GuardShield Micro 400 User Manual
Contents
1. Figure 15 Using the cascaded system it is possible for example to monitor the front and backsides of a machine using only one light curtain system Figure 7 Standard version Two protective fields Cascading Figure 15 Possible configurations Note For cascaded systems the light curtain LED s will only illuminate in the first light curtain portion closest to the safety control unit 6 5 Accessories components Table 6 Part no Description 445L AC8PC3 Patch cord for Cascaded system M12 8 pin 3M 445L AF6145 Mounting kit flat 4 pieces set 445L AF6143 Mounting kit 180 4 pieces set 440R P226AGS NNR MSR 42 Safety control module 440R P4NANS Safety control module extension unit 18 Operation Manual 6 6 Micro 400 Cascadeable Patch Cord The Cascadeable Micro 400 are offered with a 500mm integrated cable with M12 connector attached to both the top and the bottom of the light curtains When interconnecting two cascadeable light curtains the resulting cable length between light curtains is 1000mm If it is necessary to have a longer cable length between light curtains Rockwell Automation offers patch cords in 1M and 3M lengths Length see table lolerance 0 50mm Name Description Length mm Length inch Cable 1m M12 M12 8pol M F 1000 39 37 Cable 3m M12 M12 8pol M F 3000 118 11 445L AC8PC1 1 Meter M12 to M12 Micro 400 cascadeable patch cord 445L AC8PC3 32. Meter M12 to M12 Micro 400 cascadeable patch cord Figure 16 Operation Manual 7 Inspection and Service The light curtain is built without moving parts and so needs limited preventative maintenance 7 1 Cleaning The optical windows should be cleaned with a soft and damp cloth depending on the degree of dirt build up ATTENTION In no case should aggressive or abrasive materials be used to clean the GuardShield Micro 400 otherwise the range could be reduced and disturbances may occur 7 2 Inspections Depending on the valid regulations the light curtain must 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 GuardShield Micro 400 safety light curtain The following statuses are possible Table 7 Action Light curtain LED Move test rod slowly over the entire red protective field Remove test rod from green protective field The test rod should be moved through the protective field according to the diagram shown in Figure 13 7 3 Decommissioning The safety light curtain may only be removed if the machinery or assembly line will be closed definitively and may not be brought back into operation without the use of tools If the light curtain has to be disposed of it can easily be disassembl
3. in the GuardShield Micro 400 Operation Manual GuardShield Micro400 Standard Profile Mounting kit wide optional 4 pcs per kit For side mounting from the front with one fastening and one locking screw 60 Distance plate Not necessary for wall mounting see comment stated below only necessary for standard profile mounting Locking screw Hole for fastening screw Note When fitting without distance plate an opening for the retaining screw must be provided in addition to the hole for the fixing screw Rockwell part number 445L AF6145 Mounting kit 180 standard e Ideal for mounting in the same axis as the light curtain Ideal for mounting from the side D Rockwell part number 445L AF6143 Figure 12 Mounting brackets for the standard profile 13 GuardShield Micro400 Transmitter Receiver Figure 13 Correct testing of a protective field using a test rod 5 3 Electrical installation 5 3 1 Connection diagram The connection of a GuardShield Micro 400 to a machine controller must occur using an MSR 4X Series safety control module The speed and ease of the connection can be improved by using connection cables provided by Rockwell Automation Table 4 The connection cables are offered with color coded rings attached to each cable remove
4. 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 Micro400 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 safeguarding of person
5. one color ring from the cable as necessary White Transmitter Blue receiver 5 3 2 Test According to EN 954 1 when connecting a MSR 4X Series safety control unit in the context of a risk assessment it may not be necessary to conduct tests with a higher level controller 5 3 3 Power supply The power supply and the evaluation of the protective field of a GuardShield Micro 400 light curtain can fundamentally only be carried out through a MSR 4X Series control unit 5 3 4 Bringing into operation The transmitter and receiver units must be connected to a MSR 4X Series safety control unit GuardShield Micro 400 to MSR 4X Series safety control module then the supply voltage may be connected to the control unit After power up there is an automatic self test duration lt 5 s of all sys tem components 14 Operation Manual Provided the protective field is not interrupted and the transmitter and receiver are correctly aligned the self test of the GuardShield Micro 400 system will be successfully ended This is indicated by the illumination of the green LED on the GuardShield Micro 400 light curtain Figure 5 If the light curtain detects an interruption in the protective field after a successful power up the safety contacts of the controller unit will open within the sum of the response time for the light curtain and the response time for the control unit In addition the green LED turns off and red LE
6. stops E before a person s finger hand arm s or body reaches the hazard 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 mounted 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 For most applications Rockwell Automation recommends the ANSI formula which incorporates additional factors to be considered when calculating the safety distance GuardShield Micro400 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 63 Is the OSHA recommended hand speed constant in inches per second 1 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 cranksha
7. the pre requisites outlined in Figure 3 must be kept More detailed information regarding installation height is described in EN 294 Operation Manual 5 1 4 Response time light curtain The GuardShield Micro 400 light curtain system Light curtain and MSR4X Series safety control module has various configurable operating modes The standard response time of the light curtain t jw is dependant on the physical resolution and is shown on the product label An overview of the resolution table is also given in chapter 6 2 and 6 3 Important information The response time of the GuardShield Micro 400 light curtain system is dependent on the operating mode The minimum safety distance from the danger point to the light curtain for the current operating mode may never be undercut and when modified must be adapted to reflect any changes to the response time and resolution 5 1 5 Response time safety control units The response time of an MSR 4X Series safety control unit is described in the corresponding configuration control document 5 1 6 Distance to reflective surfaces Reflective surfaces which may cause reflections within the transmitter and receiver aperture angles i e an interruption of the protective field would not be recognized Figure 9 Should reflective surfaces arise i e aluminum container passing near the light curtain or if the danger point itself is reflective i e a steel blade the safety dista
8. 2 5 9 13 17 13 10 13 17 14 19 13 11 10 19 17 14 11 10 12 O Operating mode Operation range Outputs P Power supply Precaution Principle of operation Product label Protective height R Reflective surfaces Regulations Resolution Response time Restrictions RJ45 S Safety circuit Safety distance Selection table Self test Standards Supply voltage System design T Technical data Test rod Trouble shooting Operation Manual 10 11 13 13 18 19 11 15 19 11 15 13 16 13 13 19 13 17 13 Operation Manual GuardShield Micro400 23 AB Allen Bradley Please contact us for Technical Assistance Inthe U S 1 440 646 5800 Outside U S 0 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 Automation 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
9. 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 Brihlstrae 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 29481 10000026004 Ver 01 March 2009 Copyright 2008 Rockwell International All right reserved Printed in USA
10. D turns on see Table 1 5 3 5 Outputs A GuardShield Micro 400 safety light curtain pair has no outputs which could be used for direct connection to a machine controller Every connection to a machine controller or a safety circuit is done through an MSR 4X safety control unit This means that these may only be connected to the machine controller for information purposes They may under no circumstances be used within the safety circuit of the machine The status outputs of the control units are not safety related 5 3 6 Trouble shooting With the help of the LED display all system conditions and faults of the GuardShield Micro 400 systems are indicated The possible conditions of the LED are shown in Table 1 The conditions of the status outputs may also be obtained from the operation manual of the MSR 4X Series safety control module External faults These fault conditions can be reduced when the installation is rectified 1 None or not enough supply voltage to the safety control unit 2 Transmitter and receiver not correctly aligned 3 Transmitter and receiver light curtains are reversed in the MSR 4X Series safety control module 4 Incorrect assembly in the case of cascaded systems 5 Connectors make poor contact Operation Manual Internal faults LED of the GuardShield Micro 400 blinking red 1 Examine connections of transmitter and receiver 2 Turn the supply voltage off and on again If the LED o
11. Operation Manual GuardShield Micro400 Safety Light Curtain GuardShield Micro400 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 of the contents of this
12. ation with the standard mounting bracket set will keep the initial alignment during operation even in harsh industrial environments For the installation height and safety distance please refer back to the previous information given Likewise be aware that the transmitter and receiver connection cables must always be located on the same end of the protective field If this is not the case the protective field will have dangerous unprotected areas Figure 11 11 GuardShield Micro400 Transmitter Receiver Correct gt gt Transmitter Receiver Figure 11 Layout of the transmitter receiver 5 2 1 Mounting brackets The backside of the light curtain profile has continuous grooves to fix the mounting brackets at any position along the light curtain housing Further brackets may be obtained as an option to offer the possibility of mounting on the side or in the centre Figure 12 5 2 2 Alignment procedure The alignment procedure can be made easier with the use of integrated indicator LEDs Table 1 1 12 Mount the transmitter and receiver with the previously mentioned brackets Make sure that the longitudinal axis of both are oriented parallel For a vertical or horizontal mounting a level might help to find the correct position Operation Manual Take care that the receiver and transmitter are oriented in the same direction This means the beginning of the protective field whi
13. ce 7 1 Cleaning 7 2 Inspections 7 3 Decommissioning Product labels Technical Data 10 11 11 11 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 4 and the respective standards IEC 61496 The CE conformity declaration and the product approval certification TUV is available on line at www ab com safety These 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 Micro 400 is 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 Should some of these instructions not be carefully followed serious injury or death may occur The installer or system integrator will be fully responsible for a safe integration of the light curtain Z IMPORTANT Save This Manual This operation manual is part of the GuardShield Micro 400 safety light curtain system It must be kept accessible during the whole life cycle for all personnel who are responsible for installation operation maintenance and safety control CEQ Operation Manual 2 Introduction GuardShield Micro 400 light curtains are Active Optoelect
14. ch is found next to the cable which leads to the MSR 42 safety control unit must be located at the same end of the protective field It is not allowed to mount the GuardShield Micro 400 systems turned 180 Figure 11 After aligning the longitudinal axis of the transmitter and receiver rotate the receiver along the longitudinal axis to find the receiving angle During rotation the receiving angle is shown by the illumination of the green LED in the GuardShield Micro 400 light curtain If this green LED is blinking the amount of light detected by the receiver is not sufficient for stable operation After realigning the light curtain the protective field must be briefly interrupted After removing the object from the protective field a sufficient intensity level is indicated by the illumination of the green LED in the light curtain Adjust and mount the receiver at the centre of this operating angle After aligning the receiver rotate the transmitter to find the emitting angle During rotation the emitting angle is shown by the illumination of the green LED in the GuardShield Micro 400 light curtain Adjust and mount the transmitter at the centre of this operating angle Control the protective function of the GuardShield Micro 400 light curtain by using the test rod according to Figure 13 The insertion of this rod into the protective field at any position has to lead to a protective field interruption illumination of the red LED
15. e field height and special configuration must be chosen so that the danger points are only accessible through the protective field 3 Response time The response time 15 pws Of the GuardShield Micro 400 can be found on the product label and in the selection table in the next section The response time of one system which has cascaded light curtains chapter 6 2 and 6 3 is the sum of all of the beams sum of the total control height A The response time of the complete system can be found on the product label Example To safeguard a machine a cascaded system must be made up of horizontal and vertical segments to prevent someone from standing between the vertical light curtain and the danger point The vertical part has a protective height of 900 mm the horizontal module is 600 mm The response time of this set up is identical to a light curtain with the protective height of 1500 mm 4 Corner mirrors Using corner mirrors allows the combination one protective field with another Each corner mirror reduces the range by approx 15 440L AM1250300 16 440L AM0750300 440L AM0750300 440L AM0750450 440L AM0750600 440L AM0750750 440L AM0750900 440L AM0751050 440L AM0751200 440L AM1250300 440L AM1250450 440L AM1250600 440L AM1250750 440L AM1250900 440L AM1251050 440L AM1251200 Operation Manual GuardShield Micro400 6 2 Selection table 14 mm resolution Table 3 Catalog No Protection Max Weight p
16. ed and separated using state of the art technology and following valid national regulations be recycle GuardShield Micro400 8 Product labels Necessary information may be found on two product labels which are attached to both the transmitter as well as the receiver portion of the light curtain Explanation of terminology Table 8 Receiver Receiver Classification of the device AOPD Type Active optoelectronic protective equipment type 2 or type 4 based on IEC 61496 1 2 IP enclosure rating Response time Response time 15 pws for the protective process 19 GuardShield Micro400 Operation Manual 9 Technical Data Table 9 Protective height L 150 1200 mm See Table 3 and Table 4 Max system length 1800 mm Total of Cascaded segments Max system length GuardShield See chapter 4 2 Figure 7 Micro 400 From controller to the last emitting or receiving element Operating range Resolution 14 and 30 mm Object detection capably tesut 14mm Max number of beams 255 Eauipmentoess m ooe Time tor s tt check when swichingonUyl lt Ss 7 0 S Response time See Table 38067064 Cd comes mzawa Sd Safety category GuardShield Micro 400 Category 4 of EN 954 1 GuardShield Micro 400 in combination with a MSR 4X Series safety control module Standards IEC 61496 part 1 and 2 a Approvals T V CSA UL Certificates www ab com safety Enclosure rating IP54 Tem
17. er system Packaging height L response time incl packaging LxWxH mm fo aws ms ca kg mm 445L P4C0150FP 445L P4C0300FP 445L PACOGOOFP 600 445L P4CO900FP 900 445L P4C1200FP 10 6 3 Selection table 30 mm resolution Table 4 Catalog No Protection Max Weight per system Packaging height L response time incl packaging LxWxH mm fraw MS ca kg mm 440L P4E0600FP_ 600 7 4480400000 900 o2 lt 22 24 90 27 Notes 1 Total length Length from cable input to the end cap inclusive 2 The response time for GuardShield Micro 400 with MSR 42 3 The mentioned response times are maximum values The times depend on the controller type and the configuration The real response time may be faster Table 5 Resolution Catalog No Protection Max Weight per system Packaging height L response time incl packaging LxWxH mm tk ews ms ca kg mm 965x160x90 19 263 lt 620 600 6460600 445 14mm 445L C4C0900FP_ 900 920 lt 341 24 1410x160x90 445L C4E0600FP_ 600 620 lt 7 20 90 160 965 445L C4E0900FP_ 900 920 lt 202 24 1 410x 160x90 17 GuardShield Micro400 6 4 Cascaded systems All of the GuardShield Micro 400 light curtains mentioned in the previous table can be cascaded by interconnecting host modules This means there can be multiple protective fields using simple plug in connections to combine them with one another
18. f the safety light curtain is still blinking red please contact Rockwell Automation technical support Reference plane Finger protection resolution 14 mm Reference plane Hand protection resolution 30 mm Figure 14 Beam geometry for systems with finger protection and for systems with hand protection GuardShield Micro400 15 GuardShield Micro400 6 Selection of a safety light curtain 6 1 Check list To select a GuardShield Micro 400 safety light curtain please follow the questions below 1 Regulations Look up carefully the current regulations and codes applicable to the particular application in your country Local authorities and professional organizations as well as Rockwell Automation representatives will provide necessary assistance USA Occupation Safety and Health Administration OSHA others like ANSI RIA and further professional organizations GB Health and Safety Executive HSE safety consultants and professional organizations 2 Protective field Determination of e Required operating range up to 5 m e Protective field height in increments of 150 mm e Resolution object detection capability 14 mm and 30 mm e Position of the light curtain e g length of protective fields for cascaded systems length of extension cables e Length of connection cable to GuardShield Micro 400 or a MSR 4X Series safety control units Table 2 Operation Manual Operating range protectiv
19. ft 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 operator injury The ANSI Safety Distance Formula The ANSI safety distance formula is as follows Dg Tg T Thm Dos D Minimum safety distance between the safe guarding device and the nearest point of operation hazard in inches 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 B11 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 Ty Stop time of the machine tool measured at the final control element Te Response time of the control system Note T and T are usually measured by a stop time meas
20. nce must be 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 GuardShield Micro 400 S 72mm forR lt 3m S x 0 0219 forR23m Dangerous point Optical axis Reflective surface Figure 9 Distance to reflective surface GuardShield Micro400 5 1 7 Multiple light curtain arrangement When using several optoelectronic safety devices e g GuardShield Micro 400 systems in the same application the systems should be installed in a way such that they cannot interfere with each other Care must be taken so that each receiver only receives light from its own transmitter Figure 10 Transmitter Receiver Transmitter Receiver Transmitter Receiver Receiver Transmitter 5 eg a E E 3 E Figure 10 Multiple light curtain arrangement The safety light curtain has been thoroughly tested against foreign 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 or flashing warning lamps should be avoided 5 2 Mechanical installation Be aware that a rigid and flat base isolated against shock and vibration should be selected to mount the GuardShield Micro 400 This in combin
21. nel on a variety of machinery The GuardShield family of safety light curtains are general purpose presence sensing devices which are designed to 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 ensure proper operation The protected machinery must have a consistent reliable and re
22. nual After selecting the appropriate light curtain catalog numbers for a Cascaded Micro 400 system select the standard Micro 400 pair as the last segment in the cascaded system and also select interconnecting patch A Cascadeable pair of GuardShield Micro 400 light curtains has a 20 inch 500mm pigtail with a female M12 qd on the bottom of the Micro 400 light curtain and a 20 inch 500mm pigtail with a male M12 qd attached to the top of the Micro 400 transmitter and receiver When connecting two cascadeable segments together the resultant cable length between segments is 40 inches 1000mm If an additional length between segment pairs is required Rockwell offers an M12 to M12 patch cord in 1 meter and 3 meter lengths 445L AC8PC1 or 445L AC8PC3 ATTENTION The maximum Cascaded Micro 400 system length can not exceed 10 meters as measured between the RJ45 connection at the MSR 42 Controller to the last beam in the standard Micro 400 including all cable lengths Also in addition to the 10M maximum system length the maximum number of beams in a cascaded Micro 400 system can not exceed 255 beams System length 1 x length of connection cable 1 x protective field length front side 1 x length of extension cable 1 x protective field length back side Total length maximum 10 m Figure 7 Connection of the back and front sides of a machine with only one GuardShield Micro 400 cascading system The total length of the system is e
23. 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 your GuardShield Micro 400 the only way to access the hazard must be through the sensing field of the GuardShield Micro 400 aat it Figure 3 Correct applications 15 XS AS Figure 4 Incorrect applications For the professional installation and operation please consult the relevant laws and regulations The safety officer of the manufacturing facility the local authorities OSHA in USA HSE in GB or the respective industry associations Operation Manual 4 Principles of operation The transmitter sends coded infrared light pulses 940 nm wavelength to the receiver which evaluates them If an object at least the size of the resolution of the system penetrates the protective field at least one light beam is interrupted This interruption is evaluated by the MSR4X Series safety control unit and leads to the opening of the configured safety outputs For the configuration see Operation manual for MSR 4X Series 4 1 LED indicators There is an integrated red and a green LED in the connection module to each profile near the cable which clearly signals the status of the protective field Figure 5 LED display Table 1 LED meanings ED Description Color Meaning Light curtain interrupted Green Light curtain OK Green Light curtain not interr
24. oint of operation safeguarding Hazard area safeguarding TA Entry safeguarding entry or exit Combination of entry and hazard area safeguarding Cal Combination of entry point of operation and hazard area safeguarding Typical areas of application are Robotic assembly lines Welding robots Storage facilities Automated assembly stations Small presses Automated conveyor belts ANNI GuardShield Micro400 Exit Entry Safeguarding Pointot Operation Safeguarding Hazardous Zone Safeguarding Figure 2 Areas of Applications Operation Manual In different industries Automotive Apparatus Semiconductor materials Metal processing Paper processing Micro electronics Glass manufacturing NN AARAA And anywhere working personnel need protection from dangerous machinery 3 2 Application Restrictions The application of a GuardShield Micro 400 system is not intended for the following usages In an explosive environment EX In radioactive areas Outside of a temperature range of 0 55 C 3 3 Application Conditions The correct use of a GuardShield Micro 400 requires 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
25. peatable stopping time ATTENTION 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 GuardShield Micro400 Content 1 2 o gt Approvals and Conformity Introduction 2 1 System design 2 2 Special features Applications 3 1 Areas of application 3 2 Application Restrictions 3 3 Application Conditions Principles of operation 4 1 LED indicators 4 2 Cascading using extension modules 4 3 Cascadeable System Installation 5 1 Regulations and standards gt 666 08 4 4 4 00 6 60 5 1 1 IEC Safety distance to danger point 9 5 1 2 North American Safety distance formulas 9 5 1 3 Height of protective field 5 1 4 Response time light curtain 5 1 5 Response time safety control units 5 1 6 Distance to reflective surfaces 5 1 7 Multiple light curtain arrangement 5 2 Mechanical installation 5 2 1 Mounting brackets 5 2 2 Alignment procedure 5 3 Electrical installation 5 3 1 Connection diagram 5 3 2 Test 5 3 3 Power supply 5 3 4 Bringing into operation 5 3 5 Outputs 5 3 6 Trouble shooting Selection of a safety light curtain 6 1 Check list 6 2 Selection table 14mm resolution 6 3 Selection table 30mm resolution 6 4 Cascading systems 6 5 Accessories components 6 6 Micro 400 Cascadeable Patch Cord Inspection and servi
26. perature range 0 55 C Operation Optical window Polycarbonate omesos T o o Tseem Cwm 0 6 Vibration resistance per IEC 61496 IEC60068 2 6 frequency Merron Shock per IEC 61996 IEC 60068 2 29 1 SIL3 certification only as the safety light curtain GuardShield Micro 400 and the safety control unit MSR 4X Series 20 Operation Manual GuardShield Micro400 Cable clips A protection length according to table blue or white B profile length according to table 7 874 500 a es All dimensions in mm in 20 0 3 900 90023 1200 1201 0 3 Figure 17 Standard Micro 400 ___B profile lenght according to table protection lenght according ee B e a protection length profile length 151 3 0 00 600 60103 O O 900 90103 Figure 18 Cascadeable Micro 400 21 GuardShield Micro400 Index A Accessories Alignment procedure AOPD Applications Approaching speed B Bringing into operation 0 Cascaded systems Cascading CE conformity Configuration print out Connection Connection cable Controller unit D Decommissioning Dimensional drawings Dimensions E External faults F Foreign light interferences H Height of protective field Housing l Inspection Installation Internal faults L LED indicators M Mechanical installation Mirroring Mounting brackets 22 17 1
27. qual to the individual protective field lengths plus connection and extension cables added together Operation Manual 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 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 ANSI RIA 15 06 etc 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 5 1 1 IEC Safety distance to danger point According to the standards the GuardShield Micro 400 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 control units e Resolution of the protective device e Approaching speed to the danger point e Position of the AOPD The app
28. roaching 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 5 6 gt 40 mm the safety distance S to the point of danger is calculated according to the formula For 100 mm 5 5 gt 500 mm S 2mm ms xT 8 d 14 For 5 gt 500 mm 5 1 6 mm ms xT 8 d 14 S Safety distance in mm T Total response time in ms machine stop time GuardShield Micro 400 response time MSR 4X Series safety controller response time any configured delay time GuardShield Micro400 d Resolution of GuardShield Micro 400 in 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 The physical resolution of a GuardShield Micro 400 light curtain system is calculated by the distance from lens to lens the lens diameter This resolution can be found on the product label The current resolution is always found on the last configuration printout of the safety control unit 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 f distance from the pinch point or point of operation hazard so that the machine
29. ronic Protective Device AOPD Installed rigidly in a machine they will detect the entry of personnel and can in this way safeguard dangerous areas before unauthorized interference or entry can occur One of the special characteristics of the system is its extremely small profile To obtain a safety category 4 a GuardShield Micro 400 light curtain must be connected to an MSR 4X Series safety control module A GuardShield Micro 400 system complies to annex IV of the European Machinery Directive EC 98 37 and is a certified type 4 safety light curtain according to IEC 61496 1 2 Furthermore the safety light curtain GuardShield Micro 400 in conjunction with the safety control unit MSR 4X Series fulfills the Safety Integrity Level 3 SIL3 according to EN 61508 2 1 System design GuardShield Micro 400 light curtains consist of a transmitter and a receiver unit Figure 1 Receiver blue marking Transmitter white marking Object detection cabability resolution 5 Protective field height Operating range Figure 1 Main system parameter The products are of modular construction housed in very compact and sturdy extruded aluminum profiles Both the receiver and the transmitter come standard with a M12 micro quick disconnect connection cable An overview of the available lengths of the connection cables are given in Table 4 An RJ45 connec
30. tor guarantees a quick uncomplicated and reliable connection to the MSR4X Series safety control unit GuardShield Micro400 The GuardShield Micro 400 is also offered in 8 Cascadeable configuration GuardShield Cascadeable Micro 400 safety light curtains allow the interconnection of multiple segments of the Micro 400 safety light curtain with a common pair of safety outputs This Cascadeable configurability of the GuardShield Micro 400 reduces overall system wiring and allows the GuardShield Micro 400 to be fitted into a variety of applications where the safety distances for mounting the light curtain may allow personnel to stand between the light curtain s sensing field and the hazard or where multiple sided guarding is required and the use of corner mirrors is not possible 2 2 Special features The outstanding features of the GuardShield Micro 400 safety light curtains in combination with a MSR 4X Series safety control module are Small profile of only 15 x 20 mm Finger protection resolution 14 mm Hand protection resolution 30 mm Integrated intensity display Range 0 m to 5 m with a very compact design Profile length up to 1 200 mm Protective field height in increments of 150 mm Max number of beams 255 Unaffected by dust and dirt Easy installation Maintenance free 6 IAA ARAR 3 Applications and conditions 3 1 Areas of Application GuardShield Micro 400 systems can be used as Figure 2 TA P
31. upted Green Intensity inadequate Flashing Rea o Light curtain interrupted Error Flashing All indicators relevant to the control of light curtain systems are situated directly on the MSR 4X Series safety control module Light curtain interrupte status Red GuardShield Micro400 4 2 Cascading using extension modules For simpler connection between neighboring protective fields the GuardShield Micro 400 light curtain can be easily cascaded using extension modules Figure 6 One such cascaded system allows the connection of e g front back and topsides of a machine using only one light curtain system The individual cascaded elements can be connected quickly and simply using the convenient M12 qd connectors Only the following limitations need to be considered e Amaximum of 255 light beams per system e Protection area extensions in increments of 150 mm 10 m maximum total length for light curtains extension modules and connection cable combined Figure 7 e Only a GuardShield Micro 400 prefabricated cable may be used between the light curtain and the MSR 4X Series safety control module The extension modules are connected to the main system via M12 qd connection cables The customer defines Length of the connection cable e Protective field height and Resolution e Length of the extension cable e Extension modules protective field height A complete mounting kit and test rods are provided standard with e
32. uring device 10 Operation Manual 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 Depth penetration factor It is an added distance to allow for how far into the protective field an object such as a finger or hand can travel before being detected D 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 pf 5 1 3 Height of protective field The protective field is clearly visible on the transmitter and receiver portion of the light curtain as the blue silver area with the optical lenses The protective field height L and the standard resolution d can be taken from the product label and the selection table of chapter 7 2 and 7 3 The measurements of the GuardShield Micro 400 profile end caps are chosen so that the resolution can extend to the end of the light curtain Figure 8 Depending on the application it must be checked whether possible mirroring e g a table top has an effect on this resolution chapter 5 1 5 Figure 8 Resolution at the end of the light curtain assuming no mirrored reflections When selecting or installing a light curtain
33. very system Figure 6 Example for standard and cascading systems Note In cascaded systems only the LED in the first safety light curtain will illuminate closest to the safety controller GuardShield Micro400 4 3 Cascadeable System A GuardShield Cascadeable Micro 400 safety light curtain system is comprised of one or two pair of Cascadeable Micro 400 light curtains as well as a standard Micro 400 pair as the last segment pair in the Cascaded system Z ATTENTION The standard GuardShield Micro 400 must always be the last segment in a Cascaded Micro 400 system The GuardShield Cascadeable Micro 400 system operates as a single light curtain pair with a common set of OSSDs Each segment pair is connected in series making the complete system s response time the sum of each segment pair plus the response time of the MSR 42 and other safety devices in the stop Circuit GuardShield Micro 400 cascaded pairs are offered in both 14mm and 30mm resolutions in limited protected heights It is possible to mix 14mm and 30mm resolution pairs in a Cascaded Micro 400 system The Cascadeable Micro 400 safety light curtains are ordered as pairs transmitter and receiver and are shipped under one catalog number Extension cables 2 m ii m G w a m 2 2 mn ee eh 7 lt O A A A 4 4 I Operation Ma
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