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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:39 Uhr Seite 20 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:40 Uhr Seite 30 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 58 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. 58 © 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 59 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:44 Uhr Seite 60 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 Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 61 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 61 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 62 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! 62 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 63 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 63 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 64 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! 64 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 65 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 65 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 66 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 66 © 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. 67 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 68 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 . . 68 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 69 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 69 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 70 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. 70 © 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. . 71 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 72 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 72 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 5 311 134 5 311 135 Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 73 73 Kat_Sicherheit_en 27.08.2002 13:56 Uhr Seite 74 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 74 © 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. 75 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 76 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) 76 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 77 Function – det ails – options Turning the head Actuator alignment error tolerance Turning the handle 77 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 78 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 79 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 80 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 82 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 Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 83 83 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 84 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. 84 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 85 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 86 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 87 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:57 Uhr Seite 88 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. 89 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 13:58 Uhr Seite 90 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 91 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:04 Uhr Seite 92 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:04 Uhr Seite 93 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:04 Uhr Seite 94 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 Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 95 95 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 96 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 97 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) 97 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 98 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 Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 99 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 100 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. 100 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 101 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 8 101 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 102 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 103 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 104 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:05 Uhr Seite 105 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 106 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 107 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. 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved 107 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 108 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 109 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 110 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 112 112 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 113 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 114 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 115 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 116 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 117 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 118 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 120 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 121 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 122 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 123 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 124 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 125 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 126 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 8 008 616 · © SICK AG · Industrial Safety Systems · Germany · All rights reserved Kat_Sicherheit_en 27.08.2002 14:07 Uhr Seite 128 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 © SICK AG · Industrial Safety Systems · Germany · All rights reserved · 8 008 616 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. 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Fax Norway Tel. +47 67 56 75 00 Fax +47 67 56 66 10 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