GuardShield Safe 4 and GuardShield Safe 4 PAC User Manual
Contents
1. GuardShield Safe 4 External error An external interface error can be resolved by correcting the installation due to 1 Receiver short circuit of both OSSDs of OSSD to Usp of OSSD to GND 2 Transmitter Test input open 3 None or too low power supply 4 Inadequate adjustment of transmitter and receiver Internal error orange LED is irregularly flashing Please contact the nearest ROCKWELL AUTOMATION representative Normal operation Operation status Test input closed OSSD on Protective field free Test input closed OSSD off Protective field interrupted 6 Interfacing to safety devices The interfacing of the light curtain with the machine control has to be control reliability i e a correct interface with a safety PLC or safety relays with positive guided relay contacts Figure 17 Diagram for automatic reset mode shows a diagram of a typical emergency stop relay component Other applications are mentioned in the application note Safety Interfaces with GuardShield Safe 4 on the ROCKWELL AUTOMATION homepage A N ATTENTION The safety devices and the interconnection to the machinery have to comply with the basic safety requirements as mentioned in the current regulations and standards Direct interfacing of a safety light curtain to machine control that does not meet the necessary safety integrity level i e use of general purpose PLCs or general purpose relays can cause serious injury or deat2. Figure 23 Dimensional drawing cross Section with Pin out of connector 19 GuardShield Safe 4 8 Selection of a safety light curtain 8 1 Check list In consideration of following points the selection of a proper GuardShield Safe 4 safety light curtain will be simplified 1 Regulations Look up carefully the actual regulations and codes applicable to the particular application in your country Local authorities and professional organisations as well as ROCKWELL AUTOMATION representatives will provide necessary assistance USA Occupation Safety and Health Administration OSHA others like ANSI RIA and further professional organisations GB Health and Safety Executive HSE safety con sultants and professional organisations Operation Manual 2 Protective field Determination of required operating range protective height available in increments of 120 mm resolution object detection capability 4 mm or 30 mm Operating range and protective height must be chosen so that the danger points are only accessible through the protective field 3 Response time The response time 15 pws 01 a GuardShield Safe 4 can be found on the product label and in the selection table next section 4 Corner mirrors Using corner mirrors allows safeguarding of two or three protective fields with one light curtain Each corner mirror helps reduce the operating range by approximately 15 per mirror 8 2 Selection table
3. Corner mirrors The protective field between transmitter and receiver can be guided around a corner using a mirror to allow safeguarding of two or three hazardous areas Note that using one mirror will help reduce max operating range by approx 15 It is not recommended to use more than two mirrors due to alignment difficulties that may occur Operation Manual As accessories two types of mirrors are available with different mounting plates and sizes Detailed information is available from ROCKWELL AUTOMATION 4 Principles of operation The transmitter sends coded infrared light pulses to the receiver which evaluates them If an object e g a finger 14 mm or a hand 30 mm penetrates the protective field the fully redundant solid state Output Signal Switching Devices OSSD of the receiver switch off to stop the machine As soon as the protective field is cleared both outputs switch on again automatic restart 4 1 Mode of operation GuardShield Safe 4 operates in the guard only mode with automatic restart Other modes of operation e g 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 any time during installation or operation It provides the possibility to check if the sensor is still perfectly aligned In addition it i
4. Table 3 14 mm resolution with ILAS Catalog No Protective Total length B Response time t Max range Resolution Weight per pair height A 445L P4L0120YD_ 120 299 105 6 445L P4L0240YD_ 240 410 158 6 445L P4LO360YD 360 530 211 6 445L P4L0480YD 480 650 23 6 0 6 f se f e 720 1 Oo 6 445L P4L0720YD raasi PaLoeaoyD e0 62 6 ia 6 7 0 0410960 445 960 1131 ars 6 14 40 445L P4L1080YD_ 1oso 1252 528 6 14 40 445L P4L1200YD 1200 1372 581 6 14 45 445L P4L1320YD_ 1320 1492 684 6 4 50 445L P4L1440YD 1440 1612 eez 6 4 55 asl PaLIseovD 1560 1733 o 6 4 6o 445L P4L1680YD_ 1680 1853 793 6 14 65 445L PaLi800YD 1800 1973 se 6e 4 8 E 6 es 20 Operation Manual GuardShield Safe 4 Table 4 30 mm resolution with ILAS height A mm ms m mm kg mm 445L P4S0120YD 445L P4S0240YD 445L P4S0360YD 445L P4S0480YD 480 445L P4SO0600YD 7 600 445L P4S0720YD 720 840 40 20 445L P4S0840YD 840 080 0 445L P4SO960YD 960 445L P4S1080Y 445L P4S1200 445L P4S1320YD 445L P4S1440YD 445L P4S1560YD 445L P4S1680YD 445L P4S1800YD 445L P4S1920YD 1920 2003 Table 5 Safe 4 PAC with ILAS eo 30 7 0 0 7 5 30 70 CA e Safe 4 PAC Part Numbers Catalog No Protective Total length Respon
5. aes T 0V using a test rod 0 9 MMS CY Qe Pin 1 Pine 5 3 Electrical Installation 24VDC 5 3 1 Connection diagram The transmitter and receiver are connected to the i Receiver machine control using a 5 wire cable For the transmitter and the receiver two M12 for Pind cable 3 6 5 mm are supplied 0 ipe Pin 1 24 VDC Figure 14 M12 5 Pin connector 13 GuardShield Safe 4 Receiver UMOJq Uld UMOJQ Uld dd 0 0 L ASSO AO OdA 6 dd 1 AO OA 6 1 Operation with internal test a 2 Test using a relay contact 2 3 Test using PNP output Figure 15 Wiring of the connecting cables of the M12 5 Pin connector Transmitter and receiver are supplied with M12 5 pin connectors The wiring of such connecting plugs is given in Figure 14 and Figure 15 5 3 2 Test input to transmitter Normally the test input at the transmitter is installed with a short circuit jumper to activate the transmitter If an external test is desired a contact can be connected to the test input Figure 13 The following points have to be considered e In case of operation in the modus self monitoring both OSSD outputs have to be connected separately to the safety switching of the machine The timing of test input is as follows Figure 16 Response time on test signa Time to test R
6. are a modular construction housed in a very compact and sturdy extruded aluminium profile 2 2 Special features The outstanding features of the safety light curtain systems of the GuardShield Safe 4 are ov Integrated laser alignment ILAS 4 Max 256 beams per system GuardShield Safe 4 Finger 14 mm and hand protection 30 mm Large range with a compact profile type 14 mm resolution 0 m to 6 m 30 mm resolution 0 m to 6 m Tolerant to dust soiling pollution Short circuit protected semiconductor outputs Built in diagnostic LEDs Very compact design 30 x 40 mm 1 2 x 1 6 Optical synchronisation no electrical cable needed between transmitter and receiver XN NNN RN RN Maintenance free and cost effective 3 Applications 3 1 Typical applications GuardShield Safe 4 systems are used for Figure 2 TA Entry exit safeguarding Point of operation safeguarding TA Hazards area safeguarding Combination of entry and area safeguading Cal Combination of entry area and point of operation safeguarding Typical areas of applications are Robotic assembly line Welding robots Processing machinery Rotation machines Conveyor machines Automated paint shops Entry exit of automatic storage facilities N ARAR AS Typical markets are Automotive Apparatus Semi conductor industry Metal processing Paper processing Wood processing Glass manufacturing 6
7. profile has continuous grooves to attach the mounting brackets at any position along the light curtain housing Figure 18 Each system is delivered with four mounting brackets Optional available mounting brackets Figure 9 Vertical mounting brackets for mounting the light curtain in the vertical axis of the light curtain 4 adjustable POC and SICK FGS mounting profiles not adjustable The mounting brackets contain all necessary mounting parts and a separate instruction sheet to help ensure that the parts are assembled properly 5 2 2 Intelligent Laser Alignment System ILAS WARNING Class 2 Laser Do not expose your eyes to the laser beam to prevent exposure to dangerous radiation Turn ILAS off if not used To switch on ILAS Touch the hand symbol gt Operation Laser beam is blinking To switch off ILAS Touch the hand symbol R amp P again Automatically after 5 minutes Operation Manual GuardShield Safe 4 445L AF6140 Standard mounting brackets For side mounting Adjustable by 4 445L AF6144 Vertical mounting brackets optional For mounting in the vertical axis of the light curtain Adjustable by 4 445L AF6141 180 Mounting rotation 90 for applications where the mounting angle is not set using t
8. 212 ANSI B11 19 and ANSI B11 20 has to be achieved with the correct implementation of safety components With the help of a hazard analysis as laid out in EN 292 and EN 1050 a comprehensive safety evaluation has to be made when designing and planning machinery and machinery control equipment If Active Optoelectronic Protective Devices AOPD are used the required safety distances sufficient protective height and all application conditions must be considered during the planning phase Operation Manual 5 1 1 IEC Safety distance to danger point According to the standards the GuardShield Safe 4 light curtain and the point of danger must be separated by a defined safety distance This minimum distance safeguards that the danger point may only be reached after the hazardous motion has stopped The safety distance see also standards EN 294 EN 775 EN 811 EN 999 depends on e Machine stop time e Response time of the protective device light curtain safety relays e Resolution of the protective device e Approaching speed to the danger point e Position of the AOPD The approaching speed is dependent on safety distance S as follows S gt 500 mm speed 2 mm ms S gt 500 mm speed 1 6 mm ms In cases of vertical installation of the light curtains within an industrial environment and a resolution of the light curtain system d where 14 mm lt d gt 40 mm the safety distance S to the point of danger is calcula
9. Operation Manual GuardShield Safe 4 GuardShield Safe 4 PAC Safety Light Curtain GuardShield Safe 4 Operation Manual Important User Information solid state equipment has operational characteristics differing from those of electromechan ical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http literature rockwellautomation com describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable Inno event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction
10. PORTANT This instruction manual is part of the light curtain GuardShield Safe 4 It must be kept accessible during the whole life cycle for everybody who is in charge of installation operation maintenance and safety control CEQ Operation Manual 2 Introduction GuardShield Safe 4 safety light curtains are active optoelectronic protective equipment AOPE type 4 with object detection capability of 14 mm or 30 mm GuardShield Safe 4 has built in fully redundant self monitoring circuitry and complies to annex VI of the European Machinery Directive EC 98 37 and IEC 61496 as a safety component GuardShield Safe 4 is a control reliability device as well as defined in ANSI B11 19 1990 5 5 and OSHA 29 CFR 1910 212 2 1 System design GuardShield Safe 4 light curtains consist of a transmitter and a receiver Figure 1 The transmitter as well as the receiver of GuardShield Safe 4 have a standard built in intelligent laser alignment system ILAS This allows a much easier adjustment during installation and system testing compared to conventional safety light curtains The ILAS may also be used as a vibration indicator at the installation Intelligent Laser Alignment System ILAS Detection capability resolution Protection height Intelligent Laser Alignment System ILAS Operating range Figure 1 Main system parameters The products
11. Textile industry GuardShield Safe 4 Exit Entry Safeguarding Foint of Operation Safeguarding Hazardous Zone Safeguarding Figure 2 Typical Applications Operation Manual 3 2 Applications restrictions GuardShield Safe 4 is not designed and approved for any application in explosive EX or radioactive areas 3 3 Application conditions The safe application of the light curtain system GuardShield Safe 4 needs certain precautions 1 The control unit of the machine or system must be able to be electrically stopped and the stop time must be known 2 The hazardous moving parts of the machine must always be stoppable and must achieve a safe position or complete standstill within the specified stop time of the machine 3 When installing GuardShield Safe 4 the only way to access the hazard must be through the sensing field of the GuardShield Safe 4 SET T Figure 3 Correct installation 15 AS IS Figure 4 Incorrect installation For the professional installation and connection please consult the relevant laws and regulations The safety officer of the manufacturing facilities the local authorities OSHA in USA HSE in GB or the respective industry associations as well as the intensively trained employees of ROCKWELL AUTOMATION are available for any safety related queries 3 3 1
12. afeguarding of personnel on a variety of machinery The GuardShield family of safety light curtains are general purpose presence sensing devices which are designed to help protect personnel working on or near machinery The installation of the GuardShield safety light curtain must comply with all applicable federal state and local rules regulations and codes It is the responsibility of the employer to properly install operate and maintain the product as well as the machinery on which the GuardShield presence sensing device is installed GuardShield safety light curtains must be properly installed by qualified personnel GuardShield safety light curtains are presence sensing devices and will not protect personnel from heat chemicals or flying parts They are intended to signal a stop of hazardous machine motion when the sensing field is broken GuardShield safety light curtains can only be used on machinery which can be stopped anywhere in it s stroke or cycle GuardShield safety light curtains should never be used on full revolution clutched machinery The effectiveness of the GuardShield safety light curtains depend upon the integrity of the machine control circuit The machinery that the GuardShield presence sensing device is installed should have control circuitry that is fail safe in design All stopping mechanisms for the machinery should be inspected regularly to provide proper operation The protected machinery must have a c
13. ensing field or for safe guarding access to a hazardous area or machine process The protective field and the active elements respectively are clearly recognized as black surfaces with the integrated optical lenses The not monitored areas passive elements are also clearly indicated as yellow surfaces 4 5 Muting Muting of the GuardShield Safe 4 PAC is best accomplished by connecting the Safe 4 PAC to an MSR 42 multi function safety module The MSR 42 allows two muting sensors to be connected for uni directional muting The muting sensors can be positioned on the same side of the Safe 4 PAC in parallel for entry or exit end muting of a machine process The two muting sensors may also be positioned in a crossed or X configuration for bi directional muting Rockwell Automation offers a number of muting solutions Check with your local Rockwell Automation office or Rockwell Automation authorized distributor for muting application possibilities and muting application notes GuardShield Safe 4 Oo O Distance to reference plane mm Reference plane e g ground Distance to reference plane mm Reference plane e g ground Figure 6 Perimeter Systems 2 and 3 beams accord to EN999 1998 5 Installation 5 1 Regulations and standards The compliance with the fundamental health amp safety requirements as detailed in the EU Machinery Directive EC 98 37 and control reliability according to OSHA 29 CFR 1910
14. estart time after test 14 Operation Manual short circuited Test input OSSD 1 OSSD 2 Figure 16 Test timing diagram tz means the response time of the respective GuardShield Safe 4 type see product label Description 100 mA_ tp Internal test Continuous test current Peak test current Time of peak test current Internal test Iransmitte Short circuited closed inactive Red 5 3 3 Power supply GuardShield Safe 4 are devices of electrical safety level IIl extra low voltage 24 VDC 20 has to be supplied by a power supply that complies with 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 ms even in the event of voltage dips 5 3 4 Bringing into operation After the power has been applied to the GuardShield Safe 4 and the automatic power up test is successfully completed power up test time gt 3 s the green LED on the receiver and transmitter will light on The system is now ready to operate The automatic power up test will only be successful if the transmitter and receiver are properly aligned correctly connected and the protective field is not interrupted Any intrusion of an object into the protective field will switch the OSSD off within the specified response time and the LED at the receiver toggles from green to red 5 3 5 Outputs The two redundant Output S
15. gs 7 1 System with integrated controller 8 Selection of a safety light curtain 8 1 Check list 8 2 Selection table 8 3 Accessories Components 9 Inspection and service 9 1 Cleaning 9 2 Inspections 9 3 Decommissioning 10 Product labels 11 Technical Data 0030300 4 4 4 4 4 4 00 00 00 60 60 Operation Manual 1 Approvals and Conformity TUV Rheinland Product Safety GmbH performed the CE type examination according to the machinery directive EC 98 37 appendix VI and the respective standards ICE 61496 The CE conformity declaration and the product approval certification TUV is available at your nearest ROCKWELL AUTOMATION dealer or on the home page www Rockwell Automation com All ROCKWELL AUTOMATION products are developed and manufactured following generally accepted rules in industry and in compliance with a total quality management system ISO 9001 2000 ATTENTION GuardShield Safe 4 systems are only a safety protection device if all instructions in this manual and in the related documents are carefully followed and fully complied with In addition the installer is responsible to comply with all local laws and standards AN ATTENTION Failure to follow all instructions in this manual and related documents may lead to serious injury or death Rockwell Automation cannot be held liable for any injury or death due to the negligence of the purchaser or installer IM
16. h of persons If necessary consult a professional safety engineer 15 GuardShield Safe 4 Operation Manual 24V Ge 1 MSR126T ii i i 440R N23117 KI E E a 445L P4S0800YD Jumper required for normal operation ov Figure 17 Safe 4 or Safe 4 PAC for Automatic Reset mode using MSR 126T safety relay module 24V MSR126R 440R N23123 445L P4S0800YD Jumper required for normal operation OV Figure 18 Safe 4 or Safe 4 PAC for Monitored Manual Reset mode using MSR 126R safety relay module 16 Operation Manual GuardShield Safe 4 24V 1 2 5 MSR127TP 440R N23132 apao e p e TFT CLEE 445L P4S0800YD 3 Jumper required for normal operation OV Figure 19 Safe 4 or Safe 4 PAC for Automatic Reset mode using MSR 127TP safety relay module 24V MSR127RP 440R N23135 8 Ee 445L P4S0800YD Jumper required for normal operation OV Figure 20 Safe 4 or Safe 4 PAC for Monitored Manual Reset mode using MSR 127RP safety relay module 17 GuardShield Safe 4 Operation Manual JT All iy T T E a E 24V Muting Lamp MSR42 MSR45E 440R P226AGS NNR 440R P4NANS Jumper required for normal operation Sensor 2 Ribbon Cable Jumper 440R ACABL1 OV Figure 21 Safe 4 or Safe 4 PAC for Two Sensor Muting using MSR 42 multi function safety module a
17. he mounting frame 2 brackets per kit Figure 9 Different mounting brackets for a GuardShield Safe 4 11 GuardShield Safe 4 5 2 3 Adjustment Procedure without ILAS 1 Mount the transmitter and the receiver with the adjustable mounting brackets Make sure that the longitudinal axis of both are oriented parallel A spirit level might help to find the correct position 2 Take care that the receiver and transmitter are oriented in the same direction This means the controllers of the transmitter and receiver have to be at the same end of the protective field It is not allowed to mount GuardShield Safe 4 systems turned by 180 Figure 10 Incorrect R Transmitter Receiver Correct A Transmitter Receiver Figure 10 Layout of the transmitter receiver 3 After aligning the longitudinal axis of transmitter and receiver rotate the receiver around the longitudinal axis to find the receiving angle During rotation the receiving angle is shown when the green LED of the receiver controller is on 4 Adjust the receiver to the centre point of the operating angle and tighten 5 After aligning the receiver rotate the transmitter to find the emitting angle During rotation the emitting angle is shown when the green LED of the transmitter controller is on 6 Adjust the transmitter to the centre point of the operating angle and tighten 7 Control the operation of the GuardShield Safe 4 light curtai
18. ignal Switching Devices OSSD are fully monitored Any short circuits are detected The maximum load is 0 4 A higher currents are limited through short circuit protection Increased output loads may be realized using external safety interfaces Operation Manual A Important information Safety devices for connection of GuardShield Safe 4 must be built with PNP logic The outputs will be periodically controlled for short circuit and cross fault detection The output voltage at the solid state outputs is dependant on the power supply and the output load see chapter 11 Technical Data 5 3 6 Trouble shooting Possible errors and operation status are indicated with the LED indicators on the transmitter and receiver Following combinations are relevant Table 1 Transmitter Green Red Power ok west coe external oo external external Controller error Protective field error flashing off flashing internal Table 2 Receiver Protective Protective field not field interrupted No power supply No sufficient power external OSSD on on load operation protective field not interrupted normal OSSD off off load operation protective field interrupted or insufficient alignment of the system OSSD error external short all 3s circuit between OSSD 1 and short time OSSD 2 towards 0 V and off Controller error internal irregular flashing Protective field error internal flashing
19. increased such that no reflective surface lies within the distance S The increase of the safety distance is dependant of the actual operation range R according to IEC 61496 and may be calculated as follows Safe4 52 72 mm 3 gt 3m lt S2 x 0 0219 5 1 6 Multiple light curtain arrangement When using several optoelectronic safety devices in the same application the systems should be installed in such a way that they cannot interfere with each other Care must be taken that each receiver only receives light from its own transmitter Figure 8 Transmitter Receiver Transmitter Receiv Transmitter Receiver Receiver Trans E E 1 Figure 8 Multiple light curtain arrangement 10 Operation Manual The safety light curtain has been thoroughly tested against light interferences according to the stringent requirements of IEC 61496 Nevertheless any direct interference into the receiver with other infrared sources like through beam photoelectric sensors laser scanner transmitters etc should be avoided 5 2 Mechanical installation Be aware that a rigid flat base isolated against shock and vibration should be selected to mount the GuardShield Safe 4 This in combination with the standard mounting brackets set will keep the initial alignment during operation even in harsh industrial environments 5 2 1 Mounting brackets The backside of the light curtain
20. lerances the red ILAS light spot deflects from the target center when the light curtain is aligned optimally in the center of the operating range The optimal operating point can be found after alignment with ILAS chapter 5 2 4 when moving the axis in X left right and Z up down direction The optimal operating point is in the middle of the two end points where the receiver output switches from active to inactive condition Operation Manual GuardShield Safe 4 __ 24 VDC 1 2 a gi Not connected D On optimal alignment of the light curtain the ILAS light point can deflect from the ILAS target point The maximum deflection adds up to the following value due the operating distance Transmitter 2m R 7 mm D 7 mm 6m R 20mm D 21 mm 9m R 30mm D 32mm 18m R 60mm D 63mm 30m R 99mm D 105mm Figure 11 Adjustment with ILAS 5 2 6 Testing the protection field ae After Installation and Alignment of the GuardShield Safe 4 safety light curtain the protection field has to be tested with the test rod for the corresponding resolution 14 or 30 mm according Figure 12 ov OSSD 1 OSSD 2 o 2 e 9 Not connected 6 Not connected X 3 J 5 5 Figure 13 Terminal block connection see also Figure 18 Transmitter Pin 5 0 PE 4 Pin 3 Figure 12 Correct testing of the protective field
21. n by using the test rod Figure 12 Introducing the test rod into the protective field at any position must lead to a protective field interruption shining of the red LED on the receiver When mounting Perimeter Systems adjust the heights according to the recommendations in the relevant standard i e EN 999 ANSI RIA 15 06 etc 12 Operation Manual 5 2 4 Adjustment Procedure with ILAS 1 Mount the transmitter and the receiver with the adjustable mounting brackets Look for that the longitudinal axis of both are oriented parallel Take care that receiver and transmitter are oriented in the same direction This means the controllers of transmitter and receiver have to be at the same end of the protective field It is not allowed to mount GuardShield Safe 4 systems turned by 180 Figure 10 2 The ILAS is activated by touching the hand symbol Ry at the transmitter and at the receiver 3 Adjust the transmitter and receiver in a way that both laser points hit the laser target on the opposite unit Small deviations are harmless as long as they are within the aperture angle Tighten all screws firmly Switch the ILAS off when aligned Control the operation of the light curtain by using the test rod Figure 12 Introducing the test rod into the protective field at any position must lead to a protective field interruption shining of the red LED on the receiver D ol 5 2 5 Remarks to ILAS Due to dimensional to
22. nces Otherwise range reduction and false switching could arise 9 2 Inspections The light curtain must depending on the valid regulations be periodically tested by qualified and trained persons The function of the light curtain can be tested with the supplied test rod which has a diameter corresponding to the resolution of the light curtain The status is indicated through the LED display in the ROCKWELL AUTOMATION GuardShield Safe 4 light curtain Functional Test The function of the light curtain can be tested using the test rod Figure 12 which has a diameter corresponding to the resolution of the light curtain The status is displayed at the 3 LEDs at the transmitter and receiver The status can be easily read from the trouble shooting labels Transmitter Status and Receiver Status table 1 and 2 page 15 22 9 3 Decommissioning The safety light curtain may only be removed if the machinery or assembly line will be closed definitively This has to be done by removing the main 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 If the light curtain has to be disposed it can easily be disassembled and recycled using state of the art recycling technology and following current disposal regulation It does not contain harmful materials except small quan
23. nd MSR 45 E safety relay expansion module inal o hi hi g z A i i 5 E g hi Fe i ey 5 Bl ke RS g 5 hi 7 hi e Bl 6 5 3 2 hi as 0 i o 2 2 F 8 A al 8 5 28 hi ol hi BE IS hi o Fs 5 6 38 8 8 aj hj l 5 hi 1 575 177 5 to 5 L gt Z 8 OJ 5 1 17 By 29 9 1 575 40 Figure 22 Safe 4 PAC 2 and 3 passive elements 18 Operation Manual GuardShield Safe 4 7 Dimensional drawings 7 1 System with integrated controller component Transmitter Receiver M16 J M12 ILAS target ILAS Emitter Start of protective field 30 a Cross section with Pini 2 Detail connector pinning mounting groove 9 0 HI 6 Pin 7
24. ndicates any vibrations at the mounting base 4 3 LED indicators Transmitter Receiver Power on orange Power on orange Normal operation Output active green green Test input Output inactive red red D Optical D Optical IR light IR light Figure 5 LED Indicators 4 4 Perimeter systems Perimeter systems are usually produced by means of several single beam light barriers But the flexibility of the GuardShield Safe 4 system allows also the production of vertical entry safeguarding according to the standard EN 999 Such systems are composed of active and passive elements in one compact profile The active length of each is 120 mm GuardShield Safe 4 The GuardShield Safe 4 PAC is a multiple beam safety light curtain designed for perimeter or access detection around hazardous machinery or equipment The Safe 4 PAC is offered in 2 or 3 beam configurations with 360mm spacing between segments for a 2 beam pair and 360mm spacing for 3 beam pairs Both the 2 and 3 beam Safe 4 PACs have a 30 meter operating range The clear front window of the Safe 4 PAC allows for easy identification of the active sensing modules and the Integrated Laser alignment system simplifies the alignment of the Safe 4 PAC in long range and complex applications The GuardShield Safe 4 PAC multi beam safety light curtain may be used as an optical electronic fence detecting the presence of personnel as they pass through the s
25. of the contents of this manual in whole or in part without written permission of Rockwell Automation Ine 1s prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations a hazardous environment which may lead to personal injury or death property damage or economic loss tee identifies information that is critical for successful application and understanding of the product ATTENTION Identifies information about practices or circumstances that can lead to personal A injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequences Labels may be on or inside the equipment for example drive or motor to alert people Identifies information about practices or circumstances that can cause an explosion in that dangerous voltage may be present SHOCK HAZARD BURN HAZARD Labels may be on or inside the equipment for example drive or motor to alert people AN that surfaces may reach dangerous temperatures Operation Manual GuardShield Safe 4 Conditions required for proper use of the GuardShield Safety Light Curtain Please make sure you read and understand these requirements before you select and install the GuardShield safety light curtain GuardShield safety light curtains are point of operation safeguarding devices These safety light curtains are intended to be used to provide point of operation s
26. onsistent reliable and repeatable stopping time ATTENTIONS Failure to read and follow these instructions can lead to misapplication or misuse of the GuardShield safety light curtains resulting in personal injury and damage to equipment Allen Bradley badint GuardShield Safe 4 Content 1 Approvals and Conformity 2 Introduction 2 1 System design 2 2 Special features 3 Applications 3 1 Typical applications 3 2 Applications restrictions 3 3 Application conditions 3 3 1 Corner mirrors 4 Principles of operation 4 1 Mode of operation 4 2 Intelligent Laser Alignment System ILAS 4 3 LED indicators 4 4 Perimeter systems 4 5 Muting 5 Installation 5 1 Regulations and standards 5 1 1 IEC Safety distance to danger point 5 1 2 North American Safety distance formulas 5 1 3 Height of protective field 5 1 4 Response time light curtain 5 1 5 Distance to reflective surfaces 5 1 6 Multiple light curtain arrangement 5 2 Mechanical installation 5 2 1 Mounting brackets 5 2 2 Intelligent Laser Alignment System ILAS 5 2 3 Adjustment Procedure without ILAS 5 2 4 Adjustment Procedure with ILAS 5 2 5 Remarks to ILAS 5 2 6 Testing the protection field 5 3 Electrical Installation 5 3 1 Connection diagram 5 3 2 Test input to transmitter 5 3 3 Power supply 5 3 4 Bringing into operation 5 3 5 Outputs 5 3 6 Trouble shooting 6 Interfacing to safety devices 7 Dimensional drawin
27. operator injury The ANSI Safety Distance Formula The ANSI safety distance formula which is the Rockwell Automation recommended formula is as follows Ds Tg T T Die D Minimum safety distance between the safe guarding device and the nearest point of operation hazard in inches GuardShield Safe 4 K Hand speed constant in inches per second The ANSI standard value is 63 inches per second when the operator begins reaching toward the point of operation hazard from rest NOTE ANSI 211 19 1990 E4 2 3 3 5 states The value of the hand speed constant K has been determined by various studies and although these studies indicate speeds of 63 inches second to over 100 inches second they are not conclusive determinations The employer should consider all factors including the physical ability of the operator when determining the value of K to be used T Stop time of the machine tool measured at the final control element T Response time of the control system Note and are usually measured by a stop time measuring device T Response time of the presence sensing device safety light curtain and its interface if any This value is generally stated by the device manufacturer or it can be measured by the user Tpm Additional time allowed for the brake monitor to compensate for variations in normal stopping time D Depth penetration factor It is an added pf distance to allow f
28. or how far into the protective field an object such as a finger or hand can travel before being detected Dos is related to the safety light curtain s object sensitivity Object sensitivity is the smallest diameter object which will always be detected anywhere in the sensing field 5 1 3 Height of protective field The protective field is clearly visible as the black area with the optical lenses on the transmitter and receiver In addition the height of the protective field A is found on the label of each system and in the selection tables described in chapter 8 2 resolution 14 and 30 mm ATTENTION The laser beams of the ILAS are not part of the protective field Use only the protective field as mentioned on the product label Otherwise serious injury or death may occur 5 1 4 Response time light curtain The response time t is found on the product label or from the selection tables 8 2 GuardShield Safe 4 5 1 5 Distance to reflective surfaces Reflective surfaces may cause reflections within the transmitter and receiver aperture angle i e an interruption of the protective field would not be recognized Figure 7 dangerous point 5 optical axis reflective surface Figure 7 Distance to reflective surfaces Should reflective surfaces arise i e aluminium container passing near the light curtain or if the danger point itself is reflective i e a steel blade the safety distance S must be
29. ounted closer than six inches from the point of operation or pinch point hazard In the United States there are two formulas that are used to properly calculate the safety distance The first the OSHA formula is the minimum requirement for the calculation of the safety distance The second formula the one recommended by Rockwell Automation is the ANSI formula which incorporates additional factors to be considered when calculating the safety distance OSHA Safety Distance Calculation Formula The OSHA safety distance formula as specified in CFR Subpart O 1910 217 is as follows Ds 63 XT D Safety Distance 6 Is the OSHA recommended hand speed constant in inches per second Is the total stop time of all devices in the safety circuit measured in seconds This value must include all components involved in stopping the hazardous motion of the machinery For a mechanical power press it is the stopping time measured at approximately the 90 position of the crankshaft rotation Note The T number must include the response times of all devices including the response time of the safety light curtain the safety light curtain controller if used the machine s control circuit and any other devices that react to stop the hazardous motion of the machinery Not including the response time of a device or devices in the stop time calculation will result in insufficient safety distance for the application This may result in
30. se Max range Beam Spacing Number Weight per height mm in mm in time t ms m mm in of Beams pair kg 445L P4S2500YD 445L P4S3400YD 840 33 0 For further information dimensional drawings in different file formats are available on our ROCKWELLAUTOMATION homepage 8 3 Accessories Components Table 6 Corner Mirror GuardShield Safe 2 Safe 4 Narrow Corner Mirror Catalog Number Wide Corner Mirror Catalog Number Protective Height mm short range 0 4M Long range 4 15M 1201240 7207840 440L AM0751350 440L AM1250300 440L AM1250450 440L AM1250600 440L AM1250750 440L AM1250900 440L AM1251050 440L AM1251200 440L AM1251350 440L AM1251500 440L AM1251650 440L AM1251800 None Available 21 GuardShield Safe 4 Operation Manual Table 7 ROCKWELL AUTOMATION Description Part No 445L AF6140 Standard mounting kit 4 pieces 445L AF6141 Adjustable mounting kit 445L AF6142 Shock mount kit 445L AF6144 Mounting kit for POC AND Sick FGS adapter 4 pieces 445L AF6150 Optical Interface incl software 9 Inspection and service All light curtains contain only electronics and therefore need limited preventive maintenance 9 1 Cleaning The optical windows are to be cleaned with non aggressive materials only The interval between cleaning is dependant on the operating environment at the installation ATTENTION Do not use aggressive solvents or abrasive substa
31. ted according to the formula For 100 mm 5 5 gt 500 mm S 2mm ms xT 8 d 14 For S gt 500 mm S 1 6 mm ms xT 8 d 14 S Safety distance in mm 1 Total response time in ms machine stop time Safe2 Safe4 response time safety relay response time d Resolution of GuardShield Safe 4 in mm In the case of perimeter systems chapter 4 5 or light curtains with a resolution d gt 40 mm the safety distance is calculated for vertical mounted light curtains and horizontal approach according to the formula S 1 6 mm ms 850 mm More detailed information regarding safety distance and safety height can be found in EN 999 or EN 294 depending on mounting type of application 5 1 2 North American Safety Distance Formulas US Safety Distance Formula ATTENTION The GuardShield safety light AN curtains must be mounted at a sufficient distance from the pinch point or point of operation hazard to help ensure that the machine stops before a person s finger hand arm s or body reaches the hazard Operation Manual This distance referred to as the safety distance must be properly calculated prior to determining the safety light curtain protective height and mounting the light curtains on the machine Failure to properly calculate this safety distance may result in operator injury IMPORTANT Regardless of the calculated safety distance GuardShield safety light curtains should never be m
32. tion 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation Br hlstraRe 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 PN 29484 10000026005 Ver 01 April 2009 Copyright 2008 Rockwell International All right reserved Printed in USA
33. tities of materials used in electronic PCBs 10 Product labels All relevant ratings are given on the 2 product labels The labels are attached to the receiver as well as the transmitter light curtain Operation Manual GuardShield Safe 4 11 Technical Data Table 8 Protective heights 120 mm to 1920mm 120mm increments Operating range 0 9m Resolution 14 mm Object detection capability 14 mm Power supply ripple gt 10 of Usp 00000037 Equipment Class PM VDE 0106 part 100 Time for self check when switching on U 9 Output voltage Connection cable Max length 5 m Cross section max 1 5 mm Mode of operation Guard ony with automaticrestat Electromagnetic compatibility EMC IEC 614960881 Enclosure rating Pe G Temperature range 0 55 C Operation with ILAS n an ere Spe apt Enclosure Mmmmpoes0x4omm Optical window Polycarbonate bonded 23 AB Allen Bradley Guard Imaster Please contact us for Technical Assistance Inthe U S 1 440 646 5800 Outside U S 001 440 646 5800 On line http www ab com safety www rockwellautomation com http www ab com safety Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automa
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