SICK TGS (01) PDF DOCUMENT

The operating instructions for the SICK TGS testable safety light curtain contain the following information:

• mounting

• electrical installation

• commissioning and configuration

• care and maintenance

• fault diagnosis and troubleshooting

• part numbers

• conformity and approval

The following abbreviations are used in the SICK TGS manual:

ESPE: Electro-Sensitive Protective Equipment

TGSE: SICK TGS receiver unit

TGSS: SICK TGS sender unit

OSSD: (Output Signal Switching Device) Signal output selecting the safety circuit

The SICK TGS testable safety light curtain must be installed, connected, commissioned, and serviced only by qualified safety personnel. Qualified safety personnel are defined as persons who:

• due to their specialist training and experience have adequate knowledge of the power-driven equipment to be checked,

and

• have been instructed by the responsible machine owner in the operation of the machine and the current valid safety guidelines,

and

• are sufficiently familiar with the applicable official health and safety regulations, directives and generally recognized engineering practice (e.g. DIN standards, VDE stipulations, engineering regulations from other EC member states) that they can assess the work safety aspects of the power-driven equipment,

and

• have access to these operating instructions and who have read them.

The SICK TGS safety light curtain is a non-contact safety device with a resolution of 20, 30 or 40 mm. It is designed for hand protection on machines and systems and is optimized for weaving machines. There are different safety distances, depending on the resolution.

Correct Use:

The SICK TGS safety light curtain must be used only as defined for its intended applications. It must be used only by qualified personnel and only on the machine where it has been installed and initialized by qualified safety personnel in accordance with these operating instructions.

Depending on where it is installed, the SICK TGS safety light curtain alone may not offer sufficient protection, and additional mechanical safety devices may be necessary. Hazardous points must only be reached through the protection field, and the system must not start as long as there are persons within the danger area. The mounting position must prevent reaching over, under, around, and stepping behind the protective field.

If the device is used for any other purposes or modified in any way, including during mounting and installation, any warranty claim against SICK AG shall become void.

Please observe the following procedures to ensure the correct and safe use of the SICK TGS safety light curtain:

• The usage of the safety light curtain requires a risk analysis. Check whether the safety light curtain can be used as the protective device or if additional protective measures are necessary.

• National/international rules and regulations apply to the installation, use, and periodic technical inspections of the safety light curtain.

• Manufacturers and operators are responsible for observing all applicable safety regulations and rules.

• The notices and test regulations in the operating instructions must be observed.

• The organization operating the machine must prevent bypassing of the protective field using suitable additional measures.

• Changes to the configuration require a separate risk analysis and can degrade the protective function. After every change, you must check the effectiveness of the protective device.

• Tests must be carried out by qualified or specially authorized personnel and must be recorded and documented.

• The operating instructions must be made available to the operator of the machine. The machine operator must be instructed in the use of the device by qualified safety personnel.

• The external voltage supply of the devices must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204-1. The power supply unit must provide safe isolation (SELV/PELV).

For pre-commissioning tests of the SICK TGS, the following inspections are required:

• An inspection prior to placing in operation for the first time is used to confirm compliance with the safety requirements in national/international regulations, in particular the machinery safety regulations or the provision and use of work equipment regulations.

• Inspection of the effectiveness of the protection equipment on the machine in all the operating modes in which the machine can be placed, according to the checklist.

• Qualified personnel must, prior to starting work, instruct the personnel operating the machine protected by the safety device. The instruction is the responsibility of the machine operating company.

Regular testing of the SICK TGS safety device by experts should follow these guidelines:

• The inspection should be carried out in accordance with valid national regulations at the intervals defined in the regulations. The intention of these inspections is to detect any changes or manipulations of the protective devices since the original commissioning.

• The inspections should also be carried out whenever major modifications are made to the machine or protection equipment, as well as after re-adjustment or repairs in the event of damage occurring to the housing, front panel, etc.

The daily test ensures that the SICK TGS is providing effective protection to personnel. This test is necessary to detect any modifications to the mounting of the system since the last test.

To check that undetected access to the hazardous area between the opto-electronic device and the mechanical guarding is not possible:

1. Move the test rod of the appropriate diameter (20 mm, 30 mm, or 40 mm) slowly through the guarded access opening following the direction of the arrows as shown in the device diagrams.

2. Then, check to make sure there is no risk that anyone may be able to reach over or under the danger zone.

Note: During this test procedure, only the red LED on the TGSE (receiver) should be illuminated.

The SICK TGS safety light curtain has been designed to minimize environmental impact. Always dispose of unserviceable or irreparable devices in compliance with local/national rules and regulations with respect to waste disposal.

Special features of the SICK TGS safety light curtain:

• Beam coding

• Self-testing

• Practical resolution of 20, 30, and 40 mm

• Optical synchronization

Mode of operation:

The SICK TGS safety light curtain comprises a sender unit and a receiver unit. The protective field is the area between the two units, defined by the protective field height and a protective field width of up to 6 m. The protection field height determines the size of the particular system. The upper and lower limits of the protection field are identified on the system via grey marks on the casing. The synchronization between sender and receiver is optical, meaning electric connections between the two components are not required.

The LEDs on the SICK TGS units signal different operating conditions as follows:

Sender Unit (Yellow LED)

Receiver Unit (Green and Red LEDs)

Key: ● = illuminated, ○ = off

The yellow LED on the SICK TGS sender unit and the red LED on the receiver unit provide diagnostic data in a flash mode during a fault event.

Sender Unit Faults (Yellow LED):

• A single flash followed by a 1.5-second pause indicates a defective sender unit. The sender should be replaced.

• Two flashes followed by a 1.5-second pause indicate a fault at the input. The test wiring should be checked.

Receiver Unit Faults (Red LED):

• A single flash followed by a 1.5-second pause indicates a defective receiver unit. The receiver should be replaced.

• Two flashes followed by a 1.5-second pause indicate a fault at the inputs or outputs. The test wiring should be checked.

• Three flashes followed by a 1.5-second pause indicate an external sender has been detected. Check the beam coding and for external TGS senders.

The SICK TGS features beam coding to allow multiple guarding systems to operate near each other without mutual interference. Three distinct codes can be selected. When using multiple systems, you can assign different codes (e.g., Code 1, Code 2, Code 3) to adjacent systems to prevent one sender from affecting the wrong receiver.

If an identical coding must be used for different systems, the distance between a receiver (e.g., E4) and an external, identically coded sender (e.g., S1) must be at least 12 meters.

The safety distance S for the SICK TGS must be calculated to ensure a hazardous point can only be reached after the machine has completely stopped. This calculation is based on EN 999+A1 and EN ISO 13857.

The safety distance depends on:

• Stopping/run-down time of the machine or system.

• Response time of the protective device (see technical data).

• Approach speed (2 m/s up to 500 mm safety distance, 1.6 m/s above that).

• Other standard-stipulated parameters.

How to calculate the safety distance S:

1. First, calculate S using the formula for an approach speed of 2000 mm/s:

S = 2000 × T + 8 × (d – 14) [mm]

Where:

• T = Stopping/run-down time of the machine + Response time of the SICK TGS [in seconds]

• d = Resolution of the safety light curtain [in mm]

• S = Safety distance [in mm]

2. If the result for S is ≤ 500 mm, use this calculated value as the safety distance.

3. If the result for S is > 500 mm, you must recalculate S using the formula for an approach speed of 1600 mm/s:

S = 1600 × T + 8 × (d – 14) [mm]

4. If this new value for S is > 500 mm, use the newly determined value as the minimum safety distance.

5. If this new value for S is ≤ 500 mm, then use 500 mm as the minimum safety distance.

Example:

• Stopping time of machine = 290 ms

• SICK TGS response time = 30 ms

• SICK TGS resolution (d) = 14 mm

• Total time (T) = 290 ms + 30 ms = 320 ms = 0.32 s

• Initial S calculation: S = 2000 × 0.32 + 8 × (14 – 14) = 640 mm

• Since S > 500 mm, recalculate:

• Final S calculation: S = 1600 × 0.32 + 8 × (14 – 14) = 512 mm

The minimum safety distance is 512 mm.

The light beams of the SICK TGS sender can be deflected by reflective surfaces, which could lead to the non-detection of an object. To prevent this, all reflective surfaces and items must maintain a minimum distance ‘a’ from the system’s protection field.

This minimum distance ‘a’ depends on the distance ‘D’ between the sender and receiver. The required distance ‘a’ increases as the distance ‘D’ (scanning range) increases. For example, at a scanning range of 6 meters, the minimum distance ‘a’ from a reflective surface is approximately 500 mm. Refer to the chart in the operating instructions for the specific value of ‘a’ corresponding to your installation’s scanning range ‘D’.

When mounting the SICK TGS, follow these steps and special features:

• Always mount the sender and receiver parallel to one another.

• Ensure correct alignment. The optical lens systems of the sender and receiver must be located in exact opposition to each other.

• Ensure correct orientation. The system plugs of both devices must point in the same direction.

• Observe the safety distance. Mount the system according to the calculated safety distance from the hazardous point.

The base version of the SICK TGS comes with 2 sliding brackets for the sender and 2 for the receiver, both with an M5 thread. To mechanically mount the TGS:

1. Push the sliding brackets into the slot (channel) on the back of the housing.

2. Attach a side bracket or wall bracket to these sliding brackets using the clamping screw.

WARNING: Prevent the light curtains from moving!

To prevent the mounted light curtains from moving, the sliding brackets of the side brackets must be attached at the beginning and end of the slot (channel). Alternatively, mount other suitable devices to prevent possible movements.

Recommendation: When aligning installations with a large scanning range or with a deflector mirror, it is recommended to use the laser alignment aid AR 60.

The SICK TGS sender and receiver both use a 7-pin plug. The pin assignments are as follows:

Sender Unit Pinout

Receiver Unit Pinout

*As an alternative, earthing can also be effected via a sliding claw bracket at the machine.

Notes:

• The maximum connectable cable cross-section is 0.25 mm. Both units must be supplied with 24 V DC (± 20%).

• The external voltage supply must be capable of buffering brief mains voltage failures of 20 ms as specified in EN 60204-1.

The SICK TGS has internal testing, so externally initiated testing is not required for normal operation. The TGS is often used with a programmable logic control (PLC).

The OSSD (Output Signal Switching Device) output is cyclically tested in its active state. This involves a short pulse to LOW (0 V) for approximately 250 µs. When selecting control elements (like a PLC), ensure that these short test pulses do not cause the control elements to switch off.

In addition to the OSSD switching output, the signal output must also be used. The signal output:

• is not monitored.

• works like the OSSD switching output.

• is intended to facilitate 2-channel integration to provide an OFF signal to the PLC if the OSSD develops a fault (e.g., a short circuit).

Important Note: The test input on the sender unit must be connected to +24 V for the sender to transmit light pulses.

If a 2-channel connection is not possible, the SICK TGS unit must be cyclically tested externally. An evaluation circuit (like a PLC) generates the test signal and checks the OSSD state.

Wiring the test input:

The test input (pin 5) of the sender is controlled by an output from the evaluation circuit. When the contact is closed (connected to +24 V), the sender transmits. When the contact is open, the sender does not transmit.

Test Cycle:

• The evaluation circuit triggers a test pulse to the sender, which turns it off. The output of the PLC also switches off.

• This switch-off is only cancelled when the evaluation circuit (PLC) detects a corresponding response (the OSSD of the receiver turning off and then on again) at the OSSD input of the PLC.

• During the test cycle, the PLC must simultaneously monitor the FSD (Final Switching Device, e.g., the output of the PLC) to detect any faults in the output itself.

If the system test takes longer than 150 ms, the restart lock of the master evaluation circuit must be activated. If the test is unsuccessful (OSSD does not respond), the PLC must be guaranteed to switch off the machine.

The beam coding of the SICK TGS can be adjusted at the terminal block of the machine control by applying voltage to the Sel 1 and Sel 2 inputs on both the sender and receiver. This ensures the pre-set coding is retained even when units are exchanged.

¹If an invalid configuration (24 V on both Sel 1 and Sel 2) is applied, the receiver switches to lockout mode. This condition can be rectified by setting a correct configuration and switching the power off and on again.

The SICK TGS testable safety light curtain requires no operational maintenance. However, the front screen should be cleaned regularly if it is dirty.

• Do not use any aggressive cleaning agents.

• Do not use any abrasive cleaning agents.

How to clean the front screen:

1. Use a clean and soft brush to remove dust from the front screen.

2. Now wipe the front screen with a clean and damp cloth.

Note: After cleaning, always check the position of the sender and receiver to ensure that the protective device cannot be bypassed (e.g., by reaching over, under, or standing behind).

Static charges can cause dust particles to be attracted to the front screen. This can be prevented by using an antistatic plastic cleaner and lens cloth, available as accessories.

Sender Unit

Receiver Unit

Operating Data

Response Times

The dimensional drawings for the SICK TGS show a housing cross section of 31.5 mm by 28.5 mm. The overall housing length (L1) and the protection field height (L2) vary by model:

Use the following tables to select the part number for the SICK TGS sender (TGSS) and receiver (TGSE) based on the required resolution and protection field height.

Resolution 20 mm

Resolution 30 mm

Resolution 40 mm

The following checklist must be reviewed by the manufacturer/installer for the SICK TGS, with details available at least during initial commissioning. This checklist should be retained with the machine documentation for reference during recurring tests.

1. Have the safety rules and regulations been observed in compliance with the directives/standards applicable to the machine?

2. Are the applied directives and standards listed in the declaration of conformity?

3. Does the protective device comply with the required category according to EN 954-1/EN ISO 13849-1?

4. Is the access to the hazardous area/hazardous point only possible through the protective field of the ESPE?

5. Have appropriate measures been taken to prevent (mechanical protection) or monitor unprotected presence in the hazardous area when protecting a hazardous area/hazardous point and have these been secured against removal?

6. Are additional mechanical protective measures fitted and secured against manipulation which prevent climbing over or crawling beneath the ESPE?

7. Has the maximum stopping and/or stopping/run-down time of the machine been measured and has it been entered and documented (at the machine and/or in the machine documentation)?

8. Has the ESPE been mounted such that the required safety distance from the nearest hazardous point has been achieved?

9. Are the ESPE devices correctly mounted and secured against manipulation after adjustment?

10. Are the required protective measures against electric shock in effect (protection class)?

11. Is the control switch for resetting the protective device (ESPE) or restarting the machine present and correctly installed?

12. Are the outputs of the ESPE (OSSDs) integrated in compliance with the required category according to EN 954-1/EN ISO 13849-1 and does the integration comply with the circuit diagrams?

13. Has the protective function been checked in compliance with the test notes of this documentation?

14. Are the given protective functions effective at every setting of the operating mode selector switch?

15. Are the switching elements activated by the ESPE, e.g. contactors, valves, monitored?

16. Is the ESPE effective over the entire period of the dangerous state?

17. Once initiated, will a dangerous state be stopped when switching the ESPE on or off and when changing the operating mode, or when switching to another protective device?

18. Has the information label for the daily check been attached so that it is easily visible for the operator?

This checklist does not replace the initial commissioning, nor the regular inspection by qualified safety personnel.