SAFEDGE - Kirby Risk Electrical Supply
Contents
1. 4 1 SUPPLY FUSE SAFETY FUSES 500mA 2A 42 43 44 45 440F C251P Surface Mounted eee STOP RED O 500mA OPEN YELLOW O RUN GREEN O 110V A2 Z1 MC14 24 32 440F C251D Din Rail Mounted CONTROL UNIT INSTALLATION AND WIRING Follow steps 4 1 to 4 7 for correct installation IMPORTANT Wiring must be in accordance with the National Electric Code and applicable local codes and ordinances 4 1 Mains selector switch If using a 110V AC or a 230V AC supply the voltage selector switch should be set as appropriate before turning the power on The unit is set to 230V AC when manufactured 4 2 Mains input terminal LN A1 A2 If a 110V AC or 230V AC supply is used it should be wired together with a protective earth ground to the terminals shown The size of the protective earth ground wire should be at least equal to that of the supply wire Also check 4 1 If these terminals are used ignore 4 3 4 3 24V AC DC input terminal ve and ve If a 24V AC DC supply is being used the supply should be connected to these terminals ensuring that the correct polarity is observed Do not make any connections to the terminals of 4 2 Where a 24V AC or DC supply is used it must be isolated from the mains supply in accordance with international electrical safety pratice IEC 364 4 41 One pole should be earth2. C rail zinc coated steel C112 S 440F R1112 Suitable for the fixing of all the Safedge Profiles C rail PVC C112 PB Black 440F R1212PB C112 PR Red 440F R1212PR C112 PY Yellow 440F R1212PY Suitable for the fixing of all the Safedge Profiles 3 colours available C rail aluminium C112 A3 440F R1215 Ideal when external fixings of C rail is required Accepts all profiles 25 C rail aluminium C112 A4 440F R1216 Deeper rail allows cables to be run through channel under safedge profile Accepts all profiles C rail aluminium C112 A2 440F R1214 Ideal when external fixings of C rail is required Accepts all profiles ALL C RAILS ARE SUPPLIED WITHOUT FIXING HOLES C Rail 440F R1212 can be supplied curved to meet most applications 23 Each Profile uses a combination of non conductive rubber and a flexible wire cored conductive rubber bonded together to form a variety of energy absorbing Profiles The Profile has no rigid internal parts which can break through or cause fatigue failures after prolonged use The maximum operating voltage of the Profile is 12 VDC so no dangerous voltage is exposed if the Profile is accidentally cut or sheared The copper wire core throughout the length of t
3. See user manual for further information OOESOOECGMO at Ay soare POWER BEFORE OPENING eli AB MADE IN THE UK Q Q SURFACE MOUNTING DIN RAIL MOUNTING Record of Routine Inspection And Test see section 6 2 2 and 6 2 3 Date Inspected By Comments 25 INTRODUCTION The Safedge sensitive edge sensing system is ideal as a safety sensor in applications such as power operated doors automated vehicles and moving machinery beds etc It can provide a continuous line of high sensitivity touch sensing along or around practically anything This manual covers the use of the parts of the Safedge system If joints or corners are required contact your supplier All installation work must be carried out by suitably trained and qualified person nel and should be in accordance with statutory requirements for safety READ THIS MANUAL IN FULL BEFORE INSTALLATION After installation this manual should be retained in a safe and accessible place For any further assistance please contact your supplier 1 0 STORAGE amp HANDLING STORAGE The Safedge control unit and Profiles should be stored within the temperature range of 10 C to 55 C HANDLING AND TRANSPORT The Safedge control unit and Profile should be transported within the temperature range of 10 C to 55 C and should
4. Allen Bradley i Guard master SAFEDGE PRESSURE SENSITIVE SAFETY EDGE SYSTEM INSTALLATION amp USER MANUAL Allen Bradley AA READ THIS MANUAL IN FULL BEFORE INSTALLATION Int Guerdtmarte er rer After installation this manual should be rawin 0 ye hese retained in a safe and accessible place EO 26630 Guardmaster Safedge Record of Thorough Inspection And Test see section 6 2 2 and 6 2 3 Pressure sensitive safety edge system Date Inspected By Comments Installation and user manual SECTION 1 STORAGE AND HANDLING SECTION 2 SYSTEM DESCRIPTION SECTION 3 INSTALLATION amp SPECIFICATIONS SECTION 4 ELECTRICAL CONNECTIONS SECTION 5 COMMISSIONING amp USE SECTION 6 MAINTENANCE amp SERVICE ee eg SAFEDGE f Py PRESSURE SENSITIVE EDGE SYSTEM Guard lmarte CONTROL UNIT Pt No 440F C251P A1 Z2 MC 13 23 31 OOO c Ut us SRE DPDPDOAONSOCOO LISTED RUN Al Z2 MC 13 23 31 Allen Bradley 440F C251D Safedge Pressure Sensitive Safety Edge System Control Unit Supply Voltage 230 110VAC see selector 50 60Hz Or 24V AC DC 3 IP65 Hoseproof Dust tight EN 954 1 Cat 3 Safety Contacts 250V 2A N O pr EN 1760 2 RUN 8 Aux Contacts 250V 2A N C s f y Safedge Profile Voltage 12Vdc lade in th iq in the EN 954 1 Category 3 prEN 1760 2 A2 Z1 MC 14 24 32 System response time 13mS
5. E OF THE MACHINE Profile pressed REPLACE CONTROLLER Run Green LED stays on 3 2 5 Pull the connecting cable through the hole 6 2 MAINTENANCE This section should be read in full before any maintenance work is attempted Attention is drawn to regulations for planned preventative maintenance under E U Directive 89 655 EEC Implemented in Great Britain as the Provision and Use of Work Equipment Regulations 1992 During maintenance operations disconnect the machine s prime mover before working on the Safedge system Observe electrical safety precautions 19 8 3 2 6 Prick each of the copper wires with one of 5 3 APPLICATIONS the needles Press the needle contacts of the connector in the direction shown wedge outwards straight into the copper 110 230 AC SUPPLY W res Deen SAFEDGE i _ 40 K1 PROFILE a STAR q 6K RESISTOR PUSH BUTTON L fvelZ1 Z2 13 23 31 ele STOP 4 A1 J Fr Besa SAFEDGE 3 2 7 CAUTION sarence i PROFILE fik The narrow side wedge of the connector CONTROL UNIT 6K must show outwards RESISTOR L bvelz1 z2 13 23 31 A2 A1 i N E ve MC MC 14 24 32 T Tea T mairs SAFEDGE CONTROL UNIT 3 2 8 Fold back
6. Safedge system complies with the requirements of the European EMC Directive Normal operation under interference conditions likely in industrial environments is assured as it has been tested and certified NOTE Special measures may be required in the presence of abnormally high levels of EMI e g near to welding or induction heating equipment or near to radio transmitters transceivers 5 Record of Routine Inspection And Test see section 6 2 2 and 6 2 3 Date Inspected By Comments 22 6 2 4 Repair Prior to working on a Safedge system or machine control system isolate the power source to the machine and Safedge system Observe electrical safety precautions User repairs are limited to replacement with new Safedge system parts In the event of any problems the units should be returned to the supplier Any repairs to the connecting wires should be made using heat shrink butt splice connectors After replacing any parts the inspection and test shown at 6 2 2 amp 6 2 3 must be carried out with special attention given to those parts replaced TAMPERING WITH COMPONENT PARTS WILL INVALIDATE WARRANTY WARRANTY INVALID IF QUALITY SEAL IS BROKEN ON THE DIN RAIL 440F C251D CONTROL UNIT WARNING After maintenance or repair operations it is important that all fastenings cable protection etc are correctly refitted Failure to do this or the use of
7. d they are normally connected in series as shown ALTERNATIVE CONNECTION METHOD CONNECTING IN PARALLEL Amaximum of two profiles can be connected in parallel to assist in ease of wiring in certain applications Uses 15K resistor blue Uses 6K8 pE yellow y d 15 440F E0110N 440F E0110S 440F E0310S 440F E1610N 440F E1610S actuating distance 6 4mm 6 6mm 8 0mm 7 8mm 9 4mm response distance 1 2mm 1 9mm 27 2MM 8 4mm 5 0mm e max speed 100 mm s e suitable for the detection of fingers The control unit must not be mounted inside the hazard zone Access to the control unit is required for manual reset or for routine indicator observation so it must be able to be seen operating The control unit can be mounted on either side of power doors as long as the only hazard is the actual doors In all other cases the control unit can be mounted anywhere convenient outside the hazard zone taking into account the access requirements for test and maintenance 3 3 2 MOUNTING 130mm 115mm 75mm i WwwSLL WWOEL 4 x M4 Fixing Holes 120 45 5 440F C251P Surface Mounted EIEE OQOS9OOSO o B i 35MM DIN RAIL MOUNTING QO SOOS 440F C251D Din Rail Mounted 12 4 0 ELECTRICAL CONNECTIONS Safedge control unit 4 7 4 6 STOP OPEN RUN RED YELLOW GREEN INDICATION
8. de carefully to ensure that the profile 6 1 FAULT FINDING GUIDE Symptom Probable Cause Check base is completely trimmed off leaving a flush surface Yellow LED Open circuit in profile or Z1 Z2 Terminals are secure Illuminates connecting wiring Cable for breaks Profile for damage No LED s illuminate even if Supply failure Voltage selector switch is set correctly Profile is pressed Supply fuse Supply voltage is present If using contactor monitoring check 3 2 3 The shaded areas must be roughened with emery paper No LED s illuminate unless Failure to reset Profile is pressed and then the stop Red LED each contactor is functioning correctly MC MC terminals are secure illuminates Link is in place or Reset button functions correctly Unit appears to work Blown fuse Output fuses 3 2 4 The closing caps are moulded with 4 correctly but there is no Damaged or incorrect wiring All wiring for damage grommets each with a rubber plug When output fitting a resistor leave the plugs intact When Fault on Safedge causing Movement on any internal relays making a cable connection select the the Outputs to fail safe REPLACE CONTROLLER required cable exit and remove the plug from Machine does not stop if Incorrect external connections All wiring to contactors for mistakes the grommet with a hole punch Profile pressed Run Green LED goes off Machine does not stop if DO NOT ALLOW THE US
9. ed For 24V DC the negative pole should be earthed grounded With 24V AC the earthed grounded pole of the power supply should be connected to the ve terminal 4 4 Aux Output terminal 31 and 32 This terminal provides an auxiliary normally closed contact i e closed when the green Run light is off which is suitable for indication or for alarm devices As this is an auxiliary it must not be connected to the safety circuit 4 5 Safety Output terminal 13 14 23 and 24 These are volt free contacts for connection to the machine safety circuits i e they are connected in series with the machine contactor control circuit Max rating 2A at 250V AC Both of these safety circuits are internally fused but must also be externally protected with a 2A quick acting fuse If one contactor is being used terminals 13 and 24 are required and terminals 14 and 23 should be jumpered together For 2 contactors with 2 independent control circuits i e a dual channel system use 13 14 for one contactor and 23 24 for the other For 2 contactors also see 5 3 14
10. he Profile ensures that there is no significant build up of resistance over long lengths Conductive Flexible Wire Rubber Cores O Flexible copper cores send the signal to the Evaluator Non Conductive Rubber The circuit through the Profile is monitored by the Safedge control unit which when a 6KQ resistance is present i e normal run conditions produces a signal to the machine control circuit When the Profile is pressed from any direction through 90 as shown above the top conductive rubber strip compresses and touches the middle conductive rubber so creating a short circuit and the overall resistance drops This is monitored by the control unit which initiates the machine shutdown Any single fault in the Profile or the wiring connections to the Profile will be detected and the control unit outputs will go to a safe OFF state Individual Profiles connect to each other by wires axial connectors or standard 90 connectors The Profiles are connected to the control units by two wires The control unit has fully cross monitored safety relays and it is possible to configure the unit so that an external contactor fault will be detected Compliance with the requirements of EN 954 1 Category 3 and pr EN 1760 2 is achieved for the control unit regarding electrical faults and can be met for the associated part of the machine control system Compliance with the requirements of EN 954 1 Category 1 is achieved for the Profile The
11. htening torque rating 7 in Ibs suitable for wire sizes 16AWG Use 16AWG minimum Use Copper Conductors Only Temperature rating of field wiring shall not be less than ambient Profiles Profiles 440F E0110N 440F E1610N 440F E0210S QOmnNOnngaTmTY 440F E0110S 440F E0110R 440F E0510S 440F E1610S 440F E0804S 440F E0310S VADDADODOADODODOAYS Key G Good F Fair P Poor 440F A0061S 3 3 CONTROL UNIT 3 2 9 To ensure complete seal apply more adhesive on the Safedge Profile around grommet cable exit and sealing lip of the closing cap 3 2 10 Axial profile connector 440F A0061S is used for extensions and repairs see steps 1 2 3 6 and 7 for the 440F E0110 series of profiles only For other types use straight pin connectors 3 3 1 TECHNICAL SPECIFICATION Conformity Power Supply user select System response time Environmental protection Max Safedge profile voltage Nominal operating voltage Max output fuse Impulse withstand voltage Over voltage Contamination level Min switched current voltage Power consumption 440F C251P Surface mount 440F C251D DIN rail prEN 1760 2 EN 954 1 CATEGORY 3 110 230V AC 50 60Hz and 24V AC DC 10 15 13mS IP65 Enclosure IP40 DINO470 Terminals IP20 DIN0470 12V DC open circuit 4V run condition 2A quick acting 5A quick acting 2500V Category 2 Ill 10mA 10V lt 6 VA 10 Relay outputs Utilisation category Safet
12. it a jumper between these terminals on the DIN rail unit if this function is not required This terminal is also used for auto manual reset If the MC MC terminal is left jumpered or connected up to the contactors normally closed contact only the unit is in automatic reset mode In automatic reset mode the output is achieved solely by removal of the actuating force The out put is also achieved at power up of the actuator when there is no actuation force present If a spontaneous restart may generate a risk based on the result of a risk assessment to EN1050 then this mode must not be used See EN 60204 Pt 1 and EN954 Pt 1 For manual reset mode a normally open spring return not latching push button must be connected across the MC MC terminals or in series with the contactors normally closed When the actuating force is removed the unit will not operate until the button is pressed The button will also have to be pressed after power up of the control unit 4 7 Profile connection to control units These terminals are used to connect the Profile to the Z1 Brown inner conductor Z2 White outer connector Refer to 5 3 APPLICATIONS NOTE Profile must be terminated with a 6KQ Resistor yellow for series connection When two profiles are connected directly to Z1 and Z2 parallel then each profile should be terminated with a 15K resistor blue Connection in Parallel amp Series CONNECTING IN SERIES If more than one profile is to be use
13. m W 130mm D 120mm H 73mm W 45 5mm 16 way 650g 450g The Safedge Profile must be terminated with a 6KO resistor 5 0 COMMISSIONING amp USE SEQUENCE OF OPERATION 5 1 1 2 3 4 5 When the unit is installed check the following sequence of operation Manual reset mode Turn the Power on a No LED s illuminate Press the reset switch a Run Green LED illuminates b Safety contacts close c Auxiliary contacts open d Contactors energise Press the Profile a Run Green LED extinguishes b Stop Red LED illuminates c Safety contacts open d Auxiliary contacts close e Contactors de energise Release the Profile a Stop Red LED extinguishes b System has returned to step 1a If Profile is pressed before reset a Stop Red LED will illuminate each time the Profile is pressed but the safety contacts will not energise 16 4 6 Reset terminal MC MC These terminals are used for a number of different functions surface mount supplied jumpered DIN rail supplied without jumper Without the jumper the terminals can be connected to positively guided normally closed auxiliary contacts on the machine contactors to provide monitoring of the contactors in dual channel control systems If one contactor fails to isolate the power at de energisation of its control coil the Safedge system will not allow the other contactor to be energised until the fault has been rectified F
14. non approved parts may result in the Safedge system failing to achieve its specified performance 21 3 0 INSTALLATION OF THE SAFEDGE SYSTEM ONLY USE 440F A0020 CYANOACRYLATE The cyanoacrylate adhesive ensuring a lasting sealing and high protection to IP65 3 1 INSTALLATION OF C RAIL C RAIL CONNECTOR WITH RESISTOR CLOSING CAP TO CONTROL UNIT OR NEXT PIECE OF PROFILE 3 1 1 MOUNTING THE C RAIL Holes drilled on installation Fasteners not supplied 3 2 1 Cut the Safedge Profile to length Profiles without coasting chamber should be cut with rubber shears Profiles with coasting chamber should be cut with a fine tooth saw 6 2 1 Profile Cleaning The Profiles should be kept clean of deposits such as swarf and other materials to prevent damage or dead zones It is permissible to use warm water and a mild detergent to clean the surface area DO NOT USE SOLVENTS 6 2 2 Routine maintenance inspection and test recommended weekly or after repair Stop the machine clean the Profile s and allow to dry off Inspect the surface of the Profile for damage Any damage that punctures the profile could let material or liquid in It must be dealt with immediately Check that all end caps corners and joints are secure and free from damage Damaged parts must be replaced immediately Test the Profile operation Two people may be required one to press the Profile and one to observe the operation
15. not be subjected to any impact or heavy loads The original packaging should be used to give protection from excessive flexing Always unpack carefully and avoid damage by the use of knives etc 2 0 SYSTEM DESCRIPTION The Safedge system comprises of up to 50 metres of Profile cable connector a terminating resistor C rail and a control unit The control unit can monitor lengths of up to 50 metres All Profiles have the same principle of operation SAFEDGE PROFILES Cushion factor 5mm 440F E0110S 440F E0110R Red profile 440F E0110N Ineuieee resistance to oil 28 5 Cushion factor 19mm A40F E1610S 440F E1610N Increased resistance to oil 440F 0804S Cushion factor 19mm with sealing lip ree see oO oO fo wo 440F 0210S Cushion factor 41mm with sealing lip 3 g 7 440F 0510S 440F 0310S Cushion factor 5mm Cushion factor 41mm with sealing lip FOR VARIOUS CONNECTION PIECES AND ACCESSORIES PLEASE REFER TO OUR CATALOGUE Record of Routine Inspection And Test see section 6 2 2 and 6 2 3 Date Inspected By Comments 24 Record of Routine Inspection And Test see section 6 2 2 and 6 2 3 C rail aluminium C112 A Date Inspected By _ Comments 440F R1212 Suitable for the fixing of all the Safedge Profiles
16. of the control unit On systems using Manual reset mode the reset button must be continuously pressed Check that the RUN Green LED is illuminated when the profile is not pressed and that the STOP Red LED is illuminated when it is Start the machine press the Profile and check that the machine stops immediately If these checks reveal any problems do not allow use of the machine until they are rectified Record all inspections and tests in a written log 6 2 3 Thorough examination and test twice yearly or after repair To be undertaken by a person competent in electrical and mechanical engineering a Carry out tests at 6 2 2 b Isolate the power source to the machine and Safedge system Observe electrical safety precautions c Inspect the Profile and components thoroughly for mechanical damage d Disconnect the wires to the Profile at terminals Z1 Z2 e Connect the wires from the Profile to the input of an ohmmeter One person should now press the Profile with one hand at every point on the strip The resistance should measure 6K 10 when the profile is not pressed and no greater than 1K when it is If these checks reveal any problems do not allow the use of the machine until they are rectified Record the inspection and test in a written log 20 6 0 MAINTENANCE AND SERVICE 3 2 2 When using the closing cap 440F A1302 with sealing lip the profile base has to be cut back to a length of 12mm The cut must be ma
17. the sealing lip of the cap EXTERNAL FUSE a Apply adhesive to shaded area of closing ej A2 cap as illustrated then affix to edge of NJE lve 32 profile applying pressure for 10 seconds T to ensure adhesion 110 230V AC Application with 1 contactor EXTERNAL FUSE b Apply adhesive to remainder of shaded area Shown with profile pressed bs and allow sealing lip to make contact with profile SAL NR rea K1 IMPORTANT Spread the adhesive evenly over the l shaded area Do not allow adhesive to enter inside A PEN TTE a Ke the profile 110 230V AC Application with 2 contactors contactor monitoring and START STOP circuit Shown with profile pressed Brown Zi White 2 x 5 2 AUTOMATIC RESET MODE 1 Turn the power on a Run Green LED illuminates b Safety contacts close c Auxiliary contacts open d Contactors energise 2 Press the Profile a Run Green LED extinguishes b Stop Red LED illuminates c Safety contacts open d Auxiliary contacts close e Contactors de energise 3 Release the Profile a System has returned to step 1a Comparative properties Tensile strength reinforced MPa Resilience 20 C Low temperature flexibility Resistance to sunlight Resistance to heat ageing Resistance to oxidation Resistance to ozone Resistance to H2O Resistance to dilute acids Resistance to concentrated acids Resistance to oils amp greases 17 Terminal block tig
18. y inputs Indication LED 1 LED 2 LED 3 Internal controls Internal fuses Max output fuse Ambient temp range control unit Ambient temp range profile Humidity Vibration MC MC contactor monitor loop Max conductor size Terminals Installation group Material Fixing details Housing Weight Miscellaneous 11 440F C251P Surface mount 440F C251D DIN rail 2 x independant volt free N O safety contacts 1 x volt free N C auxiliary contact NOTE Auxiliary should not be used for safety AC 15 2A 250V DC DC 13 2A 30V DC Safedge profile open resistance 6KQ Green Run Yellow Open Red Stop AC voltage selector 2A safety fuses replaceable 2 off 500mAT supply fuse replaceable 1 off 500mAT supply fuse replaceable 1 off N A 4A on AC 2A on DC 10 C to 55 C 5 C to 55 C excluding 110N amp 01610N 0 C to 55 C Up to 90 RH at 55 C Tested in accordance with IEC 68 2 6 frequency range 10 55Hz displacement 0 15mm 10 cycles per axis sweep rate 1 octave per minute N C normally closed contactor loop 1x1 mm2 stranded with sleeves stripped 1x2 5 mm stranded with sleeves stripped 5mm 1 x 1 5mm2 solid conductor 8mm 1 x 4 mm2 solid conductor Minus terminal screws Plus minus terminal screws M3 5 with M2 spring action self lifting connection washer terminal boards separately removable Cin accordance with VDE 0110 Polycarbonate 4 x M4 holes 35 mm DIN Rail D 75mm H 130m
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