Operation Manual

Safe2+
Safe4
Safety Light Curtain Systems
Active Optoelectronic Protective Device
Type 2 (Safe2+)
or Type 4 (Safe4)
based on IEC 61496-1, -2

English

Serial Safety:
Safe4 / Safe2+ are extremely cost effective to purchase
and offer the user many technical advantages.
Safety light curtains for highest safety requirements!

IMPORTANT INFORMATION
FOLLOW THE INSTRUCTIONS GIVEN IN THIS MANUAL CAREFULLY. FAILURE TO DO
SO MAY CAUSE CUSTOMER COMPLAINTS AND SERIOUS CALL BACK. KEEP IN-
STRUCTION MANUAL ON SITE.

© CEDES Safety & Automation AG Version 3.9 / 29. June 2008 Part No. 102 261 E

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 Safe2+ / Safe4 Operation Manual

Content 12.1. TÜV certificate....................................... 23

12.2. CSA certificate....................................... 24
1. Approvals and Conformity .................... 2
2. Introduction........................................... 3 1. Approvals and Conformity
2.1. System design..........................................3
2.2. Special features .......................................3 TÜV Rheinland Product Safety GmbH, performed
3. Applications .......................................... 4 the CE - type examination according to the machin-
3.1. Typical applications .................................4 ery directive EC/98/37, appendix VI and the respec-
3.2. Applications restrictions ............................4 tive standards ICE 61496.
3.3. Application conditions ..............................5
3.3.1. Corner mirrors .................................5 The CE - conformity declaration and the product ap-
4. Principles of operation.......................... 5 proval certification (TÜV) is available at your nearest
4.1. Mode of operation ...................................5 CEDES dealer or on the homepage
4.2. Intelligent Laser Alignment System ILAS .....5 [Link].
4.3. LED indicators .........................................5
4.4. Cascading...............................................6
4.5. Perimeter systems ....................................7
5. Installation ............................................ 8 Warning
5.1. Regulations and standards .......................8 Safe2+ or Safe4 systems are only a safety protection
5.1.1. Safety distance to danger point .........8 device if all instructions in this manual and in the
5.1.2. Height of protective field...................8 related documents are carefully followed and fully
5.1.3. Response time – light curtain.............8 complied with. In addition the installer is responsible
5.1.4. Distance to reflective surfaces ...........8 to comply with all local laws and standards.
5.1.5. Multiple light curtain arrangement ....9
5.2. Mechanical installation.............................9 If these instructions are not (or only partially) fol-
5.2.1. Mounting brackets............................9 lowed, this may lead to serious injury or even death
5.2.2. Intelligent Laser Alignment System ILAS and legal action against the responsible installer or
(Optional with Safe2+)...................10 system integrator. In such a case claims against
5.2.3. Adjustment Procedure without ILAS..10 CEDES are not valid.
5.2.4. Adjustment Procedure with ILAS ......11
5.2.5. Remarks to ILAS .............................11 This instruction manual is part of the light curtain
5.2.6. Testing the protection field ..............11 Safe2+ or Safe4. It must be kept accessible during
5.3. Electrical Installation ..............................12 the whole life cycle for everybody who is in charge of
installation, operation, maintenance and safety con-
5.3.1. A connector cap.............................12
trol.
5.3.2. B connector cap .............................12
5.3.3. C connector cap.............................13
5.3.4. Test input to emitter........................13
5.3.5. Power supply..................................13
5.3.6. Bringing into operation...................13
5.3.7. Outputs .........................................13
5.3.8. Trouble shooting ............................14
5.3.9. OptiLink ........................................14
6. Interfacing to safety devices ............... 14
7. Dimensional drawings ........................ 16
7.1. System with integrated controller.............16
7.2. Systems with separated Controller...........17
8. Selection of a safety light curtain ....... 18
8.1. Check list ..............................................18
8.2. Selection table .......................................19
8.3. Special configuration .............................20
8.4. Accessories / Components .....................20
9. Inspection and service ........................ 20
9.1. Cleaning ...............................................20
9.2. Inspections ............................................21
9.3. Decommissioning ..................................21
10. Product labels ..................................... 21
11. Technical Data..................................... 22
12. Certificates .......................................... 23

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 Operation Manual Safe2+ / Safe4

2. Introduction The products are a modular construction housed in a

very compact and sturdy extruded aluminium profile.
Safe4 safety light curtains are active optoelectronic
If space is limited, the controller may be separated
protective equipments AOPE type 4 with object de-
from the sensor by using an interconnection cable
tection capability of 14 mm or 30 mm. Safe4 has a
(Figure 2).
built-in fully redundant self-monitoring circuitry and
complies to annex VI of the European Machinery Standard Controller
Directive EC/98/37 and IEC 61496 as a safety com- separated

ponent. Safe4 is a control reliability device as well as

Controller
defined in ANSI B11.19-1990, 5.5 and OSHA 29

Controller
CFR 1910.212.
Safe2+ safety light curtains are active optoelectronic
protective equipments (AOPE) type 2 and comply to
annex IV of the European Machinery Directive

Protective field
EC/98/37 and IEC 61496 as a safety component.
Moreover the systems comply as a control reliability

Protective field
device as defined in ANSI B11.19-1990, 5.5 and
OSHA 29 CFR 1910.212.
A special feature of the Safe2+ system compared to
ordinary safety light curtains of type 2 is that the
controllers have a built-in fully redundant self-
monitoring circuitry. This feature makes the usual
implementation of a self test at the beginning of each Figure 2: Integrated and separated Controller
machine start unnecessary. The safety function of
each Safe2+ light curtain is never influenced in any 2.2. Special features
moment by the self test monitoring.
The big advantage for you as a user is that you can The outstanding features of the safety light curtain
run the Safe2+ system in the self test mode. So you systems of Safe2+ or Safe4 are:
do not have to think about connecting and installing ! Integrated self test mode, which make an ex-
an external test. You just have to wire a system cor- ternal testing unnecessary
responding to a type 4 system. ! Configuration with fitted intelligent laser
2.1. System design alignment ILAS (as an option for Safe2+)
! Finger (14 mm) and hand protection (30 mm)
Safe2+ or Safe4 light curtains consists of an emitter available
and a receiver (Figure 1). ! Wide dynamic range with a compact profile
The emitter as well as the receiver of Safe 4 have a type:
standard built-in intelligent laser alignment system 14 mm resolution: 0 m up to 9 m
ILAS. 30 mm resolution: 0 m up to 18 m, optional 6
By request the ILAS can be supplied in the Safe2+ or 5 up to 30 m
safety light curtain. ! Max. 256 beams per system
! Tolerant to dust, soiling, pollution
This allows a much easier adjustment during installa-
! Short circuit protected semiconductor outputs
tion and system testing compared to conventional
! Electrical interface compatible to industry
safety edges. The ILAS may also be used as a vibra-
standard
tion indicator at the installation.
! Built-in diagnostic LED or optical interface
(OptiLink) for quick trouble shooting
Intelligent Laser Alignment System ILAS ! Very compact design: 30 x 40 mm (1.2" x 1.6")
Safe4
Safe4

! Very compact design for the whole dynamic

Detection capability
(resolution)
range
! Wide standard product range for resolution,
Protection height

protective height, type of application

! Separate controller as an option
! Several protective fields by cascading
! Customer specific version on request
! Optical synchronisation, no electrical cable
CEDES

CEDES

needed between emitter and receiver

Intelligent Laser Alignment System ILAS ! Modern technology
Operating range ! Insignificant power consumption
! Maintenance-free and cost effective
Figure 1: Main system parameters

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 Safe2+ / Safe4 Operation Manual

3. Applications
3.1. Typical applications
Depending on the risk analysis Safe2+ or Safe4
systems are used for (Figure 3):

! Entry / exit safeguarding

! Point-of-operation safeguarding
! Hazards area safeguarding
! Combination of entry and area safeguarding
! Combination of entry, area and point-of-
operation safeguarding

Typical areas of applications are:

! Robotic assembly line
Exit / Entry Safeguarding
! Welding robots
! Processing machinery
! Rotation machines
! Conveyor machines
! Automated paint shops
! Entry / exit of automatic storage facilities

Typical markets are:

! Automotive
! Apparatus
! Semi conductor industry
! Metal processing
! Paper processing
! Wood processing
! Glass manufacturing
! Textile industry

and at any place to protect working personnel from Point-of-Operation Safeguarding

dangerous machinery.
3.2. Applications restrictions
Safe2+ or Safe4 are is not designed and approved
for any application in explosive EX or radioactive
areas.
Safe2+ does not comply with the optical demands of
a type 4 light curtain according the international stan-
dard IEC 61496.

Hazardous Zone Safeguarding

Figure 3: Typical applications

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 Operation Manual Safe2+ / Safe4

3.3. Application conditions 4. Principles of operation

The safe application of the light curtain systems
Safe2+ or Safe4 needs certain precautions: The emitter sends coded infrared light pulses to the
receiver, which evaluates them. If an object e.g. a
1. The control unit of the machine or system must finger (14 mm) or a hand (30 mm) penetrates the
be able to be electrically stopped and the stop protective field, the fully redundant solid state Output
time must be known. Signal Switching Devices OSSD of the receiver
2. The hazardous moving parts of the machine switch off to stop the machine. As soon as the pro-
must always be stoppable and must achieve a tective field is cleared, both outputs switch on again
safe position or complete standstill within the (automatic restart).
specified stop time of the machine.
4.1. Mode of operation
3. When installing Safe 2+ or Safe4, it has to be
ensured that overreach, under reach or unpro- Safe2+ or Safe4 operates in the guard only mode
tected area situations are impossible by taking with automatic restart. Other modes of operation e.g.
all necessary steps. PSDI mode (break mode), muting, external relay
monitoring can be realized using external safety
devices.
4.2. Intelligent Laser Alignment System
ILAS
The ILAS is a most convenient feature to make
alignment a pleasure. The ILAS can be activated at
Figure 4: Correct installation any time during installation or operation. It provides
the possibility to check if the sensor is still perfectly
aligned. In addition it indicates any vibrations at the
mounting base.
4.3. LED indicators

Emitter Receiver
Figure 5: Incorrect installation

POWER Power on POWER

Power on
For the professional installation and connection, (orange) (orange)

please consult the relevant laws and regulations.

Normal operation Output active
The safety officer of the manufacturing facilities, the OK
(green) (green)
local authorities (OSHA in USA, HSE in GB) or the
respective industry associations as well as the inten- TEST Test input Output inactive
(red) (red)
sively trained employees of CEDES are available for
any safety related queries. OptiLink OptiLink
(IR light) (IR light)
3.3.1. Corner mirrors
The protective field between emitter and receiver can Figure 6: LED indicators
be guided around a corner using a mirror to allow
safeguarding of two or three hazardous areas. Note
that using one mirror will reduce max. operating ran-
ge by approx. 20 %.

It is not recommended to use more than two mirrors

due to alignment difficulties that may occur.

As accessories two types of mirrors are available,

with different mounting plates and sizes. Detailed
information is available from CEDES.

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 Safe2+ / Safe4 Operation Manual

4.4. Cascading Separated 2 protective 3 protective

Controller fields fields
Safe2+ or Safe4 allows one or several extension
modules to be connected by daisy-chaining to a
complete system (Figure 7). This can be used to
prevent someone from standing between the safety
device and the danger point (Figure 4). Any combi-
nations are possible, even mixed resolutions 14 / 30
mm. In every extension module an ILAS is integrated
for the simple and comfortable alignment depending
on the type (Safe2+ or Safe4) .

Following limitations shall be taken into considera-

tion:
• Maximum 256 light beams per controller
• The protective zone is made of units with
120 mm length
• 8 beams are used per unit with 30 mm resolution
• 16 beams are used per unit with 14 mm resolution Figure 7: Possible configurations
• 10 m maximum total length for light curtains, ex-
tension modules and connection cables combined The customers defines:
(Figure 8)
• Main system (protective height, resolution, operat-
• Max. three ILAS may be operated simultaneously ing range)
• Only a CEDES prefabricated cable may be used • Length of connection cables
between the light curtains.
• Extension modules (protective height, resolution,
operating range)
The extension modules are connected to the main
• Accessories (mounting kit, electrical ports)
system via connection cables.
Due to safety reasons combined light curtain as de-
scribed above have to be configured and tested as
complete configuration by the manufacturer.

2 x hazardous zone System length:

safeguarding
2 x length of hazardous zone safeguarding
+ 2 x length of entry safeguarding
+ 1 x length of connection cable
2 x entry safeguarding
-----------------------------------------------
Total length (max. 10 m)

Figure 8: Connection of the back and the front side of a machine with only one Safe2+ / Safe4 cascading system. The total length of the
system is equal to the individual protective field lengths, plus connection cables added together.

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 Operation Manual Safe2+ / Safe4

4.5. Perimeter systems

Perimeter systems are usually produced by means
of several single beam light barriers. But the flexibil-
ity of the Safe2+ or Safe4 system allows also the

CEDES

CEDES
Distance to reference plane [mm]
production of vertical entry safeguarding according to
900
the standard EN 999. Such systems are composed
of active and passive elements in one compact pro-
file. The element length of each is 120 mm.

The big advantage of Safe 2+ or Safe4 Perimeter

systems is the easy way of mounting and the un- 400

complicated way of starting up the operation. The

time needed to connect the wires and aligning the
optics is drastically reduced in comparison to stan-
0
dard Perimeter systems consisting of single beam R e fe re n c e p la ne (e .g . g ro u nd )
light barriers, where often mirrors are also included
which can only be positioned with difficulties.

CEDES

CEDES
The protective field and the active elements respec-
tively, are clearly recognized as black surfaces with 1100

Distance to reference plane [mm]

the integrated optical lenses. The not monitored
areas (passive elements) are also clearly indicated
as yellow surfaces.
700

300

0
Referen ce p lan e (e.g . g rou nd )
CEDES

CEDES
1200
Distance to reference plane [mm]

900

600

300

0
Reference plane (e.g. ground)

Figure 9: Perimeter systems (2-, 3- and 4-beams), accord. to EN

999 [1998]

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 Safe2+ / Safe4 Operation Manual

5. Installation S = 1.6 mm / ms x T + 850 [mm]

More detailed information regarding safety distance
5.1. Regulations and standards and safety height can be found in EN 999 or EN 294,
The compliance with the fundamental health & safety depending on mounting type of application.
requirements as detailed in the EU Machinery Direc- 5.1.2. Height of protective field
tive EC/98/37 and control reliability according to
OSHA 29 CFR 1910.212, ANSI B11.19 and ANSI The protective field is clearly visible as the black
B11.20 has to be achieved with the correct imple- area with the optical lenses on the emitter and re-
mentation of safety components. With the help of a ceiver.
hazard analysis as laid out in EN 292 and EN 1050, In addition the height of the protective field A is
a comprehensive safety evaluation has to be made found on the label of each system and in the selec-
when designing and planning machinery and ma- tion tables, described in chapter 8.2 (resolution 14
chinery control equipment. If Active Optoelectronic and 30 mm).
Protective Devices (AOPD) are used, the required
safety distances, sufficient protective height and all Warning:
application conditions must be considered during the The laser beams of the ILAS are not part of to the
planning phase. protective field.
Use only the protective field as mentioned on the
5.1.1. Safety distance to danger point
product label. Otherwise serious injury or death may
According to the standards, the Safe2+ or Safe4 light occur.
curtain and the point of danger must be separated by
5.1.3. Response time – light curtain
a defined safety distance. This minimum distance
safeguards that the danger point may only be The response time tR is found on the product label,
reached after the hazardous motion has stopped. Configuration Tool or from the selection tables 8.2.
The safety distance (see also standards EN 294, EN
775, EN 811, EN 999) depends on 5.1.4. Distance to reflective surfaces

• Machine stop time Reflective surfaces may cause specular reflections

• Response time of the protective device (light within the emitter and receiver aperture angle, i.e. an
curtain + safety relays) interruption of the protective field would not be recog-
• Resolution of the protective device nized (Figure 10).
• Approaching speed to the danger point
• Position of the AOPD dangerous point

The approaching speed is dependent on safety dis-

tance S as follows
E S2 R
S ≤ 500 mm, speed = 2 mm / ms
S > 500 mm, speed = 1.6 mm / ms #
optical axis
R
In cases of 'vertical' installation of the light curtains
reflective surface
within an industrial environment and a resolution of
the light curtain system d, (where 14 mm ≤ d ≤ 40 Figure 10: Distance to reflective surfaces
mm), the safety distance S to the point of danger is
Should reflective surfaces arise, i.e. aluminium con-
calculated according to the formula:
tainer passing near the light curtain or if the danger
point itself is reflective, i.e. a steel blade, the safety
For 100 mm ≤ S ≤ 500 mm:
distance S2 must be increased, such that no reflec-
S = 2 mm / ms x T + 8 x (d - 14)
tive surface lies within the distance S2.
The increase of the safety distance is dependant of
For S > 500 mm the actual operation range R according to IEC 61496
S = 1.6 mm / ms x T + 8 x (d - 14) and may be calculated as follows:
S = Safety distance in mm Safe4
T = Total response time in ms S2 = 72 mm für R < 3 m
(machine stop time + Safe2+ / Safe4 response S2 = R x 0.0219 für R ≥ 3 m
time + safety relay response time)
d = Resolution of Safe2+ or Safe4 in mm
Safe2+:
In the case of perimeter systems (chapter 4.5) or S2 = 131 mm für R < 3 m
light curtains with a resolution d > 40 mm the safety S2 = R x 0.0437 für R ≥ 3 m
distance is calculated for vertical mounted light cur-
tains and horizontal approach, according to the for- The safety distance may also be calculated with the
mula: Configuration Tool.
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 Operation Manual Safe2+ / Safe4

5.1.5. Multiple light curtain arrangement

5.2. Mechanical installation
When using several optoelectronic safety devices in
the same application, the systems should be in- Be aware that a rigid, flat base, isolated against
stalled in such a way that they cannot interfere with shock and vibration should be selected to mount the
each other. Care must be taken that each receiver Safe2+ or Safe4. This in combination with the stan-
only receives light from its own emitter (Figure 11). dard mounting brackets set will keep the initial
alignment during operation even in harsh industrial
Receiver
environments.
Emitter Receiver Emitter

5.2.1. Mounting brackets

The backside of the light curtain profile has continu-
ous grooves to fix the mounting brackets at any posi-
tion along the light curtain housing (Figure 22).

Edges up to a length of 1800mm are fixed using two

Emitter Receiver Receiver Emitter
brackets. Longer edges with 3 brackets. Each sys-
tem includes necessary clamps (Standard 30mm
Mounting Kit, Part No. 106 500). They are adjustable
within ± 4º for a perfect alignment of the light curtain.

Optional available mounting brackets (Figure 12):

• Vertical mounting brackets for mounting the
Figure 11: Multiple light curtain arrangement light curtain in the vertical axis of the light cur-
tain. (± 4º adjustable)
• FGS mounting profiles (not adjustable)
The safety light curtain has been thoroughly tested
• 180° Mounting, rotation ± 90°, for applications
against light interferences according to the stringent
where the mounting angle is not set using the
requirements of IEC 61496. Nevertheless any direct
mounting frame.
interference into the receiver with other infrared
sources like through beam photoelectric sensors, • Damping kit helps to reduce vibration
laser scanner, transmitters etc. should be avoided.

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 Safe2+ / Safe4 Operation Manual

Mounting kit 30mm (2 brackets)

11
Part No. 106 500
• For side mounting
M6 x 40
• Adjustable by ± 4°

29.5
M4 x 16

Mounting kit vertical 30mm (2 brackets)

M6 x 40 Part No. 106 502
• For mounting in the vertical axis of the
light curtain
• Adjustable by ± 4°

M4 x 12

29

60 Mounting kit 180° adj.

FGS mounting profile 30mm (2 brackets)
Part No. 106 503 Part No. 106 497
• A special profile which is 180° Mounting, rotation ±
47.5

compatible with existing 90°, for applications where

FGS-mountings. the mounting angle is not set
11

• Adjustments has to be using the mounting frame.

made with the FGS-
mountings, if available.

Figure 12: Different mounting brackets for a Safe2+ / Safe4

The mounting brackets contain all necessary mount-

ing parts and an separate instruction sheet to en- Operation: Laser beam is blinking
sure that the parts are assembled properly.
To switch off ILAS:
5.2.2. Intelligent Laser Alignment System
• Touch the hand symbol $ again
ILAS (Optional with Safe2+)
• Automatically after 5 minutes
5.2.3. Adjustment Procedure without ILAS
WARNING: Class 2 Laser
Do not expose your eyes to the laser to 1. Mount the emitter and the receiver with the ad-
prevent exposition to dangerous laser ra- justable mounting brackets. Make sure that the
diation! Turn ILAS off if not used! longitudinal axis of both are oriented parallel. A
spirit level might help to find the correct posi-
To switch on ILAS: Touch the hand symbol $ tion.

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 Operation Manual Safe2+ / Safe4
2. Take care that the receiver and emitter are ori- 3. Adjust the emitter and receiver in a way that
ented in the same direction. This means, the both laser points hit the laser target on the op-
controllers of the emitter and receiver have to posite unit. Small deviations are harmless as
be at the same end of the protective field. long as they are within the aperture angle.
It is not allowed to mount Safe2+ or Safe4 sys- 4. Tighten all screws firmly.
tems turned by 180° (Figure 13). 5. Switch the ILAS off when aligned.
5.2.5. Remarks to ILAS
Due to dimensional tolerances the red ILAS light
spot deflects from the target center when the light
Incorrect
curtain is aligned optimal in the center of the operat-

Empfänger
ing range. The optimal operating point can be found
Sender

after alignment with ILAS (chapter 5.2.4) when mov-

ing the axis in X- (left, right) and Z- (up, down) direc-
tion. The optimal operating point is in the middle of
Correct
the two end points, where the receiver output
switches from active to inactive condition.

Empfänger
D
Sender

On optimal alignment of the light

curtain the ILAS light point can deflect
from the ILAS target point. The
Figure 13: Layout of the emitter / receiver maximum deflection adds up to the R
following value due the operating
distance:
3. After aligning the longitudinal axis of emitter
and receiver, rotate the receiver around the
longitudinal axis to find the receiving angle.
2m
6m
9m
R = 7 mm
R = 20 mm
R = 30 mm
D = 7 mm
D = 21 mm
D = 32 mm
$
During rotation, the receiving angle is shown 18 m R = 60 mm D = 63 mm
30 m R = 99 mm D = 105 mm
when the green LED of the receiver controller
is on. Figure 14: Adjustment with ILAS
4. Adjust the receiver to the centre point of the
operating angle, and tighten. 5.2.6. Testing the protection field
5. After aligning the receiver rotate the emitter to
find the emitting angle. During rotation, the After Installation and Alignment of the Safe2+/4
emitting angle is shown when the green LED of safety light curtain, the protection field has to be
the emitter controller is on. tested with the test rod for the corresponding resolu-
6. Adjust the emitter to the centre point of the op- tion (14 or 30 mm) according Figure 15. Introducing
erating angle, and tighten. the test rod into the protective field at any position
7. Control the operation of the Safe2+ or Safe4 must lead to a protective field interruption (shining of
light curtain by using the test rod (Figure 15). the red LED on the receiver).
Introducing the test rod into the protective field
at any position must lead to a protective field When mounting Perimeter Systems adjust the
interruption (shining of the red LED on the re- heights according to the recommendations in the
ceiver). standard EN 999.

When mounting Perimeter Systems adjust the

heights according to the recommendations in the
standard EN 999.
Receiver
Emitter

5.2.4. Adjustment Procedure with ILAS

1. Mount the emitter and the receiver with the ad-
justable mounting brackets. Look for that the
longitudinal axis of both are oriented parallel.
Take care that receiver and emitter are ori-
ented in the same direction. This means, the
controllers of emitter and receiver have to be at Figure 15: Correct testing of the protective field using a test
the same end of the protective field. It is not al- rod
lowed to mount Safe2+ or Safe4 systems
turned by 180° (Figure 13).
2. The ILAS is activated by touching the hand
symbol ! at the emitter resp. at the receiver.
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 Safe2+ / Safe4 Operation Manual

5.3. Electrical Installation

5.3.2. B connector cap
The emitter and receiver are connected to the ma-
The B connector cap M12/5-pole plug connector
chine control using a 5-wire cable.
provides easy connection of a cable assembly. The
5.3.1. A connector cap plug pin assignment is shown in Diagram 18.
For the emitter and the receiver two M12 (for cable -
Ø 3 ... 6.5 mm) an two M16 cable glands (for cable -
Ø 3.5 ... 10 mm) are supplied.

Emitter Tx GND

Test 1 0V
Emitter Tx 1
3)
24 VDC
24 VDC 2
0 VDC 0 VDC + 24 VDC
Test 1 3 Test 2
1) 2)
Test 2
4
Not connected
Not connected 5
GND Not connected
6
Not connected
7
GND Reveiver Rx GND

1. Operation with internal test

2. Test using a relay contact
OSSD1 0V
3. Test using a PNP output

Reveiver Rx + 24 VDC
OSSD2
24 VDC 1
0 VDC 24 VDC
OSSD 1 2
OSSD 2 0 VDC
Not connected 3
Not connected OSSD 1 Figure 17: M12/5 Pin connector
GND 4

OSSD 2
5

Not connected
6
Receiver Emitter
Not connected
7

GND

Figure 16: Terminal block connection

(see also Figure 22)
Lumberg 4 (black)
Lumberg 2 (white)
Lumberg 5 (grey)

Lumberg 4 (black)
Lumberg 2 (white)
Lumberg 5 (grey)
Lumberg 3 (blue)

Lumberg 1 (brown) +24 VDC

Lumberg 1 (brown)
Lumberg 3 (blue)
OSSD 2

OSSD 1
PE

0V

+24 VDC
0V
PE

Test 1
Test 2

1)

1) Operation with internal test

2) Test using a relay contact 2)
3) Test using PNP output

3)

Figure 18: Wiring of the connecting cables of the M12/5 Pin

Lumberg connector (Part no. cable: 301 347)
The wiring of such connecting plugs is given in fig-
ure 17 and figure 18.

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 Operation Manual Safe2+ / Safe4

5.3.3. C connector cap Only with Safe2+:

The receiver will be connected by a normal C con- • In case of connecting an external test it could
nector cap M12/5-pole connection cable to the T be that, depending on the test type, only one
connection of the emitter. The T connector A OSSD output (OSSD1 or OSSD2) has to be
(=Safety Relay) has a connection to the power sup- considered.
ply and the OSSD output of the light curtain. The The timing of test input is as follows (Figure 19):
test input is short-circuited.
Time Value in ms
Response time on test signal t1 ≤ tR + 15
Time to test t2 > t1
Restart time after test t3 ≤ 800
short circuited

Test input open

A= Safety Relay OSSD 1 / OSSD 2

t1
t2 t3
A B
B= Receiver
A= Safety Relay
C Figure 19: Test timing diagram

Tx
tR means the response time of the respective
Rx
Safe2+ or Safe4 type (see product label).
Internal test Description Value
Continuous test current I 10 mA
C= Emitter Peak test current IP 100 mA
Time of peak test current tP 20 µs
Internal test Emitter Test LED
Emitter
Short circuited (closed) Active Green
Open Inactive Red

5.3.5. Power supply

A= Safety Relay
Safe 2+ and Safe4 are devices of electrical safety
level III (extra low voltage). 24 VDC ± 20 % has to
0 VDC
be supplied by a power supply that complies with
OSSD 1
IEC / EN 60204 and IEC / EN 60742. Such a power
supply meets the electrical safety requirements and
maintains the minimum power of 18 VDC during 20
+ 24 VDC OSSD 2 ms even in the event of voltage dips
(blue)
(black)
(white)

(brown) +24 VDC

(grey)

GND 5.3.6. Bringing into operation

After the power supply has been applied to the
GND

OSSD 2

OSSD 1

0 VDC

Safe2+ or Safe4 and the automatic power-up test is

successfully completed (power up test time < 3 s)
the green LED on the receiver and emitter will light
5.3.4. Test input to emitter on. The system is now ready to operate.
The automatic power-up test will only be successful,
Normally the test input at the emitter is installed with if the emitter and receiver are properly aligned, cor-
a short circuit jumper to activate the emitter. If an rectly connected and the protective field is not inter-
external test is desired, a contact can be connected rupted.
to the test input). Any intrusion of an object into the protective field will
switch the OSSD off within the specified response
The following points have to be considered: time and the LED at the receiver toggles from green
• In case of operation in the modus "self moni- to red.
toring" both OSSD outputs have to be con-
nected separately to the safety switching of 5.3.7. Outputs
the machine. The two redundant Output Signal Switching De-
vices (OSSD) are fully monitored. Any short circuits
are detected. The maximum load is 0.4 A, higher
currents are limited through short circuit protection.
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 Safe2+ / Safe4 Operation Manual
Increased output loads may be realized using exter- Normal operation
nal safety interfaces.
Emitter Receiver Operation status
Important information:
Safety devices for connection of Safe2+ or Safe4 Test input closed OSSD on Protective field free
the must be built with PNP logic. The outputs will be Test input closed OSSD off Protective field interrupted
periodically controlled for short-circuit and cross- Test input open OSSD off Test active
fault detection.
The output voltage at the solid-state outputs is de- 5.3.9. OptiLink
pendant on the power supply and the output load
As an accessory offers CEDES an infrared adapter
(see chapter 11 Technical Data).
(OptiLink) including a software package for ex-
5.3.8. Trouble shooting tended diagnostic purposes.
Possible errors and operation status are indicated
with the LED indicators on the emitter and receiver.
Also the OptiLink has an option that can be used for
the diagnostics (chapter 5.3.9).
Following combinations are relevant:
Table 1: Emitter
LED
Status Orange Green Red
(Power) (ok) (Test)
No power supply (external) off off on
Test input closed (external) on on off
Test input open (external) on off on
Controller error (internal) flashing off on
Protective field error (internal) flashing off flashing

Table 2: Receiver
LED Figure 20: OptiLink
Green Red
Status Orange (Protective (Protective
(Power) field not field The adapter may be snapped on the controller dur-
interrupted) interrupted)
ing normal operation and may be connected via the
No power supply
(external)
off off off interface to a MS-Windows personal computer for
No sufficient power
on off off diagnoses purposes. A detailed description about
(external)
extended diagnostic features is shipped with the
OSSD on (on-load operation,
protective field not inter- on on off diagnostic package.
rupted, normal)
The OptiLink offers apart from the diagnosis of op-
OSSD off (off-load operation,
protective field interrupted or erating conditions, the possibility to select and ana-
flashing off on
insufficient alignment of the lyse the length of the interrupted protective field.
system)
OSSD error (external, short
circuit between OSSD 1 and
OSSD 2, towards 0 V and 24
all 3s
short time off flashing 6. Interfacing to safety de-
VDC)
off
irregular
vices
Controller error (internal) off on
flashing
Protective field error (internal) flashing off flashing The interfacing of the light curtain with the machine
control has to be control reliability, i.e. a correct in-
External error: An external interface error can be terface with a safety PLC or safety relays with posi-
resolved by correcting the installation, due to tive guided relay contacts.
1. Receiver: short circuit of both OSSDs, of OSSD Figure 21 - Diagram for automatic reset mode -
to Usp, of OSSD to GND shows a diagram of a typical emergency stop relay
2. Emitter: Test input open component.
3. No or too low power supply
4. Wrong configuration in case of cascading sys- Other applications are mentioned in the application
tems note "Safety Interfaces with Safe2+ / Safe4", on the
5. Inadequate adjustment of emitter and receiver CEDES homepage or from safety relay manufactur-
ers.
Internal error (orange LED is irregularly flashing):
Please contact the nearest CEDES representative.

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 Operation Manual Safe2+ / Safe4

Danger
The safety devices and the interconnection to
the machinery have to comply with the basic
safety requirements as mentioned in the cur-
rent regulations and standards.
Direct interfacing of a safety light curtain to
machine control that does not meet the neces-
sary safety integrity level, i.e. use of general
purpose PLCs or general purpose relays can
cause serious injury or death of persons.
Consult a professional safety engineer!
Danger

+24 VDC

1 Safe4 1 Safe4
Sender/ Empfänger
Emitter Receiver
2 3 4 5 6 7 2 3 4 5 6 7

13 23 24
A1 S33 S34

CEDES
SafeC S

S21 S22 A2

14 S11 S12

0 VDC

Figure 21: Diagram for automatic reset mode with CEDES SafeC S (Part No: 103 105)

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 Safe2+ / Safe4 Operation Manual

7. Dimensional drawings
7.1. System with integrated controller

Emitter Receiver

M16

57
35
M12

145

ILAS target ILAS Emitter

B
A

Start of protective field

ILAS Emitter ILAS target

25
3

30
4

Cross section with Detail

connector pinning Pin 1 mounting groove
3
40

2
Pin 7

Figure 22: Dimensional drawing, cross Section with Pin-out of connector for systems with integrated controller

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 Operation Manual Safe2+ / Safe4

7.2. Systems with separated Controller

22

35
Controller ext. = 176

125
16

16 Profile length B 3

Length of Protective field 5

150

40
ca. 250

15.5
80

ø15
R min. 17

30

min. 35

Figure 23: Dimensional drawing, cross section with Pin-out of connector for systems with separated controller (dimensions emitter = dimen-
sions receiver)

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 Safe2+ / Safe4 Operation Manual

8. Selection of a safety light 3. Response time

The response time tR-BWS of Safe2+ or Safe4 can be
curtain found on the product label and in the selection table
(next section). The response time can also be calcu-
8.1. Check list late with the Configuration Tool.
In consideration of following points the selection of a
The total response time of a system made of several
proper Safe2+ or Safe4 safety light curtain will be
extension modules is the sum of the response time
simplified:
of the single modules (sum of the protective heights
A). The total response time of the complete system
1. Regulations
can be found on the product label.
Look up carefully the actual regulations and codes
applicable to the particular application in your coun-
Example:
try. Local authorities and professional organisations
You need a light curtain with 30 mm resolution made
as well as CEDES representatives will provide nec-
of two segments to prevent someone from standing
essary assistance.
between the light curtain and the danger point. The
USA: Occupation Safety and Health Administration
vertical portion has a protective height of 960 mm,
OSHA, others like ANSI, RIA and further pro-
the horizontal portion is 600 mm. The response time
fessional organisations
of this configuration is identical with the response
GB: Health and Safety Executive HSE, safety con-
time of a single light curtain with a protective height
sultants and professional organisations
of 1560 mm, which is the sum of 960 mm and 600
mm.
2. Protective field
Determination of
4. Corner mirrors
• required operating range, Using corner mirrors allows to safeguard two or
• protective height (available in increments of three protective fields with one light curtain.
120 mm), Each corner mirror reduces the operating range by
• resolution (object detection capability: 14 mm appr. 20 % per mirror.
or 30 mm)
• and configuration of light curtain (special con-
figuration with extension modules)

Operating range, protective height and special con-

figuration must be chosen so that the danger points
are only accessible through the protective field.

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8.2. Selection table

Table 3: 14 mm Auflösung mit ILAS
Type Protective height A Total length B Response time tR Max. range Resolution Weight per pair Part No. Part No.
(mm) (mm) (ms) (m) (mm) (kg) System with Emitter Tx;
connector cap A Receiver Rx
Tx: 106 430
Safe4-14-240 240 410 15.8 9 14 1.4 103 000 0002
Rx: 106 431
Tx: 106 432
Safe4-14-480 480 650 26.3 9 14 2.2 103 000 0004
Rx: 106 433
Tx: 106 434
Safe4-14-600 600 771 31.6 9 14 2.6 103 000 0005
Rx: 106 435
Tx: 106 436
Safe4-14-720 720 891 36.9 9 14 3.0 103 000 0006
Rx: 106 437
Tx: 106 438
Safe4-14-960 960 1'131 47.5 9 14 4.0 103 000 0008
Rx: 106 439
Tx: 106 440
Safe4-14-1200 1'200 1'372 58.1 9 14 4.5 103 000 0010
Rx: 106 441

Table 4: 30 mm Auflösung mit ILAS

Type Protective height A Total length B (mm) Response time tR Max. range Resolution Weight per pair (kg) Part No. Part No.
(mm) (ms) (m) (mm) System with Emitter Tx;
connector cap A Receiver Rx
480 Tx: 106 442
Safe4-30-480 650 15.8 18 30 2.2 103 000 0014
Rx: 106 443
Tx: 106 444
Safe4-30-600 600 771 18.4 18 30 2.6 103 000 0015
Rx: 106 445
Tx: 106 446
Safe4-30-720 720 891 21.1 18 30 3.0 103 000 0016
Rx: 106 447
Tx: 106 448
Safe4-30-960 960 1'131 26.3 18 30 4.0 103 000 0018
Rx: 106 449
Tx: 106 450
Safe4-30-1200 1'200 1'372 31.6 18 30 4.5 103 000 0020
Rx: 106 451
Tx: 106 452
Safe4-30-1560 1'560 1'733 39.6 18 30 6.0 103 000 0023
Rx: 106 453
Tx: 106 454
Safe4-30-1800 1'800 1'973 44.9 18 30 7.0 103 000 0025
Rx: 106 455

The total length "B" (figure 21) of systems "with" or systems "without ILAS" differs by 50 mm. Detailed dimensional drawings are available on the CEDES Homepage under [Link].
Other protective heights up to 1'920 mm (resolution 14 mm) or up to 2'760 mm (resolution 30 mm) on request.

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 Safe2+ / Safe4 Operation Manual
The results given to the user are the
8.3. Special configuration • exact designation of system for a clear identify-
All Safe2+ or Safe4 light curtains mentioned above ing of the customer design,
are also available with separated controllers or with • response time and
extension modules Naturally, all these versions are • safety distance.
provided with integrated self-monitoring and if re-
quired they also can be operate with external test,. All data in the software "Configuration Tool" with
regards to safety, is checked and certified by TÜV
An extensive overview of all the possibilities that the Rheinland. Calculations of the safety distances can
modularity of the Safe2+ or Safe4 systems offer are be printed out and become a part of the safety
shown in the "Configuration Tool" software. This evaluation documentation for the corresponding
program can be obtained from any of your CEDES application.
partners and is also available from the CEDES
8.4. Accessories / Components
Homepage at [Link].
Table 5
Your nearest CEDES sales office gives professional
CEDES
support for the evaluation of a special configuration. Description
Part No.
Due to safety reasons the special configuration has
to be assembled and tested at the manufacturing 106 427 Connection Cap A (Cable Gland) Tx / Rx
site. You will receive a completed and tested system 102 862 Connection Cap B (M12/5 Pin) Tx / Rx
with all safety relevant information on the type label
106 429 Connection Cap C (Double M12/5 Pin) Tx
ready for installation.
301 347 Cable, 5m, M12-M12, 5pol, M-F

102 792 Cable, 1m, MiniDin-MiniDin, 8pol, M-F

Standard configuration 102 793 Cable, 3m, MiniDin-MiniDin, 8pol, M-F
106 500 Mounting kit 30mm (2 brackets)
System with separated controller 106 502 Mounting kit vertical 30mm (2 brackets)

106 503 Mounting kit FGS 30mm (2 brackets)

Two separated protective fields
106 497 Mounting kit 180° adj. 30mm (2 brackets)

106 501 Mounting kit silent block (2 pcs.)

Two separated protective fields with separated controller
103 006 Mirror 30

103 652 Mirror 60 with mounting column

102 965 ZCH Drawing opto edges Safe4/Safe2+
Three separated protective fields
103 282 CD Configuration Tool / Optilink

104 565 OptiLink USB

Two separated protective fields by a passive zone
(Perimeter, static blanking) 103 105 Safety relay SafeC S

Figure 24: Possible configurations 104 794 Safety relay SafeCIS3-2P-4IO

Edges up to a length of 1800mm are fixed using two
For further information, dimensional drawings in brackets. Longer edges with 3 brackets.
different file formats are available on our CEDES
homepage.
9. Inspection and service
An accessory which shows clearly the whole flexibil-
ity and great variety of the Safe2+ or Safe4 family is All light curtains contain only electronics and there-
a computer program named "Configuration Tool with fore need no preventive maintenance.
OptiLink". 9.1. Cleaning
The user defines with the help of an easy working The optical windows are to be cleaned with non-
graphical editor the configuration: aggressive materials only. The interval between
1. Length and number of protective fields cleaning is dependant on the air pollution at the
2. Resolution installation.
3. Connecting type (cable gland or M12/5 pin)
4. Length of the connection cables Do not use aggressive solvents or abrasive sub-
5. System with or without ILAS stances. Otherwise range reduction and false
6. Safety category 2 or 4 switching could arise

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 Operation Manual Safe2+ / Safe4

9.2. Inspections If the light curtain has to be disposed, it can easily

be disassembled and recycled using state of the art
The light curtain must, depending on the valid regu-
recycling technology and following current disposal
lations, be periodically tested by qualified and
regulation. It does not contain harmful materials
trained persons, so that unallowed manipulations
except small quantities of materials used in elec-
and non-conform modifications may be detected.
tronic PCBs.
The function of the light curtain can be tested with
the supplied test rod, which has a diameter corre- 10. Product labels
sponding to the resolution of the light curtain. The
status is indicated through the LED display in the All relevant ratings are given on the 2 product labels.
CEDES Safe2+ or Safe4 light curtain. The labels are attached to the receiver as well as
the emitter light curtain (example):
Functional Test
The function of the light curtain can be tested using
the test rod, (Figure 15), which has a diameter cor-
CEDES Encl. Type Safe4
Swiss Made Type 4 Receiver
responding to the resolution of the light curtain. The 7302 Landquart
status is displayed at the 3 LED at the emitter re- Part. No. S4S-ASF2I-KH8-ACDA4
spective receiver. The status can be easily read S-No. 040903024 AOPD Type 4
from the trouble shooting labels "Emitter Status" and Lot-No. 040903/00000/033 SW V1.9
"Receiver Status" (table 1 and 2, page 13).
Supply voltage 24 VDC ± 20 % Enclosure rating IP65
9.3. Decommissioning Power consumption < 500 mA Response time < 14 ms
Temp. range 0 ... 55°C Operating range < 18 m
The safety light curtain may only be removed, if the
Protective height 960 mm Max. per output 0.3A, 24 VDC
machinery or assembly line will be closed defini- Resolution 30 mm
tively. This has to be done by removing the mains
supply from the machinery. It must be impossible to
bring the machinery into operation without using
tools.
The light curtain can be reused provided the current
regulations are taken into consideration.

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11. Technical Data

Table 6

Description Value Remarks

Profile length 120 ... 2'760 mm Selection table page 19

0 ... 9 m Resolution 14 mm
Operating range
0 ... 18 m, optional 6 or 5 up to 30 m Resolution 30 mm
Object detection capability 14 mm
Other resolution on request
(Resolution) 30 mm
Power supply Usp 24 VDC ± 20 % PELV, IEC 60 204-1
Power supply ripple < 10 % of Usp
Equipment Class III VDE 0106 part 100
Time for self check when switching
<3s
on Usp
Current consumption < 500 mA No-load operation
Outputs, short circuit proof 2 x PNP, 0.3 A Max. capacitive load 0.5 µF
Output voltage > Usp – 1 Load 0.1 A
Response time tR-BWS Selection table Page 17
Connector 7 pins, spacing 3.81 mm WAGO M16
Max length 60 m
Connection cable
Cross section max. 1.5 mm2
Cable gland
- axial M 16
- radial M 12, 5-Pin
3 ... 6.5 mm for M12
Outside diameter of cable
3.5 ... 10 mm for M16
Mode of operation Guard only with automatic restart
Safety category Type 2 (Safe2+), Type 4 (Safe4) Self testing
Standards IEC 61496 part1+2
Electromagnetic compatibility
IEC 61 496 part 1
(EMC)
Enclosure rating IP65
0 ... +55°C Operation with ILAS
Temperature range
-20 ... +60°C Storage / transport
Relative air humidity 15 ... 95 % Not condensing
Enclosure Aluminum profile 30 x 40 mm
Polycarbonate, bonded Optional: Coated polycarbonate,
Optical window
scratch resistant
Enclosure treatment Polyester powder coated Silicon free manufactured
ILAS Laser class 2 EN 60 825
Dimensions Dimensions and selection tables Pages 16, 17 + 19
Weight Selection tables Page 19

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12. Certificates
12.1. TÜV certificate
Safe2+ Safe4

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 Safe2+ / Safe4 Operation Manual
12.2. CSA certificate

© CEDES Safety & Automation AG " % +41 81 307 8200 " Fax: +41 81 307 8201 " csa@[Link] " [Link]

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