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SOLID-4

Safety Light Curtain

604041-2011/02

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C O N N E C T I N G A N D O P E R AT I N G I N S T R U C T I O N S

O r i g i n a l I n s t r u c t i o n s

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2 SOLID-4 Leuze electronic

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Notes on Connecting and Operating Instructions

This connecting and operating instructions manual contains information on the proper use ofSOLID-4 Safety Light Curtains in accordance with its intended purpose. It is included withdelivery.All the information contained herein, in particular the safety notes, must be carefullyobserved.This connecting and operating instructions manual must be stored carefully. It must beavailable for the entire operating time of the optical safety device.

Notes regarding safety and warnings are identified with the symbol.

Notes regarding important pieces of information are identified with the symbol.

Leuze electronic GmbH + Co. KG is not liable for damage resulting from improper useof its equipment. Familiarity with these instructions is an element of the knowledgerequired for proper use. Reprints and reproduction, in whole or in part, are permitted only with the explicitpermission ofLeuze electronic GmbH + Co. KG In der Braike 1 D-73277 Owen - Teck / Germany Phone+49 (0) 7021 / 573-0 Fax +49 (0) 7021 / 573-199 [email protected] www.leuze.com

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Contents

Leuze electronic SOLID-4 3

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1 General................................................................................................................................6

1.1 Certifications ........................................................................................................................61.2 Symbols and terms ........................................................................................................................7

1.3 SOLID-4 selection ................................................................................................................92 Safety ................................................................................................................................10

2.1 Approved purpose and foreseeable improper operation....................................................102.1.1 Proper use..........................................................................................................................102.1.2 Foreseeable misuse...........................................................................................................112.2 Competent personnel...................................................................................................................122.3 Responsibility for safety .....................................................................................................122.4 Exemption of liability ..........................................................................................................122.5 SOLID-4 Safety Light Curtains with a resolution of 14 mm to 40 mm..........................................13

2.6 SOLID-4 Safety Light Curtains with a resolution of 40 mm.............................................132.7 Additional safety instructions for access guarding with SOLID-4.......................................14

3 System setup and possible uses....................................................................................15

3.1 The opto-electronic protective device ................................................................................153.2 Cascading option .........................................................................................................................16

4 Functions ..........................................................................................................................18

4.1 Selectable functions of the SD4T Transmitter....................................................................184.1.1 Transmission channel ........................................................................................................184.2 Selectable functions of the SD4R-E Receiver....................................................................184.2.1 Transmission channel ........................................................................................................184.2.2 Start/restart interlock (RES) ...............................................................................................194.2.3 Contactor monitoring (EDM) ..............................................................................................204.3 Functions of receiver SD4R...............................................................................................214.4 Diagnostics function: Dirt and error signal output ..............................................................214.5 Test input ...........................................................................................................................21

5 Display elements..............................................................................................................22

5.1 SD4T Transmitter status displays ......................................................................................225.2 SD4R-E Receiver status displays ................................................................................................235.2.1 7-segment displays ............................................................................................................235.2.2 LED displays ......................................................................................................................245.3 SD4R Receiver status displays..........................................................................................245.3.1 7-segment display ..............................................................................................................255.3.2 LED displays ......................................................................................................................25

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6 Installation........................................................................................................................ 26

6.1 Calculating minimum distances ......................................................................................... 266.1.1 Safety distance for point of operation guarding ................................................................. 26

6.1.2 Safety distance for danger zone guarding ......................................................................... 286.1.3 Safety distance and beam heights for Safety Light Curtains as access guarding ............. 306.1.4 Minimum distance from reflective surfaces........................................................................ 326.2 Mounting notes .................................................................................................................. 336.3 Mechanical mounting......................................................................................................... 346.4 Mounting types ............................................................................................................................356.4.1 Standard mounting............................................................................................................. 356.4.2 Option: Mounting with swiveling brackets.......................................................................... 356.4.3 Option: Side mounting ....................................................................................................... 36

7 Electrical connection....................................................................................................... 377.1 M12 coupling...................................................................................................................... 377.1.1 Transmitter......................................................................................................................... 377.1.2 Receiver SD4R-E............................................................................................................... 387.1.3 Receiver SD4R.................................................................................................................. 417.2 Connection examples ........................................................................................................ 427.2.1 Connection example for transmission channel 1(TC1)...................................................... 427.2.2 Connection example for transmission channel 2 (TC2)..................................................... 437.2.3 SOLID-4 connection example with downstream relay module, MSI-RM2 ......................... 44

7.2.4 Connection example of SOLID-4 with downstream MSI-SR4 Safety Interface Device ..... 458 Startup .............................................................................................................................. 46

8.1 Switching on....................................................................................................................... 468.1.1 Display sequence with SD4T Transmitter.......................................................................... 468.1.2 Display sequence with SD4R-E Receiver.......................................................................... 478.1.3 Display sequence on receiver SD4R ................................................................................. 488.2 Aligning transmitter and receiver ....................................................................................... 488.2.1 Optimizing alignment by turning and/or tilting the transmitter and receiver ....................... 48

9 Testing .............................................................................................................................. 499.1 Testing before first startup ................................................................................................. 499.2 Regular tests...................................................................................................................... 499.3 Daily testing with the test rod............................................................................................. 499.4 Cleaning the front screens........................................................................................................... 51

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10 Troubleshooting...............................................................................................................52

10.1 What do I do if an error occurs?......................................................................................... 5210.2 Diagnostics......................................................................................................................... 52

10.2.1 SD4T Transmitter diagnostic..............................................................................................5210.2.2 SD4R-E Receiver diagnostics............................................................................................5210.3 AutoReset ....................................................................................................................................54

11 Technical data ..................................................................................................................55

11.1 General data ......................................................................................................................5511.1.1 Protective field data............................................................................................................5511.1.2 Safety-relevant technical data............................................................................................5511.1.3 General system data..........................................................................................................5511.1.4 SD4T Transmitter signal input............................................................................................56

11.1.5 SD4R-E Receiver signal inputs/outputs .............................................................................5611.1.6 Safety-related transistor outputs ........................................................................................5711.2 Safety Light Curtain/host dimensions, weights, response times ..................................................5811.3 Safety Light Curtain/guest dimensions, weights, response times......................................5911.4 Number of beams for host / guest devices.........................................................................5911.5 Bracket dimensions............................................................................................................61

12 Appendix...........................................................................................................................63

12.1 SOLID-4 scope of delivery .................................................................................................63

12.2 SOLID-4 ordering information ............................................................................................6312.2.1 SOLID-4E Host ordering information .................................................................................6512.2.2 SOLID-4 Guest ordering information..................................................................................6612.3 SOLID-4 accessories ordering information ..................................................................................6712.4 Checklists........................................................................................................................... 6912.4.1 Checklist for point of operation guarding............................................................................7012.4.2 Checklist for danger zone guarding ...................................................................................7112.4.3 Checklist for access guarding ............................................................................................7212.5 EC Declaration of Conformity.......................................................................................................73

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General


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1 GeneralSOLID-4 Safety Light Curtains are type 4 Active Opto-electronic Protective Devices (ActiveOpto-electronic P rotective Devices, AOPDs) in accordance with EN IEC 61496-1 andprEN/IEC 61496-2.All SOLID-4 Safety Light Curtains with a type SD4R-E Receiver have start/restart interlockand contactor monitoring function that can be selected and deselected, as well as displayelements (LEDs and 7-segment) for convenient startup and diagnostics.The SOLID-4 series is equipped with 2 OSSDs (transistor safety-related switching outputs)with M12 connection system as standard features.To provide the best possible solutions for specific applications, SOLID-4 series devices areavailable in various resolutions and protective field heights.

1.1 Certifications

Company

Leuze electronic GmbH + Co. KG in D-73277 Owen - Teck, Germany, has a certifiedquality assurance system in compliance with ISO 9001.

Products

SOLID-4 Safety Light Curtains are developed and manufactured in compliance withapplicable European directives and standards.EC Prototype Test in accordance with EN IEC 61496-1 and prEN IEC 61496-2carried out by: TV PRODUCT SERVICE GmbH, IQSE

Ridlerstrasse 65

D-80339 Munich

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1.2 Symbols and terms

Symbols used

Table 1.2-1: Symbols

Warning sign This symbol indicates possible dangers.Please pay especially close attention to these instructions!

Sign indicating important information.

A note, which also refers to a course of action, provides informa-tion about special attributes or describes setting procedures.Symbols for SOLID-4 TransmitterGeneral transmitter symbol

Transmitter not activeTransmitter active

Symbols for SOLID-4 ReceiverGeneral receiver symbolThe receivers active protective field is not free, outputs inOFF-stateThe receivers active protective field is free. Outputs in ON-stateThe receivers active protective field is free. Outputs in OFF-state

Signal outputSignal input

Signal input and/or output

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Terms used in this manual

Table 1.2-2: Terms/terminology, SOLID-4 Safety Light Curtains

Access guarding Detection of a persons body on entry into the danger zone isrequired.

AOPD Active Opto-electronicP rotective DeviceAOPD response time Time between penetration/entry into the active protective field of

the AOPD and when the OSSDs actually switch off.AutoReset When an error indication occurs, caused, for example, by faulty

external wiring, the AOPD attempts to start again. If the error nolonger exists, the AOPD returns to the normal state.

Contactor monitoring(EDM)

The contactor monitoring monitors the normally closed contactsof downstream positive-guided contactors and relays.

Danger zone guarding Requires detection in the foot/leg area

EDM External Device MonitoringFC Feedback circuit for EDMOSSD1OSSD2

Safety-related switching outputOutput S ignal S witchingDevice

Point of operationguarding

Requires finger, hand or arm detection

RES Start/REStart interlock.Scan All beams, beginning with the synchronization beam, are pulsed

by the transmitter in cycles one after the other.SD4 SOLID-4 consisting of transmitter and receiverSD4R SOLID-4 ReceiverSD4R-E SOLID-4 Receiver with selectable start/restart interlock and con-

tactor monitoring function (EDM)SD4T SOLID-4 TransmitterSingleScan A switch-off is made if a beam is interrupted in the first scan of the

Light Curtain.SOLID-4E SOLID-4 consisting of SD4T Transmitter and SD4R-E Receiver

Start/ restart interlock(RES)

RES prevents automatic start after the supply voltage has beenturned on and after the protective field has been penetrated/ entered.

TC1/TC2 Transmission channel 1 and transmission channel 2

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1.3 SOLID-4 selection

SD4trr-hhhhvk

SOLID-4

t - Type of deviceT: TransmitterR: Receiver

rr - Resolution/range

14: 14 mm / 0.3 6 m20: 20 mm / 0.7 14 m30: 30 mm / 0.5 9 m

40: 40 mm / 0.9 20 m90: 90 mm / 0.9 20 m

hhhh Protective field heights

150 ... 1,800 mm

v Functions (only with receiver)

E: With selectable start/restart interlock and monitoring

function

k Version/mode (only available with function "E")lWithout H G L U

Standard model Host Guest L-Shape U-Shape

Fig. 1.3-1: Selecting a SOLID-4 Safety Light Curtain

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2 SafetyBefore using the safety sensor, a risk evaluation must be performed according to validstandards (e.g. EN ISO 14121, EN ISO 12100-1, ISO 13849-1, IEC 61508, EN 62061).The result of the risk assessment determines the required safety level of the safety sensor(see Table 2.1-1). For mounting, operating and testing, document "SOLID-4 Safety LightCurtain" as well as all applicable national and international standards, regulations, rulesand directives must be observed. Relevant and supplied documents must be observed,printed out and handed to the affected personnel.Before working with the safety sensor, completely read and understand the documentsapplicable to your task.In particular, the following national and international legal regulations apply for the start-up,technical inspections and work with safety sensors: Machinery directive 2006/42/EC Low voltage directive 2006/95/EC

Electromagnetic compatibility directive 2004/108/EC Use of Work Equipment Directive 89/655/EEC supplemented by Directive 95/63 EC OSHA 1910 Subpart 0 Safety regulations Accident-prevention regulations and safety rules Ordinance on Industrial Safety and Health and Labor Protection Act Device Safety Act

Notice! For safety-related information you may also contact the local authorities (e.g., industrialinspectorate, employer's liability insurance association, labor inspectorate, occupationalsafety and health authority).

2.1 Approved purpose and foreseeable improper operation

Warning! A running machine can cause severe injuries! Make certain that, during all conversions, maintenance work and inspections, the system issecurely shut down and protected against being restarted again.

2.1.1 Proper useThe safety sensor must only be used after it has been selected in accordance with therespectively applicable instructions and relevant standards, rules and regulations regardinglabor protection and occupational safety, and after it has been installed on the machine,connected, commissioned, and checked by a competent person.When selecting the safety sensor it must be ensured that its safety-related capability meetsor exceeds the required performance level PLr ascertained in the risk assessment.
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The following table shows the safety-related characteristic parameters of the SOLID-4Safety Light Curtain.

Table 2.1-1: Safety-related characteristic parameters of the SOLID-4 Safety LightCurtain

The safety sensor protects persons at access points or at points of operation ofmachines and plants.

The safety sensor with vertical mounting detects the penetration by fingers and hands atpoints of operation or by the body at access points.

The safety sensor only detects persons upon entry to the danger zone; it does not detectpersons who are located within the danger zone. For this reason, a start/restart interlockis mandatory.

The safety sensor with horizontal mounting detects persons who are located within thedanger zone (presence detection).

The construction of the safety sensor must not be altered. When manipulating the safetysensor, the protective function is no longer guaranteed. Manipulating the safety sensoralso voids all warranty claims against the manufacturer of the safety sensor.

The safety sensor must be tested regularly by competent personnel. The safety sensor must be exchanged after a maximum of 20 years. Repairs or the

exchange of parts subject to wear and tear do not extend the service life.

2.1.2 Foreseeable misuse

In principle, the safety sensor is not suitable as a protective device in case of: danger of objects being expelled or hot or dangerous liquids spurting from the danger

zone applications in explosive or easily flammable atmospheres

Type in accordance with IEC/EN 61496 Type 4

SIL in accordance with IEC 61508 SIL 3

SILCL in accordance with IEC/EN 62061 SILCL 3

Performance Level (PL) in accordance with ISO 13849-1: 2008 PL e

Category in accordance with ISO 13849 Cat. 4

Average probability of a failure to danger per hour (PFHd)For protective field heights up to 900 mm, all resolutionsFor protective field heights up to 1800 mm, all resolutions For protective field heights up to 2850 mm, all resolutions

6.0 x 10-9 1 / h7.3 x 10-9 1 / h

On request

Service life (TM) 20 years

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2.2 Competent personnelPrerequisites for competent personnel: he has a suitable technical education

he knows the rules and regulations for occupational safety, safety at work and safetytechnology and can assess the safety of the machine he knows the instructions for the safety sensor and the machine he has been instructed by the responsible person on the mounting and operation of the

machine and of the safety sensor

2.3 Responsibility for safetyManufacturer and operating company must ensure that the machine and implementedsafety sensor function properly and that all affected persons are adequately informed andtrained.The type and content of all imparted information must not lead to unsafe actions by users.

The manufacturer of the machine is responsible for: safe machine construction safe implementation of the safety sensor imparting all relevant information to the operating company adhering to all regulations and directives for the safe starting-up of the machine

The operator of the machine is responsible for: instructing the operating personnel maintaining the safe operation of the machine adhering to all regulations and directives for occupational safety and safety at work regular testing by competent personnel

2.4 Exemption of liabilityLeuze electronic GmbH + Co. KG is not liable in the following cases: safety sensor is not used as intended safety notices are not adhered to reasonably foreseeable misuse is not taken into account mounting and electrical connection are not properly performed proper function is not tested (see Chapter 9). changes (e.g., constructional) are made to the safety sensor

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2.5 SOLID-4 Safety Light Curtains with a resolution of 14 mm to 40 mmare used for point of operation guarding, preferably in a vertical position.(See Fig. 6.1-1). Depending on the resolution selected, they can detect:

Warning! Safety Light Curtains with > 40 mm resolution are not suitable for protection of points ofoperation for which finger, hand or arm resolution is required.

2.6 SOLID-4 Safety Light Curtains with a resolution of 40 mm

are preferably used for danger zone guarding (see Fig. 6.1-2). Predominantly in ahorizontal position, the presence of people within the protective field is continuouslymonitored.

Note! As an alternative to horizontal installation of Safety Light Curtains for danger zoneguarding, a Safety Laser Scanner with configurable protective field can be used if safetycategory 3/PL d acc. to ISO 13849 is sufficient (information on ROTOSCAN Safety LaserScanners can be obtained via our branch offices and partners or at www.leuze.de).

Device type Resolution Detection withpersons age14 and over

Range Preferred area ofapplication

SD4T 14-.. /SD4R 14-..

14 mm Finger 0.3 to 6 m Point of operationguarding

SD4T 20-.. /SD4R 20-..

20 mm Hand 0.7 to 14 m Point of operationguarding

SD4T 30-.. /SD4R 30-..

30 mm Hand 0.5 to 9 m Point of operationguarding

SD4T 40-.. /SD4R 40-..

40 mm Arm 0.9 to 20 m Point of operationguarding

Table 2.5-1: SOLID-4 Safety Light Curtains for point of operation guarding

Device type Resolution Detection withpersons age14 and over

Range Preferred area ofapplication

SD4T 40-.. /SD4R 40-..

40 mm From the feetupwards

0.9 to 20 m Danger zoneguarding

SD4T 90-.. /SD4R 90-..

90 mm From the thighupwards

0.9 to 20 m Danger zoneguarding

Table 2.6-1: SOLID-4 Safety Light Curtains for danger zone guarding

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2.7 Additional safety instructions for access guarding with SOLID-4

Warning! SOLID-4 Safety Light Curtains with a resolution of 14, 20, 30 or 40 mm detect hands, armsor bodies of a person entering the danger zone, and therefore can be placed closer to thedanger zone than Safety Light Curtains with a resolution of 90 mm. In this case, the heightof the highest and lowest beam above the reference plane must be selected in accordancewith EN ISO 3857.

It applies for all versions that people are only detected during the access, their presence inthe danger zone, however, is not detected! When one or more beams are interrupted by aperson, the machine control unit must therefore go into safe interlock.The start/restart interlock function is therefore obligatory for access guarding! The start/ restart button for unlocking the device must be mounted in such a way that it cannot bereached from inside the danger zone and the entire danger zone is fully visible from its

installation position. For this, see alsoChapter 6.1.3.

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3 System setup and possible uses

3.1 The opto-electronic protective device

Mode of operationSOLID-4 consists of an SD4T transmitter and an SD4R receiver. Beginning with the firstbeam (the synchronizing beam) directly after the display panel, the transmitter pulsesbeam for beam in rapid sequence. The synchronization between transmitter and receiver isperformed optically.

The SD4R receiver recognizes the specially formed pulse bundles of the transmitter beams

and opens the corresponding receiver elements in sequence in the same rhythm. Aprotective field is consequently formed in the area between the transmitter and receiver,the height of which depends on the geometrical dimensions of the optical protective device,the width of which depends on the distance selected between the transmitter and receiverwithin the permissible range.Basic functions, such as start/restart interlock and/or contactor monitoring, can optionallybe performed by the electronics of receiver model SD4R-E. As a result, no downstreamSafety Interface Device is generally necessary if receiver model SD4R-E is chosen.

a = Transmitterb = Receiver

Fig. 3.1-1: Working principle of the opto-electronic protective device

a

b

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3.2 Cascading optionTo implement multiple linked protective fields, SOLID-4E Safety Light Curtains can beswitched one after the other by cascading via plug-in cable connections or as fixed-connected L or U-shapes.

Cascading devices makes it possible to implement adjacent protective fields, for rear areaprotection without any additional expense for control and connection, for example. The hostsystem is responsible here for all processor tasks, displays and the receiver-side interfacesto the machine and control devices.

a = SDT transmitter, host (H)b = SDT transmitter, guest (G)

c = SDR receiver, host (H)d = SDR receiver, guest (G)

Fig. 3.2-1: Cascaded system setup with cable connection

a = SDT transmitter, host (H)b = SDT transmitter, guest (G)

c = SDR receiver, host (H)d = SDR receiver, guest (G)e = Optional guest for U-shape

Fig. 3.2-2: Cascaded system setup as fixed-connected L or U-shape

ca

b d

ca

b d

e

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The following limits must be observed: The height of the protective field for the first Light Curtain (host) must be at least 225mm. Ensure that the required range of the cascaded system is within the maximum range of

all individual components.

The maximum number of beams of all components must not exceed 240. For the numberof beams n, for the individual components, please refer to the tables inChapter 11. The connection cables between the individual components are part of the guest. The

standard length is 300 mm. The connection to the host is made with an M12 plug.An additional terminating plug must be used to be able to operate a host-guest withoutconnected guest (see Chapter 12.3).

Note! With cascaded devices the response time of the entire system is always produced by theresponse time of the individual devices used.

Warning! With fixed-connected L and U-shapes, the resolution at the point of intersection can begreater than the resolution of the individual devices used (see L and U-Shape datasheet).

Devices with different resolutions can be combined for the variant with connection cable.Only devices with the same resolution can be combined for the variant with fixed-connected L and U-shape. All cascadable devices are only available as extended versionwith integrated start/restart interlock, contactor monitoring and reversible transmissionchannels.

Warning!

The safety distance must be calculated in accordance with the set resolution and theresponse time of the entire system (see Chapter 6 ).

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4 Functions

4.1 Selectable functions of the SD4T Transmitter

4.1.1 Transmission channel

The infrared beams are modulated with specially shaped pulse bundles so that they aredistinct from ambient light and undisturbed operation is consequently ensured. Weldingsparks or warning flash lights from passing forklifts do not having any effect on theprotective field.If two protective fields are located directly next to each other for two adjacent machines,measures must, however, be implemented so that the optical protective devices do notaffect each other.Both transmitters should first be set up "back to back" so that the beams run in oppositedirections. It is consequently impossible for them to affect each other.Another possible way to suppress mutual influences is to switch one of the two protectivedevices from transmission channel 1 to 2, thereby switching them to differently formedpulse bundles. This solution should be considered when more than two optical protectivedevices must be arranged next to each other.

The change from transmission channel 1 to 2 must be made both on the transmitter andthe receiver of the optical protective device in question. You will find more detailedinformation inChapter 7.

4.2 Selectable functions of the SD4R-E Receiver

4.2.1 Transmission channel

If the corresponding transmitter is switched to transmission channel 2, the receiver mustalso be set to transmission channel 2. For this, see also Chapter 7.

a = AOPD "A" transmission channel 1b = AOPD "B" transmission channel 2, not affected by AOPD "A"

Fig. 4.1-1: Transmission channel selection

a

b

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4.2.2 Start/restart interlock (RES)

The start/restart interlock function prevents the safety circuits from being releasedautomatically when the machine is turned on or the power supply is restored after a poweroutage. Only by pressing and releasing the start button within a time window is the receiverswitched to the ON-state.

If the protective field is penetrated, the start/restart interlock function ensures that thereceiver will remain in the OFF state after the protective field is released again. Thereceiver will then not be switched back to the ON state until the start button is pressed andreleased again within a time window of 0.3 to 4 seconds.

Note! The start button may not be pressed for longer than 10 seconds. An error messageappears if this is exceeded.

Warning! Without the start/restart interlock, the receiver outputs immediately switch to the ON stateafter the machine has been turned on or the power supply has been restored and after theprotective field has been freed! The operation of the protective device without start/restartinterlock is only permitted in a few exceptional cases and under the conditions of controllingprotective devices in accordance with EN ISO 12100-1 and EN ISO 12100-2. It must inparticular be ensured here that it is impossible to walk or slip through the protective field.

In the case of access guarding applications, the start/restart interlock function is obligatorydue to the fact that only access, and NOT the area between the protective field and thepoints of operation is monitored.

Warning! Before unlocking the start/restart interlock, the operator must be absolutely certain thatnobody is inside the danger zone.

Fig. 4.2-1: Start/restart interlock function in effect when the supply voltage is turnedon

Fig. 4.2-2: Start/restart interlock function after interrupting the protective field

0

I

0

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Activate the start/restart interlock: with corresponding connection of the SOLID-4E receiver (seeChapter 7) or in the downstream safety interface (e.g. MSI series also for Leuze electronic muting or

control functions) or in the downstream machine control unit or in the downstream safety PLCIf the internal start/restart interlock is activated as described in Chapter 7, the interlockfunctions are monitored dynamically. The SD4R-E receiver is only switched back to theON-state after the start button has been pressed and released again. A further preconditionhere is, of course, that the active protective field is free.If both the SOLID-4E-internal and a subsequent start/restart interlock are activated, theSOLID-4E will only perform a reset function with its assigned start button (confirmation).

4.2.3 Contactor monitoring (EDM)

Warning! The contactor monitoring of the SOLID-4E can be activated with corresponding connection(see Chapter 7 )!

The "Contactor monitoring" function dynamically monitors contactors, relays or valvesdownstream from the SOLID-4E. Precondition here are switching elements with positive-guided feedback contacts (normally closed).

You can implement the contactor monitoring function with corresponding connection of the SOLID-4E receiver (seeChapter 7) or the external contactor monitoring of the downstream safety interface

(e.g. Leuze electronic MSI series)

or the contactor monitoring of the downstream safety PLC(optional, connected via a safety bus)

If the contactor monitoring function is activated (seeChapter 7), it works dynamically, i.e. inaddition to verifying that the feedback circuit is closed before turning on the OSSDs, thesystem checks whether the feedback circuit has opened within 500 ms of being enabledand whether it has closed again within 500 ms when turning off the OSSDs. If this is not thecase, the OSSDs return to the OFF state again after being briefly switched on. An errorcode appears on the 7 segment display (F34) and the receiver goes to the error lockingstatus, from which it can only be returned to normal operation by switching the supplyvoltage off and back on again.

Fig. 4.2-3: Contactor monitoring function, combined in this example with RESinterlock

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4.3 Functions of receiver SD4RNo functions can be selected on receiver SD4R.

Attention! Without start/restart interlock, the outputs of the receiver switch to the ON state immediately after the device is switched on or after the supply voltage is restored and followingeach release of the protective field! The protective device may only be operated withoutstart/restart interlock in certain exceptional cases and under the conditions of controllingprotective devices acc. to EN ISO 12100-1, EN ISO 12100-2. In this case, care must betaken to ensure that it is impossible to step or slip past the optical protective device.

Notice! To guarantee proper operation, the transmitter that communicates with receiver SD4Rmust be set to transmission channel 1.

4.4 Diagnostics function: Dirt and error signal outputFor diagnostic purposes SOLID-4 has a short circuit-proof "Weak Beam/Error Indication"signal output for forwarding to the machine control unit. Information on connection of thesignal output and a connection example can be found in Chapter 7.

4.5 Test inputAs a type 4 AOPD, SOLID-4 has a constant self-monitoring function that independentlydetects errors in the system as well as cross and short circuits on the output cables of themachine interface. An external test signal is not required for this. To test the downstreamcontactors, an external control (e.g. protective combination) via a test signal (= pin4 of thetransmitter to 0 V or free) can switch off the OSSD outputs of the receiver and test the drop-out of the switching elements. The test time signal time is a maximum 3 seconds. After thetest the OSSDs also go to the ON-state with activated start/restart interlock, provided theprotective field is not interrupted.

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5 Display elements

5.1 SD4T Transmitter status displaysIf the transmitters green LED1 is lit, this indicates that the supply voltage is present.

Table 5.1-1: Transmitter, LED status displays

a = LED1 (green/red)b = LED2 (green/red)

Fig. 5.1-1: Transmitter status displays

Display Meaning

LED1 green LED2 off Operating voltage present, TC1 selectedLED1 green LED2 green Operating voltage present, TC2 selectedLED1 green LED2 red Operating voltage present, TC1 or TC2 selected,

external test signal activatedLED1 red LED2 any Device fault

a b

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5.2 SD4R-E Receiver status displaysTwo LEDs and one 7-segment display report the receiver's operating status.

5.2.1 7-segment displays

After the electrical supply voltage is turned on, the following data appear on the receivers7- segment display:

a = Symbol for OSSDsb = LED1 (green/red)c = Symbol for RESd = LED2, yellow

Fig. 5.2-1: SD4R-E Receiver status displays

7-segment display Meaning8. Hardware reset when turned onS Self test running (for approx. 1.5 s)1 Normal operation, channel 12 Normal operation, channel 2

F = Device faultx = Fault number, alternating with "F"

1 or 2 flashing Flashing transmission channel number Weak signal, device not

optimally aligned or dirtyTable 5.2-1: SD4R-E Receiver 7-segment display

b da c

Fx

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5.2.2 LED displays

Note! If all LED displays are in the OFF state at the same time, there is no supply voltage.

5.3 SD4R Receiver status displaysOne LED and one 7-segment display report the receiver's operating status.

LED Color Meaning

LED1 Red RED = OSSDs safety outputs in the OFF stateLED1 Green GREEN = OSSD safety outputs in the ON stateLED2 Yellow ON = Internal RES interlock activated; the OSSD safety outputs are

switched to the OFF state. If the protective field is free, the de-vice can be unlocked by pressing and releasing the start/re-start button in a time window of 300 ms to 4 s.

OFF = If the OSSDs are in ON state (LED1 = green): Internal RES isunlocked or not selected.If OSSDs are in OFF state (LED1 = red): Internal RES islocked and the protective field is not free.

Table 5.2-2: SD4R-E Receiver LED displays

a = ymbol for OSSDsb = LED1 (green/red)

Bild 5.3-1: SD4R Receiver status displays

ba

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5.3.1 7-segment display

After switching-on the supply voltage, the following data appears on the 7-segment displayof the receiver:

5.3.2 LED displays

Notice! If all LED displays are simultaneously in the OFF state, no supply voltage is present.

7-segment display Meaning8. Hardware reset at the moment of turn-onS Self test running (for approx. 1.5 sec)1 Normal operation, channel 1

F = device faultx = fault number; display alternates between this and "F"

1 or 2 flashing Flashing number of the transmission channel weak signal, de-vice not optimally aligned or dirty

Table 5.3-1: 7-segment display receiver SD4R

LED Color Meaning

LED1 red RED = OSSD safety outputs in the OFF stateLED1 green GREEN = OSSD safety outputs in the ON state

Table 5.3-2: LED displays receiver SD4R

Fx

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6 InstallationThis section contains important information on installing the SOLID-4. The SOLID-4'sprotective function is only guaranteed if the following installation specifications areobserved. These installation specifications are based on the respective applicable versionsof European standards, such as EN 999 and EN ISO 13857. If a SOLID-4 is used incountries outside of the EU, the valid requirements in those countries must also beobserved.Installation is dependent on the type of protection as described in Chapter Safety.Because of this, the situations of: Point of operation guarding Danger zone guarding Access guardingare considered separately below. The applicable distance from the protective device toreflective surfaces in the surrounding area is presented for all types of protection based on

these situations.

6.1 Calculating minimum distancesLight Curtains can only perform their protective function if they are mounted with asufficient safety distance.The calculation formulas for the safety distance depend on the type of protection. In theharmonized European standard EN 999, "Positioning of protective devices with regard toapproach speed of parts of the human body", the installation situations and calculationformulas for safety distance are described for the types of protection named above.The formulas for the required distances to reflective surfaces are based on the Europeanstandard for "Active opto-electronic protective devices" prEN IEC 61496-2.

6.1.1 Safety distance for point of operation guarding

Calculation of the safety distance for a SOLID-4 Safety Light Curtain with resolution of 14,20, 30 or 40 mm for point of operation guarding:The safety distance "S" for point of operation guarding is calculated in accordance with EN999 with the formula:

S [mm] = K [mm/s] x T [s] + C [mm]

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*) If this value cannot be achieved because of the safety distance, other measures, e.g. mechanicalbarriers, must guarantee the required maximum distance of 75 mm.

Warning! If AOPDs with additional control functions are used, the resolution must be 30 mm and theminimum distance must be S 150 mm.

S = Safety distance in mmIf the result is less than 100 mm, a distance of at least 100 mm must still be maintained.

K = Approach speed in mm/sIn the close area of 500 mm, 2,000 mm/s is used for the calculation. If the distance is great-er than 500 mm, K = 1,600 mm/s can be used for the calculation. In this case, however, aminimum of 500 mm applies for the safety distance.

T = Total delay time in seconds;total from:The response time of the protective device, tAOPD a) The response time of the safety interface, if any, tSafety interface b) The machines stopping time, tMachine c)

C = 8 x (d-14) in mmAdditional amount depending on the depth of penetration into the protective field beforeturning on the AOPD

d = Resolution of the AOPDa)b)c)

See Chapter 11.2See safety interface technical dataSee technical data of the machine or stopping time measurement

a = Safety distance (S)b = Measures to prevent penetration from abovec = Measures to prevent penetration from the sidesd = Measures to prevent penetration from the rear

e = Measures to prevent penetration from belowf = 75 mm Maximum distance to avoid walking behind*

Fig. 6.1-1: Safety distance (a) for point of operation guarding

S [mm] = 2000 [mm/s] x (tAOPD + tSafety interface + tMachine) [s] + 8 x (d-14) [mm]

f

d

b

a

e

c

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Calculation example for point of operation guarding:A Safety Light Curtain with a resolution of 20 mm, protective field height 1500 mm is usedon a machine with a stopping time of 150 ms. The response time of the safety interface is20 ms.

Warning!

Make certain during assembly that it is not possible to reach over, around or under or towalk behind the protective device.

6.1.2 Safety distance for danger zone guarding

Calculation of the safety distance and required resolution for a Safety Light Curtain fordanger zone guarding.

*) If this value cannot be achieved because of the safety distance, other measures, e.g. mechanicalbarriers, must guarantee the required maximum distance of 50 mm. From 375 mm height above thefloor 75 mm are permissible.

Stopping time of the machine tMachine = 150 msResponse time tAOPD = 25 ms

Response time tSafety interface = 20 ms

Resolution d of the AOPD = 20 mmT = 0.150 s + 0.025 s + 0.020 s = 0.195 sS = 2000 x 0.195 + 8 x (20 -14) = 438 mm

a = Safety distance (S)b = Measures to prevent access from the sidesc = Height above floord = 50 mm Maximum distance to avoid walking behind*

Fig. 6.1-2: Safety distance (a) and height (c) for danger zone guarding

a

c

d

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The height of the protective field H above the reference plane and the resolution d of theAOPD are related to each other as follows:

The safety distance "S" for danger zone guarding is calculated in accordance with EN 999using the formula:

Hmin [mm] = 15 x (d -50) [mm] or d [mm] = Hmin /15 + 50 [mm]

Hmin = Minimum height of the protective field above the reference plane,maximum height = 1000 mmHeights equal to or less than 300 mm are considered too low for adults to crawlunder

d = Resolution of the AOPD

S [mm] = K [mm/s] x T [s] + C [mm]

S = Safety distance in mmK = Approach speed of 1600 in mm/s.T = Total delay time in seconds;

total from:The response time of the protective device, tAOPD a) The response time of the safety interface, if any, tSafety interface b)

The machines stopping time, tMachine c)

C = (1200 mm 0,4 H), but not less than 850 mm (arms length)

H = Height of the protective field above the floora)b)c)

See Chapter 11.2See safety interface technical dataSee technical data of the machine or stopping time measurement

S [mm] = 1600 [mm/s] x (tAOPD+ tSafety interface + tMachine) [s] + (1200-0.4 H) [mm]

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6.1.3 Safety distance and beam heights for Safety Light Curtains as accessguarding

Determination of the beam heights and calculation of the safety distance of Safety LightCurtains with a resolution of 14, 20, 30 or 40 mm for use as access guarding, for examplewith limited space between the protective field and point of operation.

Warning!

Please also observe the additional safety instructions for access guarding with SOLID-4 inChapter 2.7 .

a = Safety distance (protective field/point of operation)b = Height of the lowest beam above the reference level, see table 6.1-1c = Height of the highest beam, see table 6.1-1d = Measures to prevent access from the sides

Fig. 6.1-3: Access guarding with Safety Light Curtain, resolution of 14, 20, 30 or40 mm

a

d

c

b

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Beam heights with use of Safety Light Curtains for access guarding in accordancewith EN 999 and EN ISO 13857:

Table 6.1-1: Beam heights above the reference plane and additional amount C foraccess guarding applications

Calculation formula for safety distance S based on EN 999:Calculation of the safety distance for a Safety Light Curtain with a resolution of up to 40mm, used for access guarding. The safety distance S is calculated as per EN 999according to the formula:

Version Resolu-tion

Lowest beam abovereference plane

Highest beam abovereference plane

Additionalamount C(see formula)

SD4-14-hhhh 14 mm As per EN ISO 13857 As per EN ISO 13857 0 mmSD4-20-hhhh 20 mm As per EN ISO 13857 As per EN ISO 13857 48 mmSD4-30-hhhh 30 mm As per EN ISO 13857 As per EN ISO 13857 128 mmSD4-40-hhhh 40 mm As per EN ISO 13857 As per EN ISO 13857 208 mmSD4-90-hhhh 90 mm 300 mm 1200 mm 850 mm

S [mm] = K [mm/s] x T [s] + C [mm]

S = Safety distance in mmK = Approach speed in mm/s

In the close area of 500 mm, 2,000 mm/s is used for the calculation. If the dis-tance is greater than 500 mm, K = 1,600 mm/ s can be used for the calculation.In this case, however, a minimum of 500 mm applies for the safety distance.

T = Total delay time in seconds;total from:The response time of the protective device, tAOPD a) The response time of the safety interface, if any, tSafety interface b) The machines stopping time, tMachine c)

C = 8 x (d-14) in mmAdditional amount depending on the depth of penetration into the protective field

before turning on the AOPDd = Resolution of AOPD up to a maximum of 40 mma) See Chapter 11.2b) See technical data of the safety interfacec) See technical data of the machine or stopping time measurement

S [mm] = 2000 [mm/s] x (tAOPD + tSafety interface + tMachine) [s] + 8 x (d-14) [mm]

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If the resolution is greater than 40 mm, for example for SOLID-4 Safety Light Curtains witha resolution of 90 mm, an additional amount is required:

The safety distance with 90 mm is therefore calculated according to the following formula:

Warning! Please also observe the additional safety instructions for access guarding with SOLID-4 inChapter 2.7 .

Warning! When using access guarding, it must be ensured that the start/restart interlock function isactive and that unlocking from inside the danger zone is not possible.

6.1.4 Minimum distance from reflective surfaces

Warning! Reflective surfaces near optical protective devices can indirectly deflect the transmitter'sbeams into the receiver. This can cause an object in the protective field not to be detected!Therefore, all reflective surfaces and objects (material containers, cans, etc.) must be keptat a minimum distance from the protective field. The minimum distance depends on thedistance "b" between the transmitter and the receiver.

With the calculation of the minimum distance to reflective surfaces it must be ensured thatwith a protective field width of 3 m or less, at least a minimum distance of 131 mm isachieved. With protective field widths over 3 m the minimum distance "a" is calculatedusing the following formula:

C = 850 mm (arms length)

S [mm] = 1600 [mm/s] x (tAOPD + tSafety interface + tMachine) [s] +850 [mm]

a = Distanceb = Protective field widthc = Reflective surface

Fig. 6.1-4: Minimum distances from reflective surfaces

a [m] = 0.044 x b [m]

a

c

b

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6.2 Mounting notes

Special notes on mounting a SOLID-4 Safety Light Curtain forpoint of operationguarding : Calculate the safety distance according to the formula inChapter 6.1.1. Ensure that it is impossible to reach under, over, around or walk behind the Safety Light

Curtain. Observe the maximum distance between machine table and protective field of 75 mm,

with reference to a table height of 750 mm. If this is not possible because the safetydistance is too big, a mechanical barrier must be provided.

Observe the minimum required distance to reflective surfaces.

a = Distance [mm]b = Protective field width [m]

Fig. 6.1-5: Minimum distances from reflective surfaces as a function of the width ofthe protective field

3

b

a

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Special notes on mounting a SOLID-4 Safety Light Curtain fordanger zone guarding : Calculate the safety distance according to the formula in Chapter 6.1.2. The resolution

determines the minimum height of the protective field above the floor. Ensure that the maximum height of the protective field above the reference plane of

1000 mm is not exceeded and only heights equal to or less than 300 mm are consideredimpossible for an adult to crawl under (also see EN 999). It must not be possible to step into the danger zone from the sides. Suitable hard guards

must be provided. When mounting the device, ensure that it is impossible to pass onto the housings of the

optical components (thereby allowing entrance into the danger zone).

Note! Positioning behind corresponding cutouts on the hard guards on the sides preventsstepping onto transmitter or receiver housings.

Consider the position of the last light beam before the machine. It must not be possible tostand undetected between this light beam and the machine.Special notes on mounting a SOLID-4 Safety Light Curtain foraccess guarding : Calculate the safety distance according to the formula inChapter 6.1.3. The highest and the lowest light beam and therefore the height of the protective field for

Safety Light Curtains with a resolution of 14, 20, 30 or 40 mm is determined by therequirements in acc. with EN ISO 13857.

Access guarding may only be operated with the start/restart interlock function. Activatethe internal RES interlock function of the SD4R-E or the RES interlock function of thedownstream interface and check their effectiveness.

Ensure while installing the start/restart button, that it is impossible to press this buttonfrom inside the danger zone. Make sure that the complete danger zone can be seen fromthe location of the button.

6.3 Mechanical mountingWhat should generally be taken into consideration during installation? Ensure that transmitter and receiver are mounted on an even surface at the same height. Use screws for mounting that can only be loosened with a tool. Fix the transmitter and receiver in position so that they cannot be shifted. Securing

transmitter and receiver so they cannot be moved or swiveled is especially important in

the close area with a narrow protective field. The connections of transmitter and receiver must be pointing in the same direction. The safety distance between the protective field and the point of operation must be

observed. Ensure that access to the point of operation/danger zone is only possible through the

protective field. Additional access points must be guarded separately (e.g. by hardguards, additional Light Curtains or doors with locking devices).

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6.4 Mounting types

6.4.1 Standard mounting

Four brackets that can rotate 360 (two each for transmitter and receiver) are included withdelivery.

6.4.2 Option: Mounting with swiveling brackets

Four swivel mounting brackets with shock absorbers can be ordered optionally. They arenot included with delivery. The swivel range is 8.

Fig. 6.4-1: 360 rotation bracket, mounting examples

Fig. 6.4-2: Swiveling bracket with shock absorber

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6.4.3 Option: Side mounting

Mounting is optionally possible with mounting brackets with sliding nuts on the side slot.They are not included with delivery.

L-mounting bracket Z-mounting bracket

Fig. 6.4-3: Mounting examples, L-mounting bracket and Z-mounting bracket

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7 Electrical connection The electrical connection must be performed by experienced personnel. Knowledge of all

safety notes contained in these operating instructions is part of this competence.

The external supply voltage of 24 V DC +/- 20% must guarantee safe isolation from themains voltage in accordance with IEC 60742 and be able to bridge a power outageperiod of at least 20 ms. Leuze electronic offers suitable power supplies (see list ofaccessories in the Appendix Chapter 12). Transmitters and receivers must be suppliedfrom a shared power supply and must be fused against overcurrent (see Chapter 7.2).

Basically both safety switching outputs OSSD1 and OSSD2 must be looped into theworking circuit of the machine.

Signal outputs may not be used for switching safety-relevant signals. The start/restart button for unlocking the restart interlock must be mounted in such a way

that it cannot be reached from the danger zone and the entire danger zone is fully visiblefrom its installation position.

It is vital during the electrical installation that the power of the machine or system to beprotected is switched off and locked, so that the dangerous movements cannot bestarted unintentionally.

7.1 M12 couplingTransmitter and receiver are equipped with an M12 coupling; the transmitter with a 5-pinM12 coupling and the receiver with an 8-pin M12 coupling.

Warning! To ensure safe operation of the SOLID-4, only the connecting cables listed in

Chapter 12.3 Accessories may be used.

7.1.1 Transmitter

Fig. 7.1-1: SD4T 5-pin (view of the pins)

FE

2

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7.1.2.1 Transmission channel selectionThe polarity of the power supply from Pin2 and Pin7 determines the selected opticaltransmission channel.If 24 V DC is present on Pin2 and 0 V on Pin3, transmission channel 1 is selected. If 0 V is

present on Pin2 and 24 V DC on Pin7, transmission channel 2 is selected.Note! Make sure that you select the same transmission channel for both transmitter and receiver.

For optimum shielding, connecting cables with which the shield is routed on the knurled nutof the housing coupling must be used (suitable cables are listed under accessories inChapter 12.4).

Pin Color Assignment Function

1 White Input:Start/restart

Signal output:Weak signal/ error

Start/restart normally open contactsagainst 24 V DCWeak signal/error:24 V DC light reception, strong,0 V light reception weak or error

2 Brown Supply voltage 24 V DC for TC 1 and 0 V for TC 2

3 Green Input:Operatingmode/feedbackcircuit, EDM

Contactor monitoring (EDM):24 V DC: Without EDM0 V: With EDM and FC closedHigh impedance: With EDM and FC open

4 Yellow Input:Operating mode

Start/restart interlock(RES):

24 V DC: With RESJumper to Pin1: Without RES (note: signaloutput remains functional)

5 Gray Output OSSD1, transistor switching output

6 Pink Output OSSD2, transistor switching output

7 Blue Supply voltage 0 V for TC 1 and 24 V DC for TC 2

8 Red Device internallywired onhousing

Functional earth

Mountingplug housing Braidedshield Shield Functional earth

Table 7.1-2: SD4R-E Receiver connection assignment

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7.1.2.2 Operating mode selection, start/restart interlock (RES) and contactormonitoring (EDM).

The SD4R-E Receiver must be connected via an 8-pin M12 coupling. The RES/EDMfunctions can be activated via the operating mode selections, Pin3 and Pin4.

Warning! The operating mode switchover must only be made in the switched-off state. Operatingmode switchovers (RES/EDM) during operation cause a fault (F32/F33), which can only beremoved by interrupting the voltage supply.

Table 7.1-3: SOLID-4 SD4R-E Receiver operating mode selection

Without EDMWithout RES

Without EDMWith RES

With EDMWithout RES

With EDMWith RES

Pin3 24 V DC 24 V DC 0 V via closed feed-back circuit

0 V via closed feed-back circuit

Pin4 Jumper to Pin1 24 V DC Jumper to Pin1 24 V DC

Note onPin1

Signal output,weak signal/error

Start button, nor-mally open con-tact to 24 V DCand signal output,weak signal/error

Signal output, weaksignal/error

Start button, nor-mally open contactto 24 V DC andsignal output,weak signal/error

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7.1.3 Receiver SD4R

Notice! When using an SD4R receiver, make certain to select transmission channel 1 on thecorresponding transmitter.

For the best-possible shielding, use connecting cables on which the shield extends to theknurled nut of the housing coupling (suitable cables are listed under accessories,Chapter 12.4).

Fig. 7.1-3: SD4R 5-pin (view of the pins)

Pin Color Assignment Function

1 Brown Supply voltage 24 V DC

2 White Output OSSD1, transistor switching output3 Blue Supply voltage 0 V

4 Black Output OSSD2, transistor switching output

5 Gray Device internallywired onhousing

Functional earth

Mountingplug housing

Braidedshield

Shield Functional earth

Table 7.1-4: SD4R Receiver connection assignment

FE

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7.2 Connection examples

7.2.1 Connection example for transmission channel 1(TC1)

a = EDM feedback circuitb = Positive-driven relays, spark suppression is pro-

vided by the receiver

c = Release circuit, 2-channel*

d = Release circuit, 1-channel*e = External testing selectedf = Polarity for transmission channel 1

g = Start/restart buttonh = 2 A fine-wire fuse, melting fuse*) Always use both of the contacts in the release circuit; protect against overcurrent.

Fig. 7.2-1: SD4R-E Receiver, TC 1, with RES, with EDM

1 2 3 4 51 2 34 5

k1

k2

SOLID-4SD4R-E

SOLID-4SD4T

K1 K2

+24 V DCGND

FE

nc

F

6 78 k1k2 k1k2

ef

h

g

f f

a b

dc

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7.2.2 Connection example for transmission channel 2 (TC2)

When selecting TC 2, the polarity of the supply voltage on the transmitter and the receivermust be reversed.

a = EDM feedback circuitb = Positive-driven relays, spark suppression is

provided by the receiverc = Release circuit, 2-channel*

d = Release circuit, 1-channel*e = External testing selectedf = Polarity for transmission channel 2g = Start/restart button

h = 2 A fine-wire fuse, melting fuse*) Always use both contacts in the release circuit.

Fig. 7.2-2: SD4R-E Receiver, TC2, with RES, with EDM

12 3 4 512 3 4 5

k1

k2

SOLID-4SD4R-E

SOLID-4SD4T

K1 K2

+24 V DCGND

FE

nc

f

F

6 7 8 k1 k2k1k2

h

eg

f f

a

c d

b

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7.2.3 SOLID-4 connection examplewith downstream relay module, MSI-RM2

Warning! If K4 and K5 are installed in the same switching rack as the MSI-RM2, each relay must beconnected via a separate connecting cable with the MSI-RM2. The connecting cables mustbe routed in a strong conduit so that mechanical damage is prevented. Also be sure to

follow the MSI-RM2 connection and operating instructions.

Note! Additional functions such as Muting or Cycle Control can be implemented with intelligentsafety interfaces of the MSI series from Leuze electronic. For this, see accessories inChapter 12.3 .

a = EDM feedback circuit

b = Positive-driven relays, spark suppressionrequiredc = Release circuit, 2-channel*

d = Release circuit, 1-channel*

e = External testing selectedf = Polarity for transmission channel 1g = Start/restart buttonh = 2 A fine-wire fuse, melting fuse

*) Always use both contacts in the release circuit.

Fig. 7.2-3: SD4R-E Receiver, TC1, with RES, with EDM and MSI-RM2

1 2 3 4 51 2 3 4 5

SOLID-4SD4R-E

SOLID-4SD4T

+24 V DCGND

FE

nc

6 7 8

K5

K4

k4 k5k5k4

k5

k4a

Y1

Y2

B3

A2B1

1412 11

24 2221

L+Ph

L-N

F h

L+Ph

L-N

MSI-RM2

f

eg

f f

b

b

c d

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7.2.4 Connection example of SOLID-4 with downstream MSI-SR4 Safety InterfaceDevice

Attention! If K3 and K4 are installed in the same switching rack as the MSI-SR4, each relay must beconnected via a separate connecting cable with the MSI-SR4. The connecting cables mustbe routed in a strong conduit so that mechanical damage is prevented. Also be sure tofollow the MSI-SR4 connection and operating instructions.

Figure 7.2-4: Receiver SD4R with MSI-SR4

SOLID-4 / SD4R

+ 2 4 V

+ 2 4 V

T e s

t

O S S D 1

SOLID-4 / SD4T

O S S D 2

0 V F E F E 0 V

Var. B

Var. A

4

1 42

-A1 1 2

3

4 -A2 1 2

3

1 4-W1 -W2

5

-W2 SH3-W1

5

SH3

-K3 -K4-K4

-K3

0VPE

+24V

PE.

+24V

0V.

n . c .

14 24 42

13 23 41

A1

A2-K3

1

2

1

2

L+ L+

L- L-

-S1

-K3

-K4

+ 2 4 V

0 V

MSI-SR4

A1-A3

A2

S22 S12 S31 S33 S34 S35

2 A O P D -

1 A O P D +

33

34

A1

A2-K4

2 A O P D +

I V - 0

R E S - 0

R E S - I

1

2

*

*

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8 Startup

Warning! Before starting up the SOLID-4 on a power-driven production machine for the first time, anexperienced and commissioned person with suitable training must check the entire setupand the integration of the opto-electronic protective device into the machine control system.

Before switching on the supply voltage for the first time and while the transmitters andreceivers are being aligned, it must also be ensured that the outputs of the opticalprotective device do not have any effect on the machine. The switching elements thatfinally set the dangerous machine in motion must be safely switched off and secured fromrestarting.The same precautionary measures apply after each change in parameter-based functionsof the optical protective device, after repairs or during maintenance work.Only after it has been determined that the optical protective device functions correctly can itbe integrated into the machine's control circuit!

8.1 Switching on

Warning! Without internal start/restart interlock function and with free protective field the OSSDsimmediately switch to the ON state!

Make sure that the transmitter and receiver are protected against overcurrent (for fuse size

see Chapter 7.2). There are special requirements for the supply voltage: The power supplymust guarantee secure mains supply isolation, have a load current reserve of at least250 mA and be able to bridge a power outage for at least 20 ms.

8.1.1 Display sequence with SD4T Transmitter

After the power supply is turned on and the self-test is completed, the LEDs indicate thecurrent operating status (see Chapter 5.1).

Warning! If the transmitter signals with error display (LED1 lights permanently red/LED2 any display),the 24 V DC supply voltage and the wiring must be checked. If the error remains after it isturned on again, stop the startup process immediately and send in the defective transmitterto be checked.

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8.1.2 Display sequence with SD4R-E Receiver

After the device is turned on, "8." appears for a few moments on the transmitter displayfollowed by an "S" for about 1.5 seconds for the self test. The display then switches andpermanently shows the selected transmission channel, "1" or "2".

Warning! If the receiver signals with the error display, the 24 V DC supply voltage and the wiringmust be checked. If the display remains after it is turned on again, stop the startup processimmediately and send in the defective receiver to be checked.

The displays of the receiver LEDS after switching on: without start/restart interlock function(RES, FS).

Warning! The receiver switches to the ON-state as soon as it receives all beams!

The LED displays of the SD4R-E Receiver with activated internal start/restart interlockfunction after it is turned on (for activation seeChapter 7.1.2):

LED Without internal RES, transmitter/re-ceiver aligned and protective fieldfree

Without internal RES, transmitter/re-ceiver not aligned or protective fieldnot free

LED1 Green = ON-state of theOSSDs

Red = OFF state of theOSSDs

LED2 No display = RES not locked No display = RES not locked

Table 8.1-1: LED displays, receiver SD4R-E with start/restart interlock not activated(RES)

LED With internal RES, before unlockingwith the start/restart button while theprotective field isfree

With internal RES, before unlockingwith the start/restart button while theprotective field isinterrupted

LED1 Red = OFF state of theOSSDs

Red = OFF state of theOSSDs

LED2 Yellow = RES locked No display = RES locked

Table 8.1-2: LED displays, receiver SD4R-E with start/restart interlock activated (RES)

LED With internal RES, after unlockingwith the start/restart button while theprotective field isfree

LED1 Green = ON-state of theOSSDs

LED2 No display = RES unlocked

Table 8.1-3: LED displays, receiver SD4R-E with start/restart interlock activated (RES)

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8.1.3 Display sequence on receiver SD4R

After switch-on, "8." appears on the transmitter display for a few moments followed by an"S" for approx. 1.5 sec. indicating a self test. The display then switches and constantlydisplays the selected transmission channel, either "1" or "2".

Attention! If the receiver responds with the error display, the 24 V DC connection voltage and wiringare to be inspected. If the display persists after switching on again, immediately interruptstart-up and return the defective receiver to us for inspection.

The displays on the receiver LEDs after switch-on:

Attention! As soon as the receiver receives all beams, it switches to the ON state!

8.2 Aligning transmitter and receiverTransmitter and receiver must be at the same height or, if installed in a horizontal position,be at the same distance from the reference surface and lightly fastened at first. The narrowspecified angle of beam spread of 2 requires increased precision in aligning the twocomponents with each other before the devices are screwed firmly into place.

Note! If cascaded AOPDs are aligned with each other, it must always be in the order of host first,then guest.

8.2.1 Optimizing alignment by turning and/or tilting the transmitter and receiver

The difference between free protective field (display shows the numbers of the transmis-sion channel) and weak signal (channel number flashes on the display) enables alignmentoptimization.If the components are already aligned, it is recommended that you optimize the alignment,e.g. by turning the receiver. Turn the receiver with slightly loosened brackets until the 7-segment display starts to flash. Take note of the position. Now turn the receiver in theopposite direction until the display lights constantly and further, until it flashes again. Nowturn the receiver back in between the two positions determined. Screw the receiver firmlyinto place to prevent turning. Now do the same with the transmitter.For cascaded systems, the procedure can be performed for all transmitters and receiversone after the other, beginning with the host. A precise preliminary alignment of allcomponents is also required here.

LED Transmitter/receiver aligned and pro-tective fieldclear

Transmitter/receiver not aligned orprotective fieldnot clear

LED1 green = ON-state of the OSSDs red = OFF-state of the OSSDs

Table 8.1-4: LED display receiver SD4R

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Testing


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9 Testing

9.1 Testing before first startupTesting by an experienced technician before first startup must ensure that the opticalprotective device and any other safety components that might be present have beenselected in accordance with local regulations and applicable European Directives, espe-cially the European Machine and Work Equipment Directive and that they provide therequired protection when properly operated. Use the regulations listed above, where required, with the help of the checklists provided

in the Appendix of these instructions, to check that the protective devices are properlyinstalled, that they are properly wired into the controls and that they work in all machineoperating modes. When selecting the checklist, note the type of protection (point ofoperation, danger zone or access guarding).

The same testing requirements apply if the machine in question has not been operatedfor a longer period of time and after major modifications or repairs if this could affect thesafety of the machine.

Observe the specifications regarding the instructing of operation personnel by experi-enced technicians before work is started. Instructing personnel is the responsibility of themachine owner.

The results of this test are documented for the machine owner in accordance withISO 9000 ff.

9.2 Regular tests

Regular tests must also be carried out in accordance with local regulations. These aredesigned to discover changes (e.g. in stopping times) or manipulations to the machine orprotective device. You must have the effectiveness of the protective device checked by an experienced

technician at suitable intervals, but at least once a year. The applicable checklist in the Appendix may also be used during regular testing.Leuze electronic also provides a specialist service for regular tests.

9.3 Daily testing with the test rod

SOLID-4 are self-monitoring Safety Light Curtains. Nevertheless it is very important tocheck the effectiveness of the protective field every day to be sure that the protection alsoremains effective at every point after a parameter or tool change.

Warning! Never use your fingers, hand or arm for checking the system!

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When selecting the test rod, use the identification plate of the receiver with the resolutioninformation as a guideline.

If the internal start/restart interlock function is selected, but the AOPD is released, LED1lights up green on the SD4R-E Receiver. When the test rod is inserted, LED1 switches to

red, and the restart interlock locks. During the testing procedure, LED2 must not light upat any position of the protective field. Only after the test rod has been taken out of theprotective field does LED2 light up yellow (restart interlock locked).

If the AOPD is being operated without the internal start/restart interlock, it is sufficient towatch LED1 on the receiver during the testing procedure. When the test rod is insertedinto the protectiv

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