5 311 136
5 311 137
5 311 138
5 311 139
S p r i n g i 11 0 R P
Part no.
5 311 290
Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 119
Regulations and
S t a n d a rd s
41
8
01
EN 2
Type pArEStandard
N9
99
2
nd
Type B Standard1 a
-
EN
N
2
29
E
Type
1 C Standard
08
8
EN
60
20
4
18
N4
101
0
EN
prEN
EN 1
050
EN
92
6
EN
29
4
Regulations and St andards
A guide to the relevant regulations
and standards.
119
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Risk Analysis – Control Categories
Safety consideration for safety guards
Monitoring of movable safety guards includes the devices for
position monitoring and for signal processing in the control
system.
Signal processing of the safety circuits must be integrated in the
overall control system so that this cannot be rendered ineffective
by other control elements.
Safety Interlock
Control Voltage
Signal Processing
Safety Circuit
Control Circuit
with
Safety Function
Control Circuit
with
Operating Function
Release
Load Circuit
with possible
Risk of Hazard
Load Circuit
without possible
Risk of Hazard
Design of a machine control system
Safety circuits may carry out an operational function, but must
primarily perform safety tasks and be able to directly intervene
in load circuits where there is potential danger.
Safety guards and their monitoring and signal processing
systems have to satisfy variously high requirements, depending
on the degree of potential danger to persons and machines.
Possible realization forms extend from a simple mechanicalaction position interlock to a self-monitoring locking mechanism
with start-up testing. The requirement level which should
be satisfied in an individual case can be determined in a risk
analysis that takes into account the danger parameters.
120
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Risk Analysis – Control Categories
Risk estimation according to EN 954-1
The method described in this standard permits the risk involved
in a particular application to be estimated on the basis of a few
parameters which are characteristic for the risk.
Risk estimation (EN 954)
This risk analysis allows determination of a so-called requirement
class from a predefined classification scheme.
Category selection
B
1
2
3
4
S1
Starting point
for risk
estimation
for the
safety-related
part of the
control system
P1
F1
P2
S2
P1
F2
P2
Risk estimation in case of faults in the safety related parts of the
control system and selection of an appropriate category
S – Severity of injury
P – Possibility of avoiding the hazard
S 1 – Slight (normally reversible) injury
S 2 – Serious (normally irreversible) injury including death
P 1 – Possible under specific conditions
P 2 – Scarcely possible
B, 1–4 Categories for safety-related parts of control systems
F – Frequency and/or exposure time to the hazard
F 1 – Seldom to quite often and/or the exposure time is short
F 2 – Frequent to continuous and/or the exposure time is long
●
Preferred categories for reference points
●
Possible categories which can require additional
measures
●
Measures which can be over dimensioned for the
relevant risk
121
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Control Categories
C a t e g o r i e s o f s a f e t y - r e l a t e d C o n t ro l S y s t e m s a c c o rd i n g t o E N 9 5 4 - 1
Category 2)
B
Summary of requirements
Safety related parts of machine control systems
and/or their protective equipment, as well as their
components, shall be designed, constructed,
selected, assembled and combined in accordance
with the state of the art so they can withstand the
expected influence.
System behaviour 1)
The occurrence of a fault can
lead to the loss of the safety
function.
Main principle
to achieve safety
Mainly characterized
by selection
of components
1
Requirements of B shall apply.
Well-tried components and well-tried safety
principles shall be used.
2
Requirements of B and the use of well-tried safety
principles shall apply.
Safety function shall be checked at suitable intervals
by the machine control system.
The occurrence of a fault can
lead to the loss of the safety
function but the probability of
occurrence is lower than for
category B.
• The occurrence of a fault
can lead to the loss of the
safety function between
the checks.
• The loss of safety function
is detected by the check.
3
Requirements of B and the use of well-tried safety
principles shall apply.
Safety-related parts shall be designed, so that:
• a single fault in any of these parts does not lead
to the loss of the safety function; and
• whenever reasonably practicable the single fault
is detected.
4
• When single fault occurs the
safety function is always
performed.
• Some but not all faults will
be detected.
• Accumulation of undetected
faults can lead to the loss of
the safety function.
Requirements of B and the use of well-tried safety
principles shall apply. Safety-related parts shall be
designed, so that:
• When faults occur the safety
• a single fault in any of these parts does not lead
in time to prevent the loss
of the safety function.
to the loss of the safety function; and
Mainly characterized
by structure
function is always performed.
• The faults will be detected
• the single fault is detected at or before the next
demand upon the safety function. If this is not
possible, then an accumulation of faults shall not
lead to a loss of the safety function.
1)
2)
The categories are not intended to be used in any given order or in any given hierarchy in respect of safety requirements.
The risk assessment will indicate whether the total or partial loss of the safety function(s) arising from faults is acceptable.
122
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Regulations – St andards – Re commendations
Standard / Regulation
IEC 204-1
EN 60204 Part 1
DIN VDE 0113
IEC 947-5-1
EN 60947
DIN VDE 0660 200
EN 775
VDI 2854
EN 292-1
EN 292-2
EN 954
EN 1050
EN 1088
BIA-Report 3/89
ZH 1/153
Reference sheet 2/96
Employers’ Liability Insurance Association for
Precision Mechanics and Electrical engineering
Source
Laws and ordinances
Accident prevention regulations (VGB number)
as well as directives, safety regulations,
principles, codes of practice (ZH 1/number)
DIN-standards and VDMA standard sheets
VDE-regulations
BIA-Report
Description
Electrical equipment of industrial machines
General requirements
Low voltage, switchgear and controlgear/position switches
with positive opening operation
Safety requirements for construction, equipment and operation of robot systems
Safety requirements for automated manufacturing systems
Safety machines, basic terms, general design principles and specifications
Safety of machines
Safety related parts of control systems
Part 1: General design
Safety of machines, risk assessment
Interlocking devices with and without guard locking
Configuration and analysis of electromechanical safety circuits for position
monitoring of movable safety guards
Selection and installation of electromechanical locking facilities.
Reference sheet for selection and attachment of electromechanical
locking devices for safety functions.
Contact
Available in bookshops or from
Carl Heymanns-Verlag KG, Luxemburger Str. 449, D-50939 Köln 41
Phone: +49 221/46 01 00, Fax: +49 221/46 01 69
Carl Heymanns-Verlag KG
Address see above
Beuth-Verlag GmbH, Burggrafenstr. 6, D-10787 Berlin
Phone: +49 30/2601-1, Fax: +49 30/2601-231
VDE-Verlag GmbH, Bismarckstr. 33, 10625 Berlin
Phone: 030/348001-0
Berufsgenossenschaftliches Institut für Arbeitssicherheit – BIA
Alte Heerstraße 111, Postfach 20 43, D-53754 St. Augustin 2
Phone: (+49 22 41) 2 31-02
123
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Regulations – St andards – Re commendations
Standard / Regulation
United States Regulations / Standards
Description
Definition of a Safety System
OSHA 1910...
Control Reliability
ANSI B 11...
Single Component Failure
ANSI/RIA R 15.06-1992
Source
ANSI Standards
Government and industry regulations,
specifications and standards,
ANSI, BS, IEC, ISO, VDE, DIN
Code of Federal Regulations
(CFR)
Contact
American National Standards Institute
11 West 42nd St.
New York, NY 10036
Phone: 212-642-4900
Global Engineering Documents
15 Inverness Way East
Englewood, CO 80112-5704
Phone: 303-792-2181/800-854-7179
Fax: 303-397-7935
Occupational Safety & Health Administration
Phone: 212-264-3825
124
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Colour Code Table
C o d e f o r c o l o u r m a r k i n g a c c o rd i n g I E C 757
Colour
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Grey
White
Pink
Gold
Turquoise
Silver
Green-Yellow
Abbreviation old
sw
br
rt
or
ge
gn
bl
vi
gr
ws
rs
–
tk
–
gnge
Abbreviation new
BK
BN
RD
OG
YE
GN
BU
VT
GY
WH
PK
GD
TQ
SR
GNYE
125
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Definition of terms
S a f e t y I n t e r l o ck
categories
Safety switches are divided
into two different categories.
S a f e t y S w i t ch e s
category 1
Safety switches where the
switching element and actuator form a unit.
S a f e t y S w i t ch e s
category 2
Safety switches where the
switching element and actuator do not form a design unit,
but are functionally combined
or separated during actuation.
Au t o m a t i c m o d e
Automatic mode is an operating mode where, in contrast
to manual mode, only system
start-up is initiated by human
intervention. All further
sequences are executed
automatically.
D a n g e ro u s
conditions
These conditions which may
lead to injuries. Safety switches
eliminate this risk in conjunction with proper use of the
safety guard.
Manipulation
Installation
S t a n d a rd s
Manipulation is the intended
deactivation or defeating of
safety guards and their components. Safety switches and
guards must be designed so
that the safety functions cannot be changed or bypassed
by hand or by using a simple
tool. Simple tools include
screwdrivers, ballpoint pens,
nails, pieces of wire, adhesive
tape, etc.
Simple tools do not include
items which have to be produced using tools in more
than one operation. Dismantling of parts, turning the safety interlock from its protective
position, use of a second actuator or bridging of contacts
do not fall into the category of
bypassing in a simple manner.
Wilfull and intended deactivation of safety guards is always
treated as a grossly negligent
act with corresponding consequences in the event of accidents. At the design stage, it
should be remembered that
simple and proper operation
of machines and installation
must remain possible in spite
of the safety guards. If this
fact is forgotten, this may lead
to safety measures being
bypassed.
The mounting location and
installation method of safety
switches are decisive criteria
in ensuring reliable monitoring
of safety guards and their
functioning with respect to
general operating safety.
Safety guards and their components such as safety
switches must be viewed in direct relation to their possible
ma-nipulation. Design precautions should therefore be taken to practically eliminate
these possibilities.
Equally important to observance of general rules and
regulations, e.g. form-fit
assembly of all safety components in safety guards, a
further reduction in risk can
also be achieved by implementation of preventive
design measures.
Certain regulations, standards,
directives and recommendations must be observed when
designing safety devices and
their components.
● Mounting of safety switches behind the safety
guards or inside the
installation.
● Locking out of the actuator
entry opening of the safety
switch (category 2) when
the safety guard is open
(see lockout bar, page
71/91).
● Assembly location of the
interlock actuator in a socalled C-rail to prevent the
use of a “second” actuator.
Manipulation protection by
means of a C-rail
126
© SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616
Risk analysis
It is necessary to carry out a
risk analysis in order to determine the safety objectives
and the corresponding measures required. The required
safety solutions are defined
by taking into account the risk
parameters and the degree of
danger.
(See chapter “Norms and
Standards” for further information).
Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 127
S w i t ch i n g
elements
The switching elements of
safety switches must possess
positive actuators. The switching elements for the safety
function must be positively
driven or, in the case of snapaction switching elements,
guarantee reliable opening
of the NC contact when the
positive opening point is
reached.
A distinction is made between
the following switching element types corresponding to
their switching behaviour:
● Slow-action
contact element
Contact element which
opens or closes dependent
on the speed of its actuation.
● Snap-action
contact element
Contact element which
opens or closes independently of the speed of
its actuation.
S a f e t y g u a rd s
Cycle operation
P o s i t i ve o p e n i n g
A basic distinction is made between fixed and movable
safety guards. Fixed safety
guards are used at dangerous
locations where it is not
necessary to intervene or
where intervention is necessary only on rare occasions.
These guards are normally
permanent and can be removed only by means of tools.
Movable safety guards are
used wherever it is necessary
to reach into the dangerous
location for the purpose of
machine operation, fault
rectification or during set-up
mode. These guards are
monitored by means of safety
switches.
This involves manual intervention at dangerous locations
during the working cycle of
the machine.
Here, the safety measures
must guarantee a high safety
level in monitoring of the
safety guard and in signal processing. If these conditions
are satisfied, the start command can be issued in this
mode after proper return of
the safety guard to its protective position.
Positive opening for safety
switches means that there
must be positive force transmission between the actuator
and switching element.
The actuation mechanism
must be designed so that the
contact point opens reliably
and remains open in activated
condition even in the event of
mechanical failure, e.g. breakage of a spring or contact
welding.
Further regulations are
defined in the standard
IEC 947-5-1, EN 60947,
VDE 0660, part 200.
S a f e t y s w i t ch e s
Safety switches are safety devices which are used to monitor movable safety guards.
They must reliably interrupt
the circuit when the guard in
question is opened and keep
the circuit open until the guard
is closed again.
Safety switches with solenoid
interlock are locking devices
which act in conjunction with
the control to keep movable
safety guards in their safety
position until dangerous conditions no longer exist.
Safety operating
units
These are manually-operated
control devices which are
designed for working in the
danger areas of machines and
installations.
The protective effect of movable safety guards is deactivated under certain conditions
when working in “Manual”
mode. Authorized personnel
can enter danger zones with
the safety operating unit to
perform programming set-up,
observation, repair, test or
service work.
(For further information, refer
to page 88, Chapter “Safety
operating units”).
SICK Safety switches marked
with this symbol indicate N/C
interlocks with positively driven
contacts. This also meets the
requirements of IEC 947-5-1.
127
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Safety Switches
Categories
Safety switches are divided into two functionally different categories corresponding to the definition of the German Employers’ Liability
Insurance Association.
Safety Switches Category 1
Safety Switches Category 2
Safety switches where the switching element and actuator form
one constructional and functional unit.
Functional characteristic:
Safety function when the safety switch actuator is moved.
Category 1:
Safety switches where the contact element and actuator do not
form a constructional unit, but are functionally combined or separated during actuation.
Functional characteristic:
Safety function when the actuator is removed from the safety
switch.
Category 2:
Actuator
Actuator
Activation of
safety function
Activation of
safety function
This distinction results in basic design criteria for safety switches applications.
Hinged door
Hinged door
Sliding cover
Sliding cover
Opening
Opening
Opening
Opening
Installation example for interlocks of the category 1
Application
safety position switch with trip dogs,
Installation example for interlocks of the category 2
Application
swing door monitoring with cam plate actuation,
Safety switch without locking
in case with only rare or occasional intervention at dangerous
locations, e.g. service covers, flaps, lift-out covers etc.
sliding covers and protective screens with trip dogs or for
monitoring of protective covers which have to be opened
during operation with two safety switches and safety relay
or corresponding relay or contactor control.
Safety locking devices
protective covers and guards for opening during operation in
cases with dangerous machine run-down movements or continuing dangerous conditions.
128
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Kat_Sicher_Umschlag_en 28.08.2002 11:34 Uhr Seite 1
Th e d i a l o g u e c o n t i n u e s .
GB 9.02 PK
R e p l y
Copy, complete and fax.
Company
Name
Position/
Department
Address
Phone/Fax
Industry/Field
of application
I would like to know more
about:
______________________
______________________
I am interested in a detailed
consultation with one of
your project consultants.
Please arrange an appointment for me.
Australia
Tel. +61 3 94 97 41 00
008 33 48 02 – toll free
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Tel.
Fax
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Tel. +47 67 56 75 00
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Representatives and agencies
in all major industrial nations.
+1(952) 9 41-67 80
+1(952) 9 41-92 87
SICK AG · Industrial Safety Systems · Sebastian-Kneipp-Strasse 1 · 79183 Waldkirch · Germany
Phone +49 76 81 2 02 0 · Fax +49 76 81 2 02 38 15 · www.sick.de
Safety Swit
8 008 616/17-07-02 · GO/SM · Printed in Germany (07.02) · We reserve the right to make changes
F a x
Post code/
Town