FGS F l e x i b l e Li g h t G r i d S y s t e m S a f e t y Li g h t C u r t a i n

Installation/Operation Manual

TABLE OF CONTENTS
Contents 1 1.1 2 2.1 2.2 2.3 3 4 4.1 4.2 Introduction Features Applications Areas of Application Application Conditions Corner Mirrors System Design Theory of Operation Mode of Operation Host/Guest Cascade (Daisy-Chaining) Installation General Safety Distance to Point of Operation Distance to Reflective Surfaces Multiple Safety Systems Per Application Mechanical Installation (Mounting Brackets) Electrical Installation Test Input (Sender) Switching Outputs (Receiver) RS-485 Communication Interface Specifications Table General Weight of Systems Dimensional Drawings Connection Diagrams Connection Diagram for Terminal Strip (FGSS/FGSE) Connection of DIN Connector LCU-AM (7 022 760) LCU-15-AM (7 022 782) LCU-X Page 3 3 4 4 5 6 6 7 7 7 Contents 9 Selection of an OptoElectronic Safety Systems FGS Selection Table Safety Light Curtain Cables Sender Unit Safety Light Curtain Cables Receiver Unit Accessories Selection Table Corner Mirror Selection Table Mounting Stands Diagnostics Troubleshooting Diagnostic Table Page

9.1 9.1 9.2 9.4 9.5 9.6 10 10.1 10.2

22 22 23 24 25 25 26

5 5.1 5.1.1 5.1.2 5.1.3 5.2 5.3 5.3.1 5.3.2 5.3.3

8 8 8 9 9 10 11 11 12 12

27 27

Agency Approvals EU Europe Rheinland TUV Am Grauen Stein D-51105 Koln BIA Berufsgenossenschaftliches Institut fur Arbeitssicherheit Alte Heerstrasse 111 D-53757 St. Augustin ISO 9001 DQS Certificate

6 6.1 6.2 7 8 8.1

13 13 14 15,16,17 18

J Japan Japanese Ministry of Labour

18 18 19 20 21

8.2 8.3 8.4 8.5

INTRODUCTION

Introduction

FGS safety light curtains are active opto-electronic protection devices (AOPD) with resolutions of 14 mm or 30 mm. SICK FGS safety light curtains are self-checking (AOPD) and belong to Safety Category 4. They have been designed for industrial applications and are characterized by:
Resolution

High degree of reliability Maintenance-free components Practical size Sturdy modular construction Universal application possibilities Simple installation

Protected Height

For practical applications, the following specifications are valid:

1.1

Features

Scanning Range

Special features of the FGS safety light curtain are: Control-reliable solid-state outputs State of the art microprocessor technology with custom-designed ASICs (Application Specific Integrated Circuits) Easy assembly and alignment Internal terminal strips or quick-disconnects Long scanning range and high resolution Small housing cross section: 52 mm x 55 mm Fast response time Large excess gain Possibility to daisy-chain numerous sensors (to prevent personnel from standing between protective field and the point of operation) Construction in compliance with pr EN 50100 (self-checking)

Fig. 1. Threshold values of an FGS safety light curtain.

Maximum scanning range Resolution (object sensitivity) Maximum height of protective field Minimum height of protective field

6 m/18 m 14 mm/30 mm 1814 mm/1832 mm 314 mm/332 mm

The optical axis (center of exit window) is marked on the end cap.

APPLICATIONS

2.1

Areas of Application

FGS safety light curtains can be used for point of operation, (Fig. 2), area (Fig. 3), perimeter and entry/exit (Fig. 4) safeguarding applications. Typical areas of application are: Presses in the metal, plastics, rubber, leather and stone industries Punches in the leather, metal textile and plastics processing industries Filter presses Trimming presses and cutters Processing machines and welding presses Assembly lines Revolving transfer machines Automatic assembly equipment Paper-cutting machines Fig. 2. Point of operation safeguarding with an FGS safety lightly curtain.

Fig. 3. Hazardous area safeguarding with an FGS safety light curtain.

APPLICATIONS

Fig. 4. Entry / exit safeguarding with an FGS safety light curtain.

2.2

Application Conditions

The machine or system control must be able to be stopped electrically. The FGS monitors the switching outputs for short circuits. The hazardous machine motion must be able to be stopped at all times. The installation of th FGS must adhere to the ANSI specification B11.19/E4.2.3.3.6, which states: A presence sensing device shall prevent the operator or others from reasonably reaching over, around, under or through the sensing field into the hazardous area. Auxiliary safeguarding may be required in conjunction with the FGS to accomplish this requirement. (Fig. 5). All pertinent regulations apply to installation and operation. Local authorities or the respective industry associations are available for technical safety questions.

Fig. 5. The devices must be mounted so that the following are not possible: reaching over, reaching under and standing behind defensive fields.

SYSTEM DESIGN

2.3

Corner Mirrors

The protective field between the FGS sender (FGSS) and the FGS receiver (FGSE) can be guided around corners using corner mirrors (Fig. 6). This allows the FGS to safeguard multiple sides of a hazardous area or point of operation.

Fig. 6. Hazardous area safeguarding with the FGS and a corner mirror.

System Design

The safety light curtain consists of a sender and a receiver (Fig. 7). Between these is the protective field, which is defined by the protected height and the scanning range. The length of each system is dependent on the protected height required. Synchronization between the sender and receiver takes place optically, i.e. electrical connection between sender and receiver is not necessary. The FGS is a modular construction. All optical and electrical components are housed in one sturdy, yet slim, profile.

Fig. 7. The FGS safety light curtain consists of sender and receiver. Between these is the protective field.

THEORY OF OPERATION

Theory of Operation

4.2

Host/Guest Cascade (Daisy-Chaining)

When using the daisy-chain option, take notice of the following: Maximum total number of beams is 240: 14 mm resolution= 20 beams per every 150 mm 30 mm resolution = 10 beams per every 150 mm Maximum cable length between Host/Guest devices: 300 mm (shielded) Protected height increments: 150 mm, beginning with 300 mm Figs. 8 & 9 show two possible applications. The guest sensors, unlike the main sensor, has no indicator lights. They are not designed to be used as a stand alone device. The Host/Guest and Host/Guest/Guest sensors with accessories are already prepared for daisy-chaining. Note: Host/guest/guest top Interface Cable is limited to a max. length of 10 meters.

The infrared light pulses coded by the sender are sent to the receiver, which evaluates them. If an object, e.g. a finger or a hand (> 14 mm / > 30 mm), penetrates the protective field, both outputs of the FGS switch to stop the machine.

4.1

Mode of Operation

The FGS, does not require a separate control unit or "third box" when operating in guard-only mode with manual restart. If other functions should be required, e.g. PSDI mode, blanking, muting, and others, LCU (Universal Safety Interface) devices are available. The addition of an LCU makes possible a wide variety of applications.

In order to effectively prevent someone from standing behind the sensing fields, one or several FGS devices can be connected in a daisy-chain configuration. Any desired combination is possible up to 240 beams. For example, a host 1200 mm device with 14 mm resolution for finger protection, could be connected to a guest 300 mm device, with 30 mm resolution to prevent someone from standing between the protective field and the point of operation. When using the LCU-P with "mixed" daisy-chaining (e.g. host sensor with 14 mm resolution with a guest sensor with 30 mm resolution), the Dpt must be calculated using the larger (30 mm) resolution.

Host Receiver Host Sender Host Sender

Host Receiver

Guest Receiver

Guest Receiver Guest Receiver Guest Sender

Guest Sender

Guest Sender

Fig. 8. Multiple plane sensing using the Host/Guest configuration.

Fig. 9. Multiple plane sensing using the Host/Guest/Guest configuration.

5
5.1

INSTALLATION
Middle of Depth of Protective Field

General
Safety Distance Point of Operation Top of tool

The FGS can be used in most environments (IP 65). Safety distances as well as an adequate protected height should be observed. Special attention should be given to the danger of reaching over, under, or standing behind sensing fields to reach the point of operation. This must be prevented mechanically or covered by another optical safety device (e.g. FGS daisy-chaining).

}
Protective Field Marking

Machine stop time

Bottom of tool

5.1.1 Safety Distance to Point of Operation

75 mm

Object Sensitivity S in inches (mm)

The safety device requires a certain minimum distance between the sensor and the point of operation. This ensures that the point of operation can be reached only after the hazardous motion has been stopped (Fig. 9). The safety distance (according to EN 775, 999 and 294) is dependent on the following: Machine stop time Response time of the safety device Resolution of the safety device Hand speed

To avoid the possibility of standing between the protective field and the point of operation, this distance must be maintained.

Fig. 9. Determining machine stopping time and safety distance.

2.5 (64)

2.0(51)

1.5(38) FGS 30 mm 1.2 (30) 1.0 (25)

FGS

FGS 14 mm 0.55 (14) .05(12)

0 1.0 (25) 2.0 (51) 3.1 (78) 4.0 (102) 7.0 (178)

Depth Penetration factor Dp in inches (mm) Fig.10. Depth penetration chart.

Note 1. This value will change if fixed blanking is used. Note 2. Any object sensitivity greater than 2.5 in (63.5 mm) cannot reliably detect a persons hand or arm and should be considered a perimeter guard system.

The *** formula should be used when calculating the safety distance Ds: Ds= K [Ts +Tc+Tr+Tbm] + Dpf or Ds=K [Tall] + Dpf Minimum safety distance between device and the nearest point of operation hazard (in mm) Hand speed constant: 1600 mm/sec or 63 in/sec All times

Ts= Tc= Note:

Stop time of machine tool measured at the final control element (in seconds) Response time of the control system Ts and Tc are usually measured by a stop-time measurement device and confirmed periodically Response time of the presencesensing safety device as stated on the product

Tbm=

Additional time allowed for the brake monitor to compensate for variations in normal stopping time (i.e brake wear) Added distance due to the depth of penetration factor. Can be obtained using the chart in fig. 10 or 3.4 x [ object sensitivity-7 mm]

Dpf=

Ds= K=

Tr=

Tall=

The minimum object sensitivity is stated on the product label. If beam blankouts are used, this opening should be added to the object sensitivity.

INSTALLATION

5.1.2. Distance to Reflective Surfaces Reflective surfaces that are present in the sensing field of the sender and receiver can cause reflections that may result in an object not being detected (Fig. 11). Therefore, a minimum distance (a) must be kept from the reflective objects to the optical axis (straightline connection FGSS/FGSE). The distance (a) is dependent on the distance between the sender and receiver unit, and on the alignment of the devices (Fig. 12).

Fig.11. Correct installation, correctly aligned. No optical short circuits. The object is already detected.

5.1.3. Multiple Safety Systems per Application When using two FGS systems per application, the systems should not be allowed to influence each other. As the distance between the FGSS and FGSE increases, the light beams diverge and their cross sections become larger. This could result in the light beams being received by the wrong receiver. Light beams should be received only by their corresponding receiver. In order to rule out the possibility that receivers will receive light from the wrong sender devices, their alignment must be taken into consideration during installation (Fig. 13).

Fig.12. Safety distances (a) relative to operating range.

Fig.13. Installing two FGS systems next to each other. S=sender, E=receiver)

INSTALLATION

Fig.14 . FGS mounting options: L-bracket, adjustable bracket and bracket with shock mount. (dimensions in mm)

5.2

Mechanical Installation Brackets with shock mounts can be used to reduce vibrations (e.g. on stamping presses). The brackets are attached to the sender and receiver using T-nuts. The Tnuts ride in grooves that run the full length of the light curtains on either side of the exit window. This allows for greater flexibility when mounting the light curtains.

Fixed L-brackets are included with the FGS. Optional adjustable brackets and adjustable brackets with shock mounts are available for mounting the sender and receiver units (Fig. 14). Fixed brackets can be used where no compensation for large mechanical tolerances is required. The adjustable brackets allow the sensors to be adjusted 2.

10

INSTALLATION

5.3

Electrical Installation

Sender Cable Plug 1

PIN COLOR FUNCTION + 24 V DC 0 V DC TEST TEST PE 1 2 3 4 5 BLACK BLUE GREEN/YELLOW BROWN WHITE

Connecting the FGS components is simple. Cable lengths up to 60 m are permitted (over-voltage protection for level 3 and higher (IEC 801), see Technical Data. The sender is connected to the machine control using a 5conductor cable (Fig. 15), the receiver using a 7-conductor cable (Fig. 17). The maximum wire cross section is 1.5 mm without jacket; 1 mm with jacket. All U.S. light curtains come standard with prewired mini-style quick-disconnect in the end-caps. The FGS requires +24 V DC ( 20%) power supplies, which are available from SICK.

4 3 FGS Sender Inside View of Connector

FGS Sender Top View of Connector

Pin #1

Pin #5

Pin #2

Pin #3 Pin #4

5.3.1 Test Input (Sender) The FGS switches to the green condition after the supply voltage has been applied, and the automatic power-up test has been completed. If an external test is desired (Fig. 16), a contact at the test input (MCC = Machine Control Contact). Minimum opening duration 50 ms. Continuous current during closed test input: 12 mA. In-rush current when closing: 150 mA (20 ms). Test input open = Testing = Outputs on receiver inactive (red). Test input closed = No test = Outputs on receiver active (green). The cable pin diagram for the sender is shown in Fig. 15.

Pin #1 = +24 V Pin #2 = GND Pin #3 = TEST Pin #4 = TEST Pin #5 = NC Pin #6 = NC Pin #7 = PE

Internal Connector

Mini Plug

1 2 3 4 5 6 7

1 2 3 4 5

Fig. 15. FGSS (sender) cable pin diagram.

FGSS 1 3 4 2 7 test 0V PE or test contact +24 V

Fig. 16. FGSS connection diagram.

11

INSTALLATION

5.3.2 Switching Outputs (Receiver) The output voltage UA of each channel depends on the supply voltage UV and the switching load and is at least UA = UV - 2V Both outputs OSSD1 and OSSD2 (OSSD = Output Signal Switching Device) are control reliable, actively monitored PNP solid state outputs. The outputs can catty a maximum of .05 Amps and are short circuit protected (Fig. 18). If the protected field is clear, the two outputs HIGH (active). An additional supply voltage must be applied to the outputs. Both output signals must be processed separately. They must not be connected in series or parallel.

Receiver Cable Plug

PIN COLOR FUNCTION + 24 V DC 0 V DC OUT 1 OUT 2 -RS 485 +RS 485 PE

4 7 FGS Receiver Inside View of Connector

1 2 3 4 5 6 7

BLACK WHITE BLUE BROWN GREY YELLOW GREEN

FGS Receiver Top View of Connector

Pin #1

Pin #6

Pin #2 Pin #5

Pin #3 Pin #7 Pin #4 Pin #1 = +24 V Pin #2 = GND Pin #3 = OUT 1- Pin #4 = OUT 2- Pin #5 = COM- RS 485 Pin #6 = COM+ RS 485 Pin #7 = PE
Internal Connector Mini Plug

1 2 3 4 5 6 7

1 2 3 4 5 6 7

Fig. 17. FGSE (receiver) cable pin diagram.

FGSE

5.3.3 RS-485 Communication Interface This interface serves to communicate with the LCU-P (optional). If LCU-P is not used, the connection is not used.

1 3

+24 V Imax =0.5 A RL Imax =0.5 A RL

5 RS 485 6 2 7 (LCU/diagnostics) 0V PE

Fig. 18. FGSE (receiver) connection diagram.

12

SPECIFICATIONS

6.1 General Protected field height, type-dependent Protected field width 14 mm resolution 30 mm resolution Resolution, type-dependent Enclosure rating Protection class Supply voltage Uv Ripple 1) Voltage if power fails (20 ms) Synchronization On transition time after applying supply voltage of sender and receiver Sender Unit Test output Test input Input resistance (HIGH) Sender, inactive (Test) Sender, active Reaction time in test Wave length Current consumption Receiver Unit Supply connections (OSSD) Switching voltage HIGH (Ueff) Switching voltage LOW Switching current Leakage current 3) Load capacity Switching frequency Load inductance L 4) Test impulse data 5) Test impulse width Test impulse rate Permissible cable resistance between unit and load 6) Response time On-transition time after light beam interruption

Minimum 300 mm 0.3 m 0.5 m 14 mm IP 65 1 19.2 V

Typical

Maximum 1800 mm 6m 18 m 30 mm

24 V

28.8 V 2.5 Vss

18 V optical, without separate synchronization cable 1.8 s

Uv-0.7 V 1.5 k (against 0 V) 0V 18.5 V 50 ms 880 or 940 nm 0.56 A

12 V Uv 60 ms

2-PNP semiconductors, short circuit protected2), cross monitored Uv - 2V Uv 0V 1V 5 mA 500 mA 2.4 mA 2.2 F 4/s 2.2 H 220 s 6.3 ms 240 s 265 s 19.6 ms 2.5 15 ms 15 ms 100 ms
7)

13

SPECIFICATIONS

6.1 General Continued Communication cables Cable length (twisted pair) Cable termination, internal Baud rate Current consumption (no load) Connection Line length

Minimum

Typical

Maximum 100 m

4.7 nF 9600 baud 0.68 A Plug-in terminal chamber Dependent on load, power supply unit and wire cross section. The technical specifications must be observed. 10 m 60 m 8) 1 mm2 with sleeve 1.5 mm2 without sleeve Guard only without start and restart inhibit Type 4 pr EN 50 100 Part 1 and 2 0C + 55C -25C + 70C 15% 95% 5 g 10...55 Hz per IEC 68-2-6 10 g/16 ms per IEC 68-2-29 Dependent on protective field height, see sect. 7, Dimensional Drawings 52 mm x 55 mm See 6.2-weight table
5) In the active state, the outputs are tested in a cycle (switch LOW briefly). When selecting the downstream control elements ensure that the test impulses with the parameters listed above do not lead to a shutdown. 6) The individual conductor resistor to the downstream control element must be limited to this value so that a crossed connection between the outputs can be identified. (EN 60 204 Electrical Equip. of Machines, Part 1: General Requirements must be observed). 7) This value applies if the synchronization beam is interrupted (1st beam below the LED display). 8) With screening, recommended with chamber EMV.

Max. conductor cross section Operating Mode Safety category Tested to Ambient operating temperature Storage temperature Air humidity (non-condensing) Vibration resistance Shock resistance Dimensions Height Housing cross section Weight

1) The voltage must not exceed or fall below the set limits. 2) Applies for voltages between Uv and 0 V. 3) In the case of an error (interruption of the 0 V cable) the output behaves like a resistor > 13 k after Uv. The downstream control element must identify this state as LOW. 4) With a low switching frequency 1/s the max. permissible load inductance L is higher.
L (Hy) 20 1 IL 400 mA 2 IL 500 mA 1 10 2

0 0

1.0

2.0

3.0

4.0

1/s

6.2

Weight of Systems

The values in the chart to the right are weights per system (sender plus receiver). Each component accounts for approximately 50% of total weight. There is no difference in weight between the 14 mm and 30 mm versions of each model.

FGS Model [mm] 300 450 600 750 900 1050 1200 1350 1500 1650 1800

Weight of System [kg] 2.8 4.0 5.0 6.0 7.0 8.0 9.2 10.0 11.2 12.3 13.4

14

DIMENSIONAL DRAWINGS
PG Connector or Quick Disconnect (approx. 100 mm space required for plugging in)

Note: Dimensions C & D represent the suggested distances of mounting brackets.

A FGS FGS FGS FGS FGS FGS FGS FGS FGS FGS FGS 300 450 600 750 900 1050 1200 1350 1500 1650 1800 300 450 600 750 900 1050 1200 1350 1500 1650 1800

B 384 534 684 825 985 1135 1285 1435 1586 1736 1886

C 224 374 524 675 825 975 1125 1275 1426 1576 1726

D 80 80 80 80 80 80 80 80 80 80 80

Optical Axis = Center of exit window

(Dimensions in mm)

Fig. 19. FGS Dimensional Drawing (DImensions in mm).

15

DIMENSIONAL DRAWINGS

A B

31

Middle Guest
25

A FGS FGS FGS FGS FGS FGS FGS 150 300 450 600 750 900 1200 150 300 450 600 750 900 1200

B 200 350 500 650 800 950 1250

52 55 61
Fig. 20. Middle Guest FGS dimensional drawing.

16

DIMENSIONAL DRAWINGS

A B

31

End Segment Guest A 27.5 FGS FGS FGS FGS FGS FGS 150 300 450 600 750 900 150 300 450 600 800 900 B 200 350 500 650 350 950 C *) 190 340 490 640 790 D *) 80 80 80 80 80

52 55

other sizes available on request *) special fixing on request

61
Fig. 21. Guest FGS dimensional drawing.

17

8
8.1

CONNECTION DIAGRAMS

Connection Diagram for Terminal Strip

Fig. 22 shows the pin connections for the FGS terminal strip: left, sender; right, receiver.

8.2

Connection of DIN Connector

Fig. 23 shows the connections for the DIN connector.

Fig. 22. Pin connections for terminal strip: left, sender, right, receiver.

1 2 3

This interface is manual Start/Restart only. LC1, LC2 and LC3 must be captive contact safety relays Normally open momentary contact switch. In selecting a 24 V DC power supply, please add the power consumption for LC1, LC2 and LC3 to the power consumption for the FGSE/FGSS (0.9 amp dependent on size).

Fig. 23. FGS with three relay interface.

18

CONNECTION DIAGRAMS
8.3 Connection Diagram LCU-AM (SICK PN: 7 022 760)

Fig. 24. Connection diagram LCU-AM.

1. The Safety Stop Circuit (C3/C6) is rated for 10 amps (240 V AC, 2400 VA max.). Normally Open in a "Red/No Go condition; Normally Closed in a Green/Go condition. 2. Secondary, Non-Safety, Receiver status output (C4/C5) for PLCs, Alarms, etc. Normally Open in a "Red/No Go condition; Normally Closed in a Green/Go condition. 3. Selectable Manual or Automatic mode - See Jumper (J6) on diagram. 4. Manual mode - C1/C2 = Normally open momentary contact switch. Automatic mode - C1/C2 = Jumpered. 5. For Floating 24 V DC Ground, remove Jumper R1. 6. 35 mm DIN Rail Top Hat Profile mounting. 7. Response time = 15 ms. 8. 24 V DC power supply rated for 2 amps. 9 Replacement Fuse PN 7 021 905 (F1, F2 = 500 mA). 10. Ambient operating temperature 0 to 55C. 11. Arc suppression kits should be applied across each load (solenoid of relay coil), to assure maximum contact life.

19

8
8.4

CONNECTION DIAGRAMS

Connection Diagram LCU-15-AM (SICK PN: 7 022 782)

Fig. 25. Connection diagram LCU - 15- AM.

1. The Safety Stop Circuit (C3/C6) is rated for 10 amps (240 V AC, 2400 VA max.). Normally Open in a "Red/No Go condition; Normally Closed in a Green/Go condition. 2. Secondary, Non-Safety, Receiver status output (C4/C5) for PLCs, Alarms, etc. Normally Open in a "Red/No Go condition; Normally Closed in a Green/Go condition. 3. Selectable Manual or Automatic mode - See Jumper (J6) on diagram. 4. Manual mode - C1/C2 = Normally open momentary contact switch. Automatic mode - C1/C2 = Jumpered. 5. For Floating 24 V DC Ground, remove Jumper R1. 6. 35 mm DIN Rail Top Hat Profile mounting. 7. Response time = 15 ms. 8. 24 V DC power supply rated for 2 amps is required. 9. Ambient operating temperature 0 to 55C. 10. Arc suppression kits should be applied across each load (solenoid of relay coil), to assure maximum contact life.

20

CONNECTION DIAGRAMS

8.5

Connection Diagram LCU-X

24 V DC LCU-X 2.3 2.4 1.3 1.4
Load
1

0 V DC

Safety Stop Circuit

Load

Also may be used to control 120/240 V AC In this case, A1 and A2 are connected to 24 V DC and 0V DC respectively.

LC1

LC2

LCU-X 3.1 2.3 1.3

3

3.2 2.4 1.4

LC2
2

LC1

X22 X21

LC1 T22 MPCE T21 LC2 X12

4

T4 T3 PE D2

X11 T14 T13 Reset

C2 PE

7 6 5 4 3 2 1 5
5

7 6 5 4 3 2 1 7 6 5 4 3 2 1
Internal

PE

RS 485 Out 2 Out 1 0 V DC + 24 V DC PE Not Used Test Input Test Input 0 V DC + 24 V DC

PE

MCC A2 0V DC A1 +24 V DC D1 C1

4 3 2 1
Mini Connector

All relays must be captive contact, direct drive safety relays

Fig. 26. Connection Diagram LCU-X.

1 2 3 4 5

Loads such as: clutch breaks, servo motors, contactors, dual solenoid valves, etc. Relays LC1 and LC2 are not required if load current is less than 4 amps. In this case, the optional Safety Stop Circuit and No External Contact Checking should be used (see note 3). For No External Contact Checking jumper X21 to X22, leave T21 and T22 open; then use optional Safety Stop circuit as described in note 2. If Automatic Reset is allowed, remove the N.O. push button on T13 and T 14 and jumper X11 to X12. This circuit is jumpered for continuous operation machinery. If operator intervention is required this N.C. switch must be opened greater than 50 ms during each non-dangerous portion of the machinery cycle. (Please refer to OSHA regulations to determine if this is required).

21

FGS Sender

Not Used

FGS Receiver

RS 485 +

9
9

SELECTION

Selection of an OptoElectronic Safety System

9.1
FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE FGSS FGSE

FGS Selection Table

300-111 300-111 300-211 300-211 450-111 450-111 450-211 450-211 600-111 600-111 600-211 600-211 750-111 750-111 750-211 750-211 900-111 900-111 900-211 900-211 1050-111 1050-111 1050-211 1050-211 1200-111 1200-111 1200-211 1200-211 1350-111 1350-111 1350-211 1350-211 1500-111 1500-111 1500-211 1500-211 1650-111 1650-111 1650-211 1650-211 1800-111 1800-111 1800-211 1800-211 Resolution (mm) 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 14 14 30 30 Protective Height (mm) (in) 314 (12.3) 314 (12.3) 332 (13.0) 332 (13.0) 464 (18.2) 464 (18.2) 482 (18.9) 482 (18.9) 614 (24.1) 614 (24.1) 632 (24.8) 632 (24.8) 764 (30.0) 764 (30.0) 782 (30.8) 782 (30.8) 914 (36.0) 914 (36.0) 932 (36.7) 932 (36.7) 1064 (41.9) 1064 (41.9) 1082 (42.6) 1082 (42.6) 1214 (47.8) 1214 (47.8) 1232 (48.5) 1232 (48.5) 1364 (53.7) 1364 (53.7) 1382 (54.4) 1382 (54.4) 1514 (59.6) 1514 (59.6) 1532 (60.3) 1532 (60.3) 1664 (65.5) 1664 (65.5) 1682 (66.2) 1682 (66.2) 1814 (71.4) 1814 (71.4) 1832 (72.1) 1832 (72.1) Part Number 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 012 755 756 777 778 757 758 779 780 759 760 781 782 761 762 783 784 763 764 785 786 765 764 787 788 767 768 789 790 769 770 791 792 771 772 793 794 773 774 795 796 775 776 797 798

Model Number

In the selection of an opto-electronic safety device, consider the following elements: Regulations Look up the regulations and standards applicable to the particular application. Local authorities and professional organizations can assist here. Operating Range Determine the required operating range for the application. The operating range corresponds with the width of the area to be safeguarded. The operating range should be chosen so that danger points are accessible only through the protective field. Corner Mirrors Use of corner mirrors offers the possibility to safeguard two or three sides. Use of corner mirrors will also reduce the maximum sensing range 0.5 m per mirror. Protected Height Determine the required protected height for the application. The protected height must be chosen so that danger points are accessible only through the protective field.

Please order the devices intended for daisy-chain applications (host sensor/guest sensor) separately.

22

SENDER UNIT

9.2

Safety Light Curtain Cables - Sender Unit

48.3 mm (1.9 in) Typ.

Length 0.2 m (.66 ft) up to 15 m (49.2 ft) 0.5 m (1.64 ft) 16 to 30 m (52.48 to 98.4 ft)

25.4 mm (1.0 in) Dia. Ref. 7.87 mm (0.31 in) .254 mm (0.01 in)
Fig. 27. Sender Unit.

1 Model Number KD5-SYF804 KD5-SYF812 KD5-SYF820 KD5-SYF830 KD5-SYF8.06 Length in m (ft) 4 (13.1) 12 (39.4) 20 (65.6) 30 (98.4) 0.6 (1.9) Note 1 1 1 1 2 5

Order Number 7 022 166 7 022 167 7 022 168 7 022 836 7 025 683

Material Specifications: Connector Coupling nut: Anodized aluminum Contacts: brass - gold flash over palladium nickel Female insert: PVC Molded Head: PVC yellow Cable Conductors:

Pin 1 2 3 4 5

Color Black Blue Yellow/Green Brown White

Over Jacket: Protection:

Five conductor - 18AWG stranded tinned copper Jacket PVC color per chart 300 V 105C (221F) UL recognized, CSA certified PVC Yellow 300 V 105C (221F) UL recognized, CSA certified NEMA 6p IP 68

Notes: Note 1: Strip off 2 inches of outer jacket. Strip 0.25 inch of each conductor. Tin each conductor end. Note 2: Strip off 1.5 inches of outer jacket. Strip 0.25 inch of each conductor. Tin each conductor end.

23

9
9.3

RECEIVER UNIT
Safety Light Curtain Cables - Receiver Unit Length 0.2 m (.66 ft) up to 15 m (49.2 ft) 0.5 m (1.64 ft) 16 to 30 m (52.48 to 98.4 ft)

53.34 mm (2.1 in) Typ.

25.4 mm (1.0 in) Dia. Ref. 8.26 mm (0.325 in) .38 mm (0.015 in)
Fig. 28. Receiver Unit.

7 Model Number KA17-SFF804 KA17-SFF812 KA17-SFF820 KA17-SFF830 KA17-SFF8.06 Length in m (ft) 4 (13.1) 12 (39.4) 20 (65.6) 30 (98.4) 0.6 (1.9) Note 1 1 1 1 2 6

Order Number 7 022 180 7 022 181 7 022 182 7 022 837 7 025 652

Material Specifications: Connector Coupling nut: Anodized aluminum Contacts: brass - gold flash over palladium nickel Female insert: PVC Molded Head: PVC yellow Cable Conductors:

Pin 1 2 3 4 5 6 7

Color Black White Blue Brown Gray Yellow Green

Over Jacket: Protection:

Five conductor - 18AWG stranded tinned copper Twisted Pair - 2 conductor 20AWG stranded tinned copper with over all foil shield and drain wire Jacket PVC color per chart 300 V 105 C (221 F) UL recognized, CSA certified PVC Yellow 300 V 105 C (221 F) UL recognized, CSA certified NEMA 6p IP 68

Notes: Note 1: Strip off 2 inches of outer jacket. Strip 0.25 inch of each conductor. Tin each conductor end. Note 2: Strip off 1.5 inches of outer jacket. Strip 0.25 inch of each conductor. Tin each conductor end.

24

ACCESSORIES
9.4 Accessories Selection Table
Part Number 7 021 352 7 021 351 7 021 348
4 required per system

Products L-Mounting Bracket, fixed* Mounting Bracket, adjustable Mounting Bracket, adjustable with shock mount Terminal housing with PG and Terminal Strip Terminal housings Connector, Sender (DIN) Connector, Receiver (DIN) Cable Socket, straight (DIN) Cable Socket, right-angle (DIN) Power Supply 93..265 V AC 24 V DC, 2.0 amps (PS-20) 24 V DC, 2.5 amps 24 V DC, 4 amps Safety Interface LCU-P LCU-AM LCU-15-AM LCU-X AR 60 alignment aid FGS Adapter for AR-260 * Supplied with FGS

7 021 313 7 7 6 6 021 021 006 006 353 354 612 613

7 022 755 6 010 361 6 010 362 1 7 7 1 1 4 012 022 022 013 015 030 523 760 782 410 741 282

9.5

Corner Mirror Selection Table

CORNER MIRRORS- Specially constructed mirrors for 2 and 3 sided safeguarding applications; Reduces the maximum sensing range between FGSS & FGSE by 0.5 meters (1.6 ft) for each mirror. Part Number 7 7 7 7 7 7 7 7 7 7 7 020 020 020 020 020 020 020 020 020 020 020 113 115 116 117 118 119 120 121 263 264 318 Model Number PNS 120-041A PNS 120-058A PNS 120-074A PNS 120-091A PNS 120-107A PNS 120-116A PNS 120-132A PNS 120-157A PNS 120-174A PNS 120-191A MB-PN-120 For FGS models: 300 450 600 750 900 1050 1200 1350 1500 1650 or 1800 * ML 17.016 23.609 30.188 36.656 43.188 46.453 53.031 62.844 68.859 75.931 OL 17.354 23.889 30.464 37.000 43.535 46.803 53.377 63.181 69.204 75.740 CH N/A N/A N/A N/A N/A N/A 26.689 31.591 34.602 37.870

Fig. 29. Dimensions of corner mirrors and mounting bracket (mm).

*Mounting kit for PNS Mirrors. Each kit contains 1 bracket with fasteners. Order 2 kits with each mirror.

25

ACCESSORIES

Fig. 30. Mounting Stands.

9.6

Mounting Stands Stands are of varying heights with mounting holes in increments of 25.4 mm (1 in) for a variety mounting positions. The mounting stands are made of heavy gauge steel, with welded construction and paint protection.

Mounting stands are used with light curtains or PNS corner mirrors when direct mounting on the safeguarded machine is not possible. The stands have a steel base with 4 holes for securing them to the floor.

Mounting Stands 34 in 7 020 51 in 7 020 63 in 7 020 72 in 7 020

258 259 260 261

26

DIAGNOSTICS

10

10.1

Troubleshooting

Troubleshooting can be done through the use of the LED indicators positioned on both the sender and the receiver. Fig. 31 shows the function of the indicator LEDs on the FGS.

10.2

Diagnostic Table
Appearance

Fig. 31. The LEDs on the sender and receiver of the FGS.

Identification supply voltage sender not emitting infrared light sender is emitting infrared light supply voltage obstruction sender test input open or sender not emitting infrared light system out of alignment dirt build-up sender or receiver sender or alignment receiver

Action/Checks -supply voltage and wire connections -replace sender control board or sender -test input open, check wires 3 & 4 on sender -replace sender control board or sender -sender is transmitting -supply voltage and wire connections -replace receiver control board or receiver -look for any objects protruding into protective field -restart required -test input open, check wires 3 & 4 on sender -replace sender control board or sender -adjust both curtains side to side -make sure curtains are plum and at the same level -clean exit windows -alignment -test input open, check wires 3 & 4 on sender -alignment -replace sender control board or sender -alignment -test input open, check wires 3 & 4 on sender -replace receiver control board or receiver -check for proper power by verifying proper DC input voltage -verify there is no AC or DC voltage between 0V and PE -verify OSSD's are not shorted to each other, 24VDC or 0V -replace receiver control board or receiver -light curtains synchronized with no obstruction

Sender

Receiver

amber LED off yellow LED off amber LED on yellow LED off amber LED on yellow LED on no LED lights red LED on red LED on without beam break

weak signal indicator, amber LED, is permanently lit red LED on amber LED, two blinks and a pause red LED on amber LED, three blinks and a pause 2 or more LEDs are blinking constantly

system in "lookout"

green LED is on

system okay

27

Industrial Sensors

Safety Systems

Automatic Identification

SICK is one of the worlds leading manufacturers of safety systems, sensors, and automatic identification products for industrial applications. SICK holds more than 350 patents for its innovative products. Through its Industrial Sensors, Safety Systems, Automatic Identification, and Environmental and Process Analysis divisions, the company has operations in 65 countries. SICK North America is headquartered in Minneapolis, MN. Our wide range of sensors provides solutions to suit any application in the field of automation. Even under rugged ambient conditions, objects are reliably detected, counted and positioned regardless of their form, location and surface finish.

Products from SICK provide comprehensive safeguarding of both workers and machinery. As specialists in sensor technology, SICK develops and manufactures pioneering products that provide protection in hazardous zones, dangerous locations and for safeguarding access points. By providing services, which encompass all aspects of machine safety and security, SICK is setting new standards in safety technology. Whether the tasks involve identification, handling, classification or volume measurement, innovative automatic identification systems and laser measuring systems from SICK function reliably, even under rapid cycle times. Products from SICK conform to the latest standards and can be easily integrated in all industrial environments and external applications.

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Branch offices and representatives in all major industrial countries.