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2

T A B L E O F C O N T E N T S

Contents Page

1 Introduction 31.1 Features 3

2 Applications 42.1 Areas of Application 42.2 Application Conditions 52.3 Corner Mirrors 6

3 System Design 6

4 Theory of Operation 74.1 Mode of Operation 74.2 Host/Guest Cascade 7

(Daisy-Chaining)

5 Installation 85.1 General 85.1.1 Safety Distance to

Point of Operation 8 5.1.2 Distance to Reflective

Surfaces 95.1.3 Multiple Safety

Systems Per Application 95.2 Mechanical Installation

(Mounting Brackets) 105.3 Electrical Installation 115.3.1 Test Input (Sender) 115.3.2 Switching Outputs

(Receiver) 125.3.3 RS-485 Communication

Interface 12

6 Specifications Table 136.1 General 136.2 Weight of Systems 14

7 Dimensional Drawings 15,16,17

8 Connection Diagrams 188.1 Connection Diagram for

Terminal Strip (FGSS/FGSE) 18

8.2 Connection of DIN Connector 18

8.3 LCU-AM (7 022 760) 198.4 LCU-15-AM (7 022 782) 208.5 LCU-X 21

Contents Page

9 Selection of an Opto-Electronic SafetySystems 22

9.1 FGS Selection Table 229.1 Safety Light Curtain Cables -

Sender Unit 239.2 Safety Light Curtain Cables -

Receiver Unit 249.4 Accessories Selection

Table 259.5 Corner Mirror Selection

Table 259.6 Mounting Stands 26

10 Diagnostics10.1 Troubleshooting 2710.2 Diagnostic Table 27

Agency Approvals

EU EuropeTUV RheinlandAm Grauen SteinD-51105 Koln

BIABerufsgenossenschaftlichesInstitut fur ArbeitssicherheitAlte Heerstrasse 111D-53757 St. Augustin

ISO 9001 DQS Certificate

J JapanJapanese Ministry of Labour

3

I N T R O D U C T I O N 1

Scanning Range

Protected Height

Resolution

1 Introduction

FGS safety light curtains are active opto-electronicprotection devices (AOPD) with resolutions of 14 mmor 30 mm.

SICK FGS safety light curtains are self-checking(AOPD) and belong to Safety Category 4. They havebeen designed for industrial applications and arecharacterized by:

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

For practical applications, the following specificationsare valid:

1.1 Features

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 protec-tive field and the point of operation)

• Construction in compliance with pr EN 50100 (self-checking)

• Maximum scanning range 6 m/18 m• Resolution (object sensitivity) 14 mm/30 mm• Maximum height of protective field 1814 mm/1832 mm• Minimum height of protective field 314 mm/332 mm

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

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

4

2 A P P L I C A T I O N S

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.

5

A P P L I C A T I O N S 2

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

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

2.2 Application Conditions

The machine or system control must beable to be stopped electrically. The FGSmonitors the switching outputs for shortcircuits.

The hazardous machine motion must beable to be stopped at all times.

The installation of th FGS must adhere tothe ANSI specification B11.19/E4.2.3.3.6,which states: A presence sensing deviceshall prevent the operator or others fromreasonably reaching over, around, underor through the sensing field into thehazardous area. Auxiliary safeguardingmay be required in conjunction with theFGS to accomplish this requirement. (Fig. 5).

All pertinent regulations apply toinstallation and operation. Localauthorities or the respective industryassociations are available for technicalsafety questions.

6

3 S Y S T E M D E S I G N

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

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

2.3 Corner Mirrors

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

3 System Design

The safety light curtain consists of a senderand a receiver (Fig. 7). Between these is theprotective field, which is defined by theprotected height and the scanning range.

The length of each system is dependent on theprotected height required.

Synchronization between the sender andreceiver takes place optically, i.e. electricalconnection between sender and receiver is not necessary.

The FGS is a modular construction. All opticaland electrical components are housed in onesturdy, yet slim, profile.

7

T H E O R Y O F O P E R A T I O N 4

4 Theory of Operation

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

4.1 Mode of Operation

The FGS, does not require aseparate control unit or "third box"when operating in guard-only modewith manual restart. If otherfunctions should be required, e.g.PSDI mode, blanking, muting, andothers, LCU (Universal SafetyInterface) devices are available.The addition of an LCU makespossible a wide variety ofapplications.

4.2 Host/Guest Cascade(Daisy-Chaining)

In order to effectively preventsomeone from standing behind thesensing fields, one or several FGSdevices can be connected in adaisy-chain configuration. Anydesired combination is possible upto 240 beams. For example, a host1200 mm device with 14 mmresolution for finger protection,could be connected to a guest300 mm device, with 30 mmresolution to prevent someone fromstanding between the protectivefield and the point of operation.When using the LCU-P with "mixed"daisy-chaining (e.g. host sensorwith 14 mm resolution with a guestsensor with 30 mm resolution), theDpt must be calculated using thelarger (30 mm) resolution.

When using the daisy-chain option,take notice of the following:

• Maximum total number of beamsis 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 possibleapplications. The guest sensors,unlike the main sensor, has noindicator lights. They are notdesigned to be used as a standalone device. The Host/Guest andHost/Guest/Guest sensors withaccessories are already preparedfor daisy-chaining.

Note: Host/guest/guest topInterface Cable is limited to a max.length of 10 meters.

Host Sender

Host Sender

Guest Sender

Guest Sender

Guest Sender

Host ReceiverHost Receiver

Guest ReceiverGuest Receiver

Guest Receiver

Fig. 8. Multiple plane sensing using theHost/Guest configuration.

Fig. 9. Multiple plane sensing using theHost/Guest/Guest configuration.

8

5.1 General

The FGS can be used in most environments (IP65). Safety distances as well as an adequateprotected height should be observed. Specialattention should be given to the danger ofreaching over, under, or standing behind sensingfields to reach the point of operation. This must beprevented mechanically or covered by anotheroptical safety device (e.g. FGS daisy-chaining).

5.1.1 Safety Distance to Point ofOperation

The safety device requires a certain minimum distance between the sensor and the point ofoperation. 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

The *** formula should be used when calculating the safety distance Ds:

Ds= K [Ts +Tc+Tr+Tbm] + Dpfor Ds=K [∑Tall] + Dpf

Ds= Minimum safety distance between device and the nearest point of operation hazard (in mm)

K= Hand speed constant: 1600 mm/sec or 63 in/sec

Tall= All times

5 I N S T A L L A T I O N

Middle of Depth of Protective Field

Point of Operation

Machine stop time

Top of tool

Bottom of tool

≤ 75 mm

To avoid the possibility ofstanding between the protectivefield and the point of operation,this distance must bemaintained.

Note 1. This value will change if fixed blanking is used.

Note 2. Any object sensitivity greater than 2.5 in (63.5 mm) cannotreliably detect a person’s hand or arm and should be considered aperimeter guard system.

Safety Distance

Protective Field Marking

FGS

FGS 14 mm0.55 (14)

FGS 30 mm1.2 (30)

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

Fig.10. Depth penetration chart.

Depth Penetration factor Dp in inches (mm)

2.5 (64)

2.0(51)

1.5(38)

1.0 (25)

.05(12)

0

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

Ts= Stop time of machine tool measured at the final control element (in seconds)

Tc= Response time of the control system

Note: Ts and Tc are usually measured by a stop-time measurement device and confirmed periodically

Tr= Response time of the presence-sensing 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)

Dpf= Added distance due to the depth of penetration factor. Can be obtained using the chart in fig. 10or 3.4 x [ object sensitivity-7 mm]

The minimum object sensitivity is stated onthe product label. If beam blankouts areused, this opening should be added to theobject sensitivity.

Obj

ect

Sen

sitiv

ity S

in in

ches

(m

m)

9

I N S T A L L A T I O N 5

5.1.2. Distance to Reflective Surfaces

Reflective surfaces that are present in thesensing field of the sender and receiver cancause reflections that may result in an objectnot being detected (Fig. 11). Therefore, aminimum distance (a) must be kept from thereflective objects to the optical axis (straight-line connection FGSS/FGSE). The distance (a)is dependent on the distance between thesender and receiver unit, and on the alignmentof the devices (Fig. 12).

5.1.3. Multiple Safety Systems per Application

When using two FGS systems per application,the systems should not be allowed to influenceeach other. As the distance between the FGSSand FGSE increases, the light beams divergeand their cross sections become larger. Thiscould result in the light beams being receivedby the wrong receiver. Light beams should bereceived only by their corresponding receiver.In order to rule out the possibility that receiverswill receive light from the wrong senderdevices, their alignment must be taken intoconsideration during installation (Fig. 13).

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

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

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

10

5 I N S T A L L A T I O N

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

5.2 Mechanical Installation

Fixed L-brackets are included with the FGS. Optionaladjustable brackets and adjustable brackets with shockmounts are available for mounting the sender andreceiver units (Fig. 14). Fixed brackets can be usedwhere no compensation for large mechanical tolerancesis required. The adjustable brackets allow the sensors tobe adjusted ± 2°.

Brackets with shock mounts can be used to reducevibrations (e.g. on stamping presses). The brackets areattached to the sender and receiver using T-nuts. The T-nuts ride in grooves that run the full length of the lightcurtains on either side of the exit window. This allows forgreater flexibility when mounting the light curtains.

11

5.3 Electrical Installation

Connecting the FGS components issimple. Cable lengths up to 60 m arepermitted (over-voltage protection forlevel 3 and higher (IEC 801), seeTechnical Data. The sender is connectedto the machine control using a 5-conductor cable (Fig. 15), the receiverusing a 7-conductor cable (Fig. 17). Themaximum wire cross section is 1.5 mmwithout jacket; 1 mm with jacket. All U.S.light curtains come standard withprewired mini-style quick-disconnect inthe end-caps. The FGS requires +24 VDC (± 20%) power supplies, which areavailable from SICK.

5.3.1 Test Input (Sender)

The FGS switches to the green conditionafter the supply voltage has beenapplied, and the automatic power-up testhas been completed. If an external testis desired (Fig. 16), a contact at the testinput (MCC = Machine Control Contact).Minimum opening duration ≥ 50 ms.

Continuous current during closed testinput: 12 mA. In-rush current whenclosing: 150 mA (20 ms).

Test input open = Testing = Outputs onreceiver inactive (red).

Test input closed = No test = Outputs onreceiver active (green).

The cable pin diagram for the sender isshown in Fig. 15.

I N S T A L L A T I O N 5

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

Fig. 16. FGSS connection diagram.

Pin #1 = +24 V

Pin #1

Pin #2

Pin #3

Pin #5

Pin #2 = GNDPin #3 = TESTPin #4 = TESTPin #5 = NCPin #6 = NC

Pin #7 = PE

1234567

12345¤¤

Internal¤Connector

Mini¤Plug

FGS Sender¤Inside View of Connector

FGS Sender¤Top View of Connector

1

2

3

4

5Sender Cable Plug

PIN

12345

BLACKBLUEGREEN/YELLOWBROWNWHITE

+ 24 V DC0 V DCTESTTESTPE

COLOR FUNCTION

Pin #4

1+24 V

PE

3

7

FGSS

4

20 V

test or test contact

12

5 I N S T A L L A T I O N

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

Fig. 18. FGSE (receiver) connection diagram.

5.3.2 Switching Outputs(Receiver)

The output voltage UA of eachchannel depends on the supplyvoltage UV and the switching loadand is at least

UA = UV - 2V

Both outputs OSSD1 and OSSD2 (OSSD = Output Signal SwitchingDevice) are control reliable, activelymonitored PNP solid state outputs. Theoutputs can catty a maximum of .05Amps 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.

5.3.3 RS-485 CommunicationInterface

This interface serves to communicatewith the LCU-P (optional). If LCU-P is notused, the connection is not used.

Pin #1 = +24 V¤

Pin #1¤

Pin #2¤

Pin #3¤

Pin #4¤

Pin #7¤

Pin #5¤

Pin #6¤

Pin #2 = GND¤Pin #3 = OUT 1-¤Pin #4 = OUT 2-¤Pin #5 = COM- RS 485¤Pin #6 = COM+ RS 485¤

Pin #7 = PE¤

1¤2¤3¤4¤5¤6¤7¤

1¤2¤3¤4¤5¤6¤7¤

Internal¤Connector¤

Mini¤Plug¤

FGS Receiver¤Inside View of Connector¤

FGS Receiver¤Top View of Connector¤

1¤

2¤

3¤

7¤

4¤

5¤

6¤Receiver Cable Plug¤

PIN¤

1¤2¤3¤4¤5¤6¤7¤

BLACK¤WHITE¤BLUE¤BROWN¤GREY¤YELLOW¤GREEN¤

+ 24 V DC¤0 V DC¤OUT 1¤OUT 2¤-RS 485¤+RS 485¤PE¤

COLOR¤ FUNCTION¤

1+24 V

Imax =0.5 A

Imax =0.5 A

RL

RL

RS 485

(LCU/diagnostics)

0 V

PE

3

4

5

6

2

7

FGSE

13

6.1 General Minimum Typical MaximumProtected field height, type-dependent 300 mm 1800 mmProtected field width

14 mm resolution 0.3 m 6 m 30 mm resolution 0.5 m 18 m

Resolution, type-dependent 14 mm 30 mmEnclosure rating IP 65Protection class 1Supply voltage Uv 19.2 V 24 V 28.8 VRipple 1) 2.5 VssVoltage if power fails (20 ms) 18 VSynchronization optical, without separate synchronization cableOn transition time after applying supply 1.8 s

voltage of sender and receiver

Sender UnitTest output Uv-0.7 VTest input

Input resistance (HIGH) 1.5 kΩ (against 0 V) Sender, inactive (Test) 0 V 12 VSender, active 18.5 V UvReaction time in test 50 ms 60 ms

Wave length 880 or 940 nm Current consumption 0.56 A

Receiver UnitSupply connections (OSSD) 2-PNP semiconductors, short circuit protected2), cross monitored

Switching voltage HIGH (Ueff) Uv - 2V UvSwitching voltage LOW 0 V 1 VSwitching current 5 mA 500 mALeakage current 3) 2.4 mALoad capacity 2.2 µFSwitching frequency 4/sLoad inductance L 4) 2.2 H

Test impulse data 5)

Test impulse width 220 µs 240 µs 265 µsTest impulse rate 6.3 ms 19.6 ms

Permissible cable resistance between unit and load 6) 2.5 Ω

Response time 15 msOn-transition time after light beam

interruption 15 ms 100 ms 7)

S P E C I F I C A T I O N S 6

14

6.1 General Continued Minimum Typical MaximumCommunication cables

Cable length (twisted pair) 100 m

Cable termination, internal 4.7 nF

Baud rate 9600 baud

Current consumption (no load) 0.68 A

Connection Plug-in terminal chamber

Line length Dependent on load, power supply unit and wire cross

section. The technical specifications must be observed.

10 m 60 m 8)

Max. conductor cross section 1 mm2 with sleeve

1.5 mm2 without sleeve

Operating Mode Guard only without start and restart inhibit

Safety category Type 4

Tested to pr EN 50 100 Part 1 and 2

Ambient operating temperature 0˚C + 55˚C

Storage temperature -25˚C + 70˚C

Air humidity (non-condensing) 15% 95%

Vibration resistance 5 g 10...55 Hz per IEC 68-2-6

Shock resistance 10 g/16 ms per IEC 68-2-29

Dimensions

Height Dependent on protective field height, see sect. 7, Dimensional Drawings

Housing cross section 52 mm x 55 mm

Weight See 6.2-weight table

FGS Model Weight of System[mm] [kg]300 2.8450 4.0600 5.0750 6.0900 7.0

1050 8.0 1200 9.21350 10.01500 11.21650 12.31800 13.4

6 S P E C I F I C A T I O N S

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 kΩ 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 ishigher.

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.

6.2 Weight of Systems

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

L (Hy)

20

10

00 1.0 2.0 3.0 4.0

1/s

1¤

2

1¤

2

I 400 mA

I 500 mA

L

L

15

D I M E N S I O N A L D R A W I N G S 7

A B C D

FGS 300 300 384 224 80FGS 450 450 534 374 80FGS 600 600 684 524 80FGS 750 750 825 675 80FGS 900 900 985 825 80FGS 1050 1050 1135 975 80FGS 1200 1200 1285 1125 80FGS 1350 1350 1435 1275 80FGS 1500 1500 1586 1426 80FGS 1650 1650 1736 1576 80FGS 1800 1800 1886 1726 80

(Dimensions in mm)

PG Connector or Quick Disconnect(approx. 100 mm spacerequired for plugging in)

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

Optical Axis = Center of exit window

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

16

7 D I M E N S I O N A L D R A W I N G S

Middle Guest

A B

FGS 150 150 200FGS 300 300 350FGS 450 450 500FGS 600 600 650FGS 750 750 800FGS 900 900 950FGS 1200 1200 1250

31

25

A B

52

61

55

Fig. 20. Middle Guest FGS dimensional drawing.

17

End Segment Guest

A B C D

FGS 150 150 200 *) *)FGS 300 300 350 190 80FGS 450 450 500 340 80FGS 600 600 650 490 80FGS 750 800 350 640 80FGS 900 900 950 790 80

other sizes available on request*) special fixing on request

A B

CD

27.5

52

61

31

55

Fig. 21. Guest FGS dimensional drawing.

D I M E N S I O N A L D R A W I N G S 7

18

8 C O N N E C T I O N D I A G R A M S

8.1 Connection Diagram forTerminal Strip

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

8.2 Connection of DIN Connector

Fig. 23 shows the connections for theDIN connector.

1 This interface is manual Start/Restart only.LC1, LC2 and LC3 must be captive contact safety relays

2 Normally open momentary contact switch.

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

Fig. 23. FGS with three relay interface.

∆3

19

C O N N E C T I O N D I A G R A M S 8

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 55˚C.11. Arc suppression kits should be applied across each load (solenoid of relay coil), to assure maximum contact life.

20

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

8 C O N N E C T I O N D I A G R A M S

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 55˚C.10. Arc suppression kits should be applied across each load (solenoid of relay coil), to assure maximum contact life.

21

1 Loads such as: clutch breaks, servo motors, contactors, dual solenoid valves, etc.

2 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).

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.

4 If “Automatic Reset” is allowed, remove the N.O. push button on T13 and T 14 and jumper X11 to X12.

5 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).

∆∆∆∆∆

C O N N E C T I O N D I A G R A M S 8

8.5 Connection Diagram LCU-X

7654321

2.3

Load¤

Load¤

LCU-X

LC1

LCU-X

Safety Stop Circuit

LC2

1.32.3

24 V DC 0 V DC

1.42.4

3.1

1.3

LC1

LC2

X21

X22

X11

X12

T13

T14

T21MPCE

Reset

T4

PE

RS 485 +

RS 485 -

Out 2

Out 1

0 V DC

+ 24 V DC

PE

Not Used

Not Used

Test Input

Test Input

0 V DC

+ 24 V DC

7654321

7654321

5

4321

T3

PE

D2

D1

C1

C2

PE

PE

A2 0V DC

A1 +24 V DC

T22

3.2

2.4

1.4

LC2

LC1

3¤

4

5

1

2

¤

MCC

FG

S R

ecei

ver

FG

S S

ende

r

¤

All relays must be captive contact, direct drive safety relays

Min

i¤C

onne

ctor

Inte

rnal

Also may be usedto control 120/240 V AC

In this case, A1 and A2are connected to 24 V DCand 0V DC respectively.

Fig. 26. Connection Diagram LCU-X.

22

9 S E L E C T I O N

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

9 Selection of an Opto-Electronic Safety System

In the selection of an opto-electronicsafety device, consider the followingelements:

Regulations

Look up the regulations and standardsapplicable to the particular application.

Local authorities and professionalorganizations can assist here.

Operating Range

Determine the required operating rangefor the application.

The operating range corresponds withthe width of the area to besafeguarded. The operating rangeshould be chosen so that danger pointsare accessible only through theprotective field.

Corner Mirrors

Use of corner mirrors offers thepossibility to safeguard two or threesides.

Use of corner mirrors will also reducethe maximum sensing range 0.5 m permirror.

Protected Height

Determine the required protected heightfor the application.

The protected height must be chosenso that danger points are accessibleonly through the protective field.

9.1 FGS Selection TableModel Number Resolution Protective Height Part Number

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

9.2 Safety Light Curtain Cables - Sender Unit

48.3 mm(1.9 in)

Typ.

Length

7.87 mm (0.31 in) ± .254 mm (0.01 in)

± 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.

Order Number Model Number Length in m (ft) Note7 022 166 KD5-SYF804 4 (13.1) 17 022 167 KD5-SYF812 12 (39.4) 17 022 168 KD5-SYF820 20 (65.6) 17 022 836 KD5-SYF830 30 (98.4) 17 025 683 KD5-SYF8.06 0.6 (1.9) 2

Material Specifications:ConnectorCoupling nut: Anodized aluminumContacts: brass - gold flash over palladium nickelFemale insert: PVCMolded Head: PVC yellow

Cable Conductors: Five conductor - 18AWG stranded tinned copper

Jacket PVC color per chart300 V 105°C (221°F) UL recognized, CSA certified

Over Jacket: PVC Yellow 300 V 105°C (221°F) UL recognized, CSA certified

Protection: NEMA 6p IP 68

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

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

1 Black2 Blue3 Yellow/Green4 Brown5 White

Pin Color

1

2

34

5

S E N D E R U N I T 9

Fig. 27. Sender Unit.

23

Material Specifications:ConnectorCoupling nut: Anodized aluminumContacts: brass - gold flash over palladium nickelFemale insert: PVCMolded Head: PVC yellow

Cable Conductors: Five conductor - 18AWG stranded tinned copper

Twisted Pair - 2 conductor 20AWG stranded tinned copperwith over all foil shield and drain wireJacket PVC color per chart300 V 105° C (221° F) UL recognized, CSA certified

Over Jacket: PVC Yellow 300 V 105° C (221° F) UL recognized, CSA certified

Protection: NEMA 6p IP 68

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

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

53.34 mm(2.1 in)

Typ.

Length

8.26 mm (0.325 in) ± .38 mm (0.015 in)

± 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.

24

Order Number Model Number Length in m (ft) Note7 022 180 KA17-SFF804 4 (13.1) 17 022 181 KA17-SFF812 12 (39.4) 17 022 182 KA17-SFF820 20 (65.6) 17 022 837 KA17-SFF830 30 (98.4) 17 025 652 KA17-SFF8.06 0.6 (1.9) 2

1 Black2 White3 Blue4 Brown5 Gray6 Yellow7 Green

Pin Color

1

2

34

5

6

7

9.3 Safety Light Curtain Cables - Receiver Unit

9 R E C E I V E R U N I T

Fig. 28. Receiver Unit.

25

A C C E S S O R I E S 9

9.4 Accessories Selection Table

Products Part NumberL-Mounting Bracket, fixed* 7 021 352Mounting Bracket, adjustable 7 021 351Mounting Bracket, adjustable 7 021 348with shock mount

Terminal housing with PGand Terminal Strip 7 021 313Terminal housings Connector, Sender (DIN) 7 021 353Connector, Receiver (DIN) 7 021 354Cable Socket, straight (DIN) 6 006 612Cable Socket, right-angle (DIN) 6 006 613Power Supply 93..265 V AC24 V DC, 2.0 amps (PS-20) 7 022 75524 V DC, 2.5 amps 6 010 36124 V DC, 4 amps 6 010 362Safety InterfaceLCU-P 1 012 523LCU-AM 7 022 760LCU-15-AM 7 022 782LCU-X 1 013 410AR 60 alignment aid 1 015 741FGS Adapter for AR-260 4 030 282

* Supplied with FGS

9.5 Corner Mirror Selection TableCORNER MIRRORS- Specially constructed mirrors for 2 and 3 sided safeguardingapplications; Reduces the maximum sensing range between FGSS & FGSE by 0.5meters (1.6 ft) for each mirror.

Part Number Model Number For FGS ML OL CHmodels:

7 020 113 PNS 120-041A 300 17.016 17.354 N/A7 020 115 PNS 120-058A 450 23.609 23.889 N/A7 020 116 PNS 120-074A 600 30.188 30.464 N/A7 020 117 PNS 120-091A 750 36.656 37.000 N/A7 020 118 PNS 120-107A 900 43.188 43.535 N/A7 020 119 PNS 120-116A 1050 46.453 46.803 N/A7 020 120 PNS 120-132A 1200 53.031 53.377 26.6897 020 121 PNS 120-157A 1350 62.844 63.181 31.5917 020 263 PNS 120-174A 1500 68.859 69.204 34.6027 020 264 PNS 120-191A 1650 or 1800 75.931 75.740 37.8707 020 318 MB-PN-120 *

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

Fig. 29. Dimensions of corner mirrors andmounting bracket (mm).

4 required per system

26

9 A C C E S S O R I E S

Fig. 30. Mounting Stands.

9.6 Mounting Stands

Mounting stands are used with lightcurtains or PNS corner mirrors whendirect mounting on the safeguardedmachine is not possible. The standshave a steel base with 4 holes forsecuring them to the floor.

Stands are of varying heights withmounting holes in increments of25.4 mm (1 in) for a varietymounting positions. The mountingstands are made of heavy gaugesteel, with welded construction andpaint protection.

Mounting Stands34 in 7 020 25851 in 7 020 25963 in 7 020 26072 in 7 020 261

27

D I A G N O S T I C S 1 0

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

10.1 Troubleshooting

Troubleshooting can bedone through the use of theLED indicators positionedon both the sender and thereceiver. Fig. 31 shows thefunction of the indicatorLEDs on the FGS.

10.2 Diagnostic Table

Appearance Identification Action/Checks

Sender amber LED off supply voltage -supply voltage and wire connectionsyellow LED off -replace sender control board or senderamber LED on sender not emitting -test input open, check wires 3 & 4 on senderyellow LED off infrared light -replace sender control board or senderamber LED on sender is emitting -sender is transmittingyellow LED on infrared light

Receiver no LED lights supply voltage -supply voltage and wire connections -replace receiver control board or receiver

red LED on obstruction -look for any objects protruding into protective field

red LED on sender test input -restart requiredwithout beam open or sender not -test input open, check wires 3 & 4 on senderbreak emitting infrared light -replace sender control board or sender

system out of -adjust both curtains side to sidealignment -make sure curtains are plum and at the same level

weak signal indicator, amber dirt build-up -clean exit windowsLED, is permanently lit sender or receiver -alignment

red LED on sender or -test input open, check wires 3 & 4 on senderamber LED, two blinks alignment -alignment and a pause -replace sender control board or sender

red LED on receiver -alignmentamber LED, three blinks -test input open, check wires 3 & 4 on sender and a pause -replace receiver control board or receiver

2 or more LEDs are blinking system in "lookout" -check for proper power by verifying proper DC constantly 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

green LED is on system okay -light curtains synchronized with no obstruction

Safety Systems Automatic IdentificationIndustrial Sensors

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Products from SICK provide comprehensivesafeguarding of both workers andmachinery. As specialists in sensortechnology, SICK develops andmanufactures pioneering products thatprovide protection in hazardous zones,dangerous locations and for safeguardingaccess points. By providing services,which encompass all aspects of machinesafety and security, SICK is setting newstandards in safety technology.

Our wide range of sensors provides

solutions to suit any application in the

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detected, counted and positioned

regardless of their form, location and

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Whether the tasks involve identification,

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measurement, innovative automatic

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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.

SICK is one of the world’s leadingmanufacturers of safety systems,sensors, and automatic identificationproducts for industrial applications. SICKholds more than 350 patents for itsinnovative products. Through itsIndustrial Sensors, Safety Systems,Automatic Identification, and Environmentaland Process Analysis divisions, thecompany has operations in 65 countries.SICK North America is headquartered inMinneapolis, MN.

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