Guardmaster Safedge Pressure Sensitive Safety Edge System
Contents
1. 13 7 mm 0 52 in Compensation travel at 250 N 4 1 mm 0 16 in 3 3 mm 0 13 in 2 6 mm 0 10 in Compensation travel at 400 N 6 0 mm 0 24 in 5 4 mm 0 21 in 4 4 mm 0 17 in Maximum stopping distance 5 0 mm 0 20 in 4 5 mm 0 18 in 3 6 mm 0 14 in Rockwell Automation Publication 440F UMOO2A EN P 13 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Deformation travels 440F E0110R 440F E0110S 440F E0510S Test temperature 20 C Speed 200 mm s Actuation force 60 6 N Response travel A 4 9mm Total deformation at 250 N B1 7 6mm Total deformation at 400 N B2 9 3mm Total deformation at 600 N C 11 3 mm Compensation travel at 250 N 2 6 mm Compensation travel at 400 N 4 3 mm Max stopping distance 3 6 mm Deformation travels 440F E1610N 440F E0118S Test temperature 20 C Speed 200 mm s Actuation force 84 6 N Response travel A 9 4 mm Total deformation at 250 N B1 18 5 mm Total deformation at 400 N B2 26 7 mm Total deformation at 600 N C 28 9 mm Compensation travel at 250 N 9 1 mm Compensation travel at 400 N 17 3 mm Max stopping distance 14 4 mm Deformation travels 440F E1610S 440F E0804S Test temperature 20 C Speed 200 mm s Actuation force 20 6 N Response travel A 6 9mm Total deformation at 250 N B1 25 4 mm Total deformation at 400 N2. Safedge 24V Ground 24V Ground Parallel Terminated Safedge Input Manual Reset Series Terminated Safedge Input Automatic Reset Single Channel Output Monitored Output Single Channel Output No Output Monitoring Brown Zi White 23 The wiring diagram on the left shows a 110 230V AC application with one contactor shown here with profile pressed The right side of the illustration above shows a 110 230V AC application with two contactors contactor monitoring and START STOP circuit also shown profile pressed 20 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Maintenance and Service Troubleshooting Guide Symptom Probable Cause Check The yellow OPEN LED illuminates Open circuit in profile or connecting wiring Ensure Z1 Z2 terminals are secure Check cable for breaks Check profile for damage Not one LED illuminates even if profile is Supply failure Make sure that voltage selector switch is set pressed correctly Check supply fuse Ensure that supply voltage is present Not one LED illuminates unless profile is Failure to reset If using contactor monitoring ensure that each contactor is functioning correctly Ensure that MC NC terminals are secure Check that link is in place and that Reset button f
3. B2 30 6 mm Total deformation at 600 N C 32 9 mm Compensation travel at 250 N 18 4 mm Compensation travel at 400 N 23 7 mm Max stopping distance 19 7 mm Deformation travels 440F E0310S 440F E0210S Test temperature 20 C Speed 200 mm s Actuation force 87 0N Response travel A 8 6 mm Total deformation at 250 N B1 22 0 mm Total deformation at 400 N B2 42 5 mm Total deformation at 600 N C 47 6 mm Compensation travel at 250 N 13 4 mm Compensation travel at 400 N 33 9 mm Max stopping distance 28 3 mm 14 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Selecting the Cushion Factor Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual One of the important characteristics of edge systems is called cushion factor The cushion factor is the distance the profile can be depressed after the signal is generated This is important when the profile is mounted on automated doors Automated doors will continue to close for some finite time after the profile sends the initial stop signal Thisis known asthe system response time The system response time is the sum of the Safedge control unit response time the control system response time and the mechanical stopping time Systems with longer response time should utilize larger cushion factors Users must validate that injury does not occur if parts of the body get jammed for example between the sensing edge and the fixed part of a mach
4. One person should now press the profile with one hand at every point on the strip The resistance should measure 6KO 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 see typical written log on page 23 Repair Prior to working on a Safedge system or machine control system isolate the power source to the machine and Safedge system Observe all applicable 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 part of the system the inspection and test procedures detailed in the last two sections must be carried out with special attention given to those parts replaced TAMPERING WITH COMPONENT PARTS WILL INVALIDATE IMPORTANT WARRANTY WARRANTY IS INVALID IF QUALITY SEAL IS BROKEN ON THE DIN RAIL 440F C251D CONTROL UNIT After maintenance or repair operations it is essential that all fastenings cable protection etc be correctly refitted Failure to do IMPORTANT so or the use of non approved parts may result in the Safedge system failing to achieve its specified performance 22 Original Instructions in English Rockwell A
5. a position detection at a position close to where the maximum hazard speed occurs Normally closed contacts of this position detection should be connected into the machine control stop circuit at the point at which the output signal switching devices would be connected The machine should be run several times in the worst anticipated conditions and the distance travelled beyond the actuating point of the position detection measured The maximum distance measured should be regarded as the stopping distance Determine the maximum permissible force When available the maximum permissible force should be taken from a type C standard for the specific machine or be in accordance with the risk assessment The risk assessment should take into account the body parts and types of persons to be protected for example children or elderly persons The speed shape and material of the sensor and maximum pressure exerted by the device should also be considered The maximum permissible force should be as low as possible Select the device Using the force distance relationship data or diagrams provided by the manufacturer select the safeguard with the required maximum operating speed which provides at least the required minimum overtravel distance before the maximum permissible Original Instructions in English Rockwell Automation Publication 440F UM002A EN P 5 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual force is r
6. 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 of the control unit On systems using manual reset mode the reset button must be pressed continuously Check that the green RUN LED is illuminated when the profile is not pressed and that the red STOP LED is illuminated when it is Start the machine press the profile and check that the machine stops immediately If these checks reveal any problem do not allow use of the machine until the problems are rectified Record all inspections and tests in a written log Original Instructions in English Rockwell Automation Publication 440F UMO02A EN P 21 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual 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 as listed in previous paragraph b Isolate the power source to the machine and Safedge system Observe usual electrical safety precautions C Inspect the profile and components thoroughly for mechanical damage d Disconnectthe wires to the profile at terminals Z1 Z2 e Connectthe wires from the profile to the input of an ohmmeter
7. safety relays it is therefore possible to configure the unit to detect an external contactor fault Compliance with the requirements of EN ISO 13856 2 2013 is achieved forthe control unit regarding electrical faults and can be met for the associated part of the machine control system B10d for profile is 10 000 The 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 8 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Faults are excluded per ISO 13849 Edges must be installed in an environment that does not cause degradation of profile material Edges must be properly sealed to prevent non conductive fluids from filling the profile cavity that would prevent pressing the profile Profile must be connected to qualified controller Special measures may be required in the presence of abnormally high levels of EMI e g near IMPORTANT i i i welding or induction heating equipment or near radio transmitters or transceivers ATTENTION Because fault exclusion is used Safedge systems can achieve up to PLd Cat 3 Each application installation user shall determine required PL level The system as installed must meet required PL level Installation of the
8. 10 230V AC selectable 8 z C sae Pas Pis 24V AC DC iz 2 ee user manual for further information Isolate before opening C Ns POWER BEFORE OPENING A2 Z MC 14 24 32 e x2 92 MADE IN THE GERMANY 3 X2 C b Surface Mounting DIN Rail Mounting Introduction The Safedge sensitive edge sensing system is ideal as a safety sensor in applications such as power operated doors automated vehicles moving machinery beds etc for use when objects are detected by touch It can provide a continuous line of high sensitivity touch sensing along or around practically anything System Description The Safedge system consists of up to 50 meters of profile a cable connector a terminating resistor a C rail and a control unit The control unit can monitor lengths of up to 50 meters All profiles have the same principle of operation 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 personnel and should be in accordance with statutory requirements for safety READ THIS MANUAL IN FULL BEFORE INSTALLATION After installation this manual should remain in a safe and accessible place For further assistance please contact your supplier Storage and Handling Storage The Safedge control unit and profiles should be stored within the temperature range of 10 55 C 14 131 F Handling and Transp
9. 18S Cushion factor 3 75 mm 0 15 in Level of Protection IP67 Actuation Angle 45 Weight 0 259 kg m 0 016 Ib ft Rockwell Automation Publication 440F UM002A EN P g 8 50 1 97 U 440F E1111S Cover profile only nonfunctioning Weight 0 300 kg m 0 018 Ib ft Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Ss voL 5 C rail aluminium C112 A 440F R1212 Suitable for attaching all the Safedge profiles Ss 100039 iu 4 25 J 0 98 C rail zinc coated steel C112 S 440F R1112 Suitable for attaching all the Safedge profiles TEES ac d C rail PVC C112 PB 2 Black 440F R1212PB C112 PR Red 440F R1212PR C112 PY Yellow 440F R1212PY Suitable for attaching all the Safedge profiles Available in 3 colors C rail aluminium C112 A3 440F R1215 Ideal when external fixing of C rail is required Accepts all profiles 25 0 98 25 0 98 ln trae T 18 0 70 l 25 0 98 C rail aluminium C112 A4 440F R1216 This deeper rail allows cables to run through channel under Safedge profile Accepts all profiles 10 039 30 1 18 A Safedge system consists of the following components Pressure sensitive profiles which act as sensors Profile Model No 440F EAbcde Profile 440F E0110S C rail alum
10. 6 a C Eg Cort vel vel 31 32 13 vas pe SUPPLY FUSE SAFETY FUSES 500 mA 2A 4 2 4 3 4 4 4 5 440F C251P surface mounted z OD x Qu 21 G SUPPLY FUSE STOP RED C 500 mA OPEN YELLOW O RUN GREEN C 110V A2 Z1 MC 14 24 32 440F C251D mounted on DIN rail 440F C251D mounted on DIN rail Control Unit Installation and Wiring IMPORTANT Main selector switch see 4 1 in drawing above If using a 110V AC or a 230V AC supply set the voltage selector switch accordingly before turning the power on By default the factory setting of the unit is 230V AC Wiring must be in accordance with the British National Electric Code and applicable local codes and ordinances Carefully follow the steps listed below for correct installation Main input terminal LN PE A1 A2 PE see 4 2 in drawing on page 16 If using a 110V AC or 230V AC supply the power supply should be wired together with a protective earth ground to the terminals shown The size of the protective earth PE ground wire should at least be equal to that of the supply wire Also check the main selector switch If these terminals are used ignore the following paragraph 16 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual 24V AC DC input te
11. E RRUDU ex weds eU UP EE REA UEERNES M EE KUU E soe aa 4 Storage and Handling eoe RE Ere A LER GG E CER e ee EE RR EN ER ee ds Bac ee YE REANO aA eicev n NEA 4 Sep cer 4 Handlingand Transport 5 4 ve EDU de ERDMWSA TE RAXEEUDUN C ER ERU Aa aont Meer ah OR A PERDU sve LE DA RA ed vets 4 Safedge Selection 4 4 ais ye eR un Ree Oe ER XA salable ee ex tnetbdes Eo C eee UR OS EA aa ace VER E NY SY S che TRI ORE CSS RUE 5 Selection Proced ie 2 yr desea bte e E ve E YES DAR eo be sea E PA OX Salen Faved ORE Dena de A RC CHEERS MU Pe TEL REST REN NAA 5 Safedge Protlles amp enue bce Pew RIP EE E Ne UE Y RO RUNE RR weed ewes ER MA MEO PE EUN Lab Su EUN ta eR ERELE M DS RNE 6 Installation of the Safedge System 5 iic RE ERE E ER deeded abana dg e E bRSaN AN EERR IRNRh ST UE a RES nis 9 Inistallation oF C Rall i iere RIS EIN OG ike an Awe band E NU EARE fees E VE dis A Gal Meee RR ah ees RED 9 Mounting the C Rail 43 629 p s tI pam em ee thd aida PESE Dee sola eden b Abadia dune deddash eres epa MIND EIE E EP AS NET 10 Assembly and Installation of the Safedge Profile 2 cece cece cece ce ne nee en ene ne ener hehe hehe e hs hee ehe 10 Sensing Surface of Safedge Systems er S ccc cece nen ne nnn EEE EEE EEE EEE EEE heh hs eere hehehe 11 Control Unit Technical Specifications 21222 eese pire aree eS Rr ERU UpDe SEE E ee ede OE SUE RU ER bing Wege ume Be SR ee ee Oe RON 12 Force Travel Relationship eese ies eee chew ER SAE Hid a ee a ea oy e
12. Guardmaster Safedge gt Allen Bradley Pressure Sensitive Safety Edge System Installation and User Manual 440F Original Instructions in English ode Ree WF Rockwell Allen Bradley Rockwell Software Automation Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in the guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Rockwell Automation publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Rockwell Automation sales office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as t
13. H 73 mm W 45 5mm respectively 4 72 x 2 87 x 1 79 in 16 way 450 g 14 1 oz avdp The Safedge profile must be terminated with a 6 KO resistor 500 mm 19 8 in Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual 440F E0510S 440F E0110R 440F E0110S 6 6 mm 0 26 in 1 9 mm 0 07 in 440F E1610N 440F E0118S 440F E0804S 440F E1610S 440F E0210S 440F E0110N 440F E0310S 8 0 mm 0 31 in 27 2 mm 1 07 in 7 8 mm 0 30 in 8 4 mm 0 33 in 9 4 mm 0 37 in 5 0 mm 0 20 in Actuating distance Response distance 6 4 mm 0 25 in 1 2 mm 0 05 in 440F E1111S is a cover profile only and is nonfunctioning e max speed 100 mm s 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 visible when in operation The control unit can be mounted on either side of the 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 Force Travel Relationship Since the Safedge system is a contact device a force is required to operate the device This force is dependent on the shape of the object applying t
14. I III LI LILIIDIUTMM IM A A A E A EORR 21 Routine Maintenance Inspection and Test recommended weekly or after repair lessen 21 Thorough Examination and Test twice yearly or after repair ssssssssssessssssssssesese ee he he e hme hee 22 R pailt z cesis tes MER S CHER CEDENS RNMOUERIISN AERE CEREREM LUN BAM EOM RN NOE E nO A hed Esau NUNT KRAMER OLOR TA 22 Record of Routine Inspection and Test see Maintenance section cece cece cece ee nnn eee emm eee 23 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P 3 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Introduction IMPORTANT Read this manual in full before installation After installation this manual must be retained in a safe and accessible place Allen Bradley TM GC C P puisse zi a i Guach frente CONTROL UNIT Pt No 440F C251P Al E Z2 MC 13 23 31 O 21 OOO 1 440F C251D TONERS fe Allen Bradley See a OPEN VA g O RUN Guard master stor E Guard Imaster E Safedge Pressure Sensitive Safety Edge System SA F E DG E FA SA F E DG E erba 8 Control unit Supply Voltage 230 110VAC see selector OPEN a Pas 50 0 or 24V AC DC Control unit 2 SECD252 e IP65 Hoseproof Dust tight ISO 13849 1 5 6 Safety Contacts 0 An Contacts 250V 2A N C ISO 13856 2 b O C Piso BASEL EN Ea A1 A2 1
15. Safedge System ONLY USE 440F A0020 CYANOACRYLATE This type of cyanoacrylate adhesive ensures a lasting sealing and high protection in accordance with the IP65 rating Installation of C Rail CONNECTOR WITH RESISTOR CLOSING CAP TO CONTROL UNIT OR NEXT PIECE OF PROFILE Original Instructions in English Rockwell Automation Publication 440F UM002A EN P 9 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Mounting the C Rail installation supplied Holes drilled on Fasteners not Assembly and Installation of the Safedge Profile 10 Original Instructions in English 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 When using the 440F A1302 closing cap with sealing lip the profile base must be cut back to a length of 12 mm 0 46 in The cut must be precisely made to ensure that the profile base is completely trimmed off leaving a flush surface The shaded areas must be roughened with emery sand paper The closing caps are molded with four grommets each with a rubber plug When fitting a resistor leave the plugs intact When making a cable connection select the appropriate cable exit and remove the plug from the grommet with a hole punch Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Sa
16. arative Properties EPDM Profiles 440F E0110S 440F E0110R 440F E0510S 440F E1610S 440F E0804S 440F E0310S 440F E0210S 440F E0118S NBR CR Profiles 440F E0110N 440F E1610N Tensile strength reinforced mPA Resilience 20 C Low temperature flexibility Resistance to sunlight Resistance to heat ageing N oO N eo Resistance to oxidation Resistance to ozone Resistance to H20 Resistance to dilute acids Resistance to concentrated acids F F G G F F G F F G VAL A A A A oc o oc Resistance to oils amp greases 440F E1111S is a cover profile only and is nonfunctioning Key G Good F Fair P Poor IMPORTANT Profile must be selected according to intended environment Original Instructions in English Rockwell Automation Publication 4A0F UMOO2A EN P 19 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Applications L1 ee ee eer ees i L1 L2 L3 Liezi zz X1 1 i ATO 440F C251D 7 V Fn A 440F C251P 440F C251P oll N Series Terminated Safedge Input Manual Reset Series Terminated Cascaded Safedge Input Automatic Reset Dual Channel Output Monitored Output Dual Channel Output No Output Monitoring 24V DC 24V DC Reset ET E27E3 K1 wo L1 L2 L3 Safedge Safedge n RB eo pu C N UI N J
17. ble 1 off Max output fuse Ambient temp range control unit N A 10 55 C 14 131 F 4 Aon AC 2 Aon DC Ambient temp ranges profile 5 55 C 23 131 F EPDM Ethylene Propylene Diene Modified Rubber excluding 110N amp 01610N 0 55 C 32 131 F NBR CR Acrylonitrile 34 nitrile Butadiene Rubber Chloropriene Rubber Humidity Up to 90 RH at 55 C 131 F Vibration Tested in accordance with IEC 68 2 6 frequency range 10 55 Hz displacement 0 15 mm 10 cycles per axis sweep rate 1 octave per minute MC MC contactor monitor loop N C normally closed contactor loop Max conductor size 1x 1 sq mm 0 001 sq in stranded with sleeves stripped 5 mm 0 2 in 1 x 1 5 sq mm 0 002 sq in solid conductor 1x 2 5 sq mm 0 004 sq in stranded with sleeves stripped 8 mm 0 31 in 1 x 4 sq mm 0 006 sq in solid conductor Terminals Minus terminal screws M2 spring action Plus minus terminal screws M3 5 with self lifting connection washer terminal boards separately removable Installation group C in accordance with VDE 01 10 Material control unit Polycarbonate Mounting details 4x M4 holes 45 mm DIN rail 22 5 mm DIN rail Housing Weight Miscellaneous Bend radius minimum 12 Original Instructions in English D 75 mm H 130 mm W 130 mm respectively 2 95 x 5 12x 5 12 in 650 g 22 9 oz avdp D 120 mm
18. e IM epe T ode ERERULUE POP E et 13 Deformation Travels 4 ceres orbe IN tis noe A XR hahaa teeth Eee RE YER NR epe A EE R ELE EE ey CERES neq 13 Selecting the Cushion Factor 09 IR Re ee AAXTEPPONS REPRE ESTA RE Y RACER POO PEREAT OUO RIAM PODURUEN USD NR DU TEX 15 h fet iquiiaro REEL 15 Terminal Connections inca ooscce tete EEPIEIA VL ore e e pb AE E ERU RD REA aa Bun qu koe E UR TO RR E EK 15 Safedge Control Unit Electrical Connections 6 ccc cece ne eene hehehe hehehe he emen here he he s eere hene 16 Control Unit Installation arid Wifing dur Re Leer pF FTH Rea Aad ewes De SUPE ne SHER DAES me name ULIS ORE oe UR seer ee malere HET 16 Mainselector Switch oeer reiese RARE Eher ERE ae tae murky FREE PN UH Eder ek Ne nU sw VERSA NE VERE RAE UO dE Ea 16 Maininp ttermihal s 2s er bere v RRRUDRRRER ET ae ORO RARE SRL RR EE Mq CE EO EE ance xa ke ee bes eR TRA en SERE 16 24V AC DC input terminal ve and ve iiir Rosie epi Dy eee a e RE AERIRIM RE TER RR e avalon deta OR EI ET CS Pe VERE eda 17 Auxiliary Output terminals 31 and 32 ser sneen er eT er SEERE heh he heh he ee eae hehe 17 Safety Output terminals 13 14 23 and 24 iissssssssesssseseslesseses ehem heh heh he hehehe nhe eee 17 Reset terminal MC MC 4 eere Re aon ASE DN IUE P SR ERI Pee A ed Ee ete a IDEEN RA 17 Profile connectiorrto conttol nits 1 04 reme eer pner e RE ne x AR P E eee IAEA EU En CU ER UNE Bigelutus BOVE eese Qe ons 17 Connection in Parallel and Seri
19. eached If a pressure sensitive edge or pressure sensitive bar with sufficient overtravel cannot be found it can then be necessary to improve the stopping performance of the machine Safedge Profiles mm in 285 110 P3 125 Toad 9 0 35 2 0 D Cushion factor 5 mm 0 20 in 440F E0110S 440F E0110R Red profile 440F E0110N Increased resistance to oil NBR Level of Protection IP67 Actuation Angle 20 Weight 0 501 kg m 0 031 lb ft 25 0 98 M4 rdl Cushion factor 19 mm 0 75 in 440F E1610S 440F E1610N Increased resistance to oil NBR Level of Protection IP67 Actuation Angle 3 45 Weight 0 782 kg m 0 048 Ib ft 30 1 18 440F E0310S Cushion factor 41 mm 1 60 in Level of Protection IP67 Actuation Angle 45 Weight 1 198 kg m 0 074 lb ft 28 5 12 5 0 48 0 4 5 0 96 is 28 30 2 1 10 1 18 9 2 0 08 Hl 440F E0510S Cushion factor 5 mm 0 20 in with sealing lip Level of Protection IP67 Actuation Angle 45 Weight 0 596 kg m 0 037 Ib ft 25 0 98 440F E0804S Cushion factor 19 mm 0 75 in with sealing lip Level of Protection IP67 Actuation Angle 45 Weight 0 972 kg m 0 060 Ib ft 6 Original Instructions in English 440F E0210S Cushion factor 41 mm 1 60 in with sealing lip Level of Protection IP67 Actuation Angle 45 Weight 1 288 kg m 0 080 Ib ft 440F E01
20. ed 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 12V DC operators are therefore not exposed to potentially dangerous voltage should the profile be accidentally cut or sheared The copper wire core throughout the length of the profile ensures that there is no significant build up of resistance over long lengths Conductive Flexible Wire Contact 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 in the presence of a 6KO resistance 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 thus creating a short circuit which in turn drops the overall resistance This is monitored by the control unit that initiates the machine shutdown Any single fault in the profile or the wiring connections to the profile will be detected in that case the control unit outputs go to a safe OFF state Individual profiles connect to each other via wires axial connectors or standard 90 connectors Two wires connect the profiles to the control units The control unit has fully cross monitored
21. es s poco EE Yee Cres A RAN ERE EOPIR Cen ERI AA LERFERERODIW VOU RCRUM AA ERE 18 Connecting in Series cose eee RE aaa acon E e Up E EU RR MEE ea bs Waa ER S RICE eR VERRE C ERES VA ACTU EA uia 18 Alternative Connection Method ioo cucu s ety xr eXEERRODS S UREEXESRT eU lod Pods UST TRE ge AER AR OXPO RE E UTERE ERE AT OA kee ee EN 18 Connecting in Parallel cu iro aie Oe YER EA Y vr AR ee ee tee EU UON CER ee ea VE AUR ods 18 Commissioning and Use Sequence of Operation 6 cece cence eee sees hes hee hs ee he hehehe 18 Man al Reset Mode ccn e Ghee ante hag An RE NAR UE OS NN ER LUCI ERES DU I dS SR ele ERR RES ULUNI S eae cewek EN 18 Automatic Reset Mote 55 ssilenerR E ERR Rt er ied Sha tee See ale eee ed dha DORE Pana elated HUN RERUMS CU PE E began betes 19 Comparative Properties rds kept Pec we IRAM eh be oU e Ue RR ER LUCERE OR Rc ako Rara es oldie viv ene ER ERES TA 19 Applications z ovesd eee NER I ter EE ARMES E REA epi eek a qa Eee es xri e ebur ea Na alike ex xk ede e RR RO ER we 20 Maintenance and Service 55i 2 is tae Pesce A SD LEE put CDU S EE Ire UR Me neto bes RE TER HU EAT SS ARR Rue LOCARE MEDIUS Pale saw candies tenes 21 Troubleshooting Guide cis c e eorr epe ye Code se ethane ea OU RE REP UN VEE E PENA V Oe Y REV ga Venue uet era A 21 Maintenarice s serpens ev ER RERULECS LENS Sedona bes NES WESC ARES Tem ed O NEQU EE E Ea ah a AEE C OW FR Le e E V REDE RES TES EEESRCQ SE INE 21 Profile Cleaning TEEUEETER
22. fety Edge System Installation and User Manual Pull the connecting cable through the hole Pierce each of the copper wires with one of the needles Press the needle contacts of the connector in the direction shown wedge outwards straight into the copper wires WARNING The narrow side wedge of the connector must show outwards Fold back the sealing lip of the cap then a Applyadhesive to shaded area of closing cap as illustrated then affix to edge of profile applying pressure for ten seconds to ensure adhesion b Apply adhesive to remainder of shaded area and allow sealing lip to make contact with profile Spread the adhesive evenly over the shaded area Ensure that no adhesive enters the profile IMPORTANT To ensure complete seal apply more adhesive to the Safedge profile especially around the grommet cable exit and sealing lip of the closing cap The axial profile connector 440F A0061S is used for extensions and repairs see steps above for the 440F E0110 series of profiles only For other types use straight pin connectors When inserting the profile into the C rail a lubricant may be used to reduce friction When installing do not pull on connecting cable or on rubber profile Sensing Surface of Safedge System The sensing surface of the Safedge system is active along almost the full length of the edge The 10 mm at the beginning and end are not active Original Instructions in English Rockwell Automation Pub
23. he force the speed of the object and deformation distance on the profile To help understand the force requirements the European standard ISO 13856 2 2013 provides three test objects travelling at two speeds Shown in the graph below is the force that is applied over the deformation distance on the surface of the profile Note that the force required to operate the corners is greater than the force required along the straight section of the profile This force must be used as a guideline as the inanimate object can not be harmed Force vs Distance Force vs Distance 300 300 250 25 200 2 z 150 g D e 2 100 1 50 5 0 0 0 2 0 3 6 5 5 72 87 0 0 19 39 54 74 8 8 0 08 0 14 0 22 0 28 0 34 0 07 0 15 0 21 0 29 0 35 Vp 10 mm s Distance mm in Vp 100 mm s Distance mm in Deformation travels Deformation Travels 440F E0110N Test temperature 20 Speed 10 mm s 100 mm s 200 mm s 600 N Actuation Force 36 5N 51 4N 71 7N P Response travel A 5 3 mm 0 21 in 5 6 mm 0 22 in 7 4 mm 0 29 in 400 N E Total deformations at 250 N B1 9 4 mm 0 37 in 8 9 mm 0 35 in 10 0 mm 0 39 in 250 P Total deformations at 400 N B2 11 4 mm 0 45 in 11 0 mm 0 43 in 11 8 mm 0 46 in 1 Threshold forces 2 Min actuation force Force deformation path diagram Original Instructions in English Total deformations at 600 N B2 13 2 mm 0 52 in 12 9 mm 0 51 in
24. hose described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permission of Rockwell Automation is prohibited Throughout this manual we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property AN damage or economic loss Identifies information that is critical for successful application and understanding of the product AMANN identifies information about practices or circumstances that can lead to personal 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 that dangerous voltage may be present Labels may be on or inside the equipment for example drive or motor to alert people that surfaces may reach dangerous temperatures It is recommended that you save this user manual for future use 2 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Table of Contents Introduction MP EE 4 System Description ss eese e TENE ULEA E ees Dasara NV RN CE he halbiea bum nel bibs aimee EE
25. ine Users might also consider a reversing option When the profile is depressed the Safedge control unit sends a signal to a reversing relay Since the reversing relay is not a safety rated device the user must still confirm that injury does not occur if parts of the body get jammed Mounting mm in n 120 4 72 lt 130 5 12 gt 15 me t 75 2 95 e 5 Gf 5 130 5 12 115 4 53 4x M4 Fixing Holes d Y I p 440F C251P surface mounted E 45 5 1754 A 118 4 64 di 35 mm DIN N A X rail mounting OO S8OOSO B e 35 mm DIN rail mountin O SSOOSO 440F C251D mounted on DIN rail 440F C252D mounted on DIN rail Terminal Connections To prevent strain on terminal connections use connection boxes and coiled cables Original Instructions in English Connection Box Control Unit Closing Cap C Rail Connector with Resistor Closing Cable Cap Connector Rockwell Automation Publication 440F UM002A EN P 15 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Safedge Control Unit Electrical Connections 47 4 6 STOP OPEN RUN RED YELLOW GREEN LED INDICATION OOQ ps
26. inium C112 A2 440F R1214 Ideal when external fixing of C rail is required Accepts all profiles 440F EBbcde 440F E0110R 440F ECbcde 440F E0110N 440F ED bcde 440F E0510S 440F EEbcde 440F E1610S 440F EFbcde 440F E1610N 440F GF bcde 440F E0804S 440F EH bcde 440F E0310S 440F Elbcde 440F E0210S 440F EJbcde 440F E0510S 440F EKbcde 440F E0804S 440F ELbcde 440F E0210S 440F EM bcde 440F E0118S 440F EN bcde 440F E1111S 440F EObcde Original Instructions in English 440F E1111S Rockwell Automation Publication 440F UMO02A EN P 7 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual where b indicates with or without c rail for mounting c indicates location of cable entrance d indicates the termination of the profile and cable length e indicates the length of the profile in mm and is a five digit number Control units which evaluate the sensor signal Control Unit Model No Description 440F C251P Enclosure of surface mounting 440F C251D Enclosure for DIN rail mounting 440F C252D Enclosure for DIN rail mounting PLEASE NOTE THAT ALL C RAILS ARE SUPPLIED WITHOUT FIXING HOLES IMPORTANT The C Rail 440F R1212 can be supplied curved to meet most applications Each profile uses a combination of non conductive rubber and a flexible wire cored conductive rubber bond
27. lication 440F UMOO2A EN P 11 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Control Unit Technical Specifications 440F C251P Surface AA0F C251D DIN Rail Mount 440F C252D DIN Rail Conformity EN 13849 Pld Cat 3 EN ISO 13856 2 2013 System response time 13 mS Environmental protection IP65 Enclosure IP40 DINO470 Enclosure IP40 DINO470 Terminals IP20 DINO470 Terminals IP20 DINO470 Max Safedge profile voltage 12V DC open circuit Nominal operating voltage 4V run condition Max output fuse 2 A quick acting 5 A quick acting Impulse withstand voltage 2500V Over voltage Category 2 Contamination level Il Min switched current voltage 10 mA 10V Power consumption 6 VA Relay outputs 2 x independent volt free N O safety contacts 1 x volt free N C auxiliary contact NOTE Auxiliary should not be used for safety 1 x independent volt free N O safety contacts 1 x volt free N C auxiliary contact NOTE Auxiliary should not be used for safety Utilization category AC 15 2A 250V DC DC 13 2A 30V DC Safety inputs Safedge profile open resistance 6 KO Indication LED 1 Green RUN LED 2 Yellow OPEN LED 3 Red STOP Internal controls AC voltage selector Internal fuses 2 A safety fuses replaceable 500 mAT supply fuse reset ability 1 off 2 off 500 mAT supply fuse replacea
28. n are the property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication Drawing No 440F UM002A EN P supersedes 440F IN003A EN P 31611 Ver 03 February 2015 Copyright 2015 Rockwell Automation Inc All Rights Reserved Printed in USA
29. ntrol circuits i e a dual channel system use 13 14 for one contactor and 23 24 for the other For two contactors also see the Applications section Reset terminal MC MC or X1 X2 on the 440F C2522 see 4 6 in drawing on page 16 These terminals are used for a number of different functions the surface mount version is supplied with jumpers while the DIN rail version is supplied without a 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 energization of its control coil the Safedge system will not allow the other contactor to be energized until the fault has been rectified Fit 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 remains jumpered or connected only to the contactor s normally closed contact the unit is in automatic reset mode In automatic reset mode the output is achieved solely by removal of the actuating force The output 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 I5O12100 then this mode must not be used See IEC60204 1 and EN I5013849 1 For manual reset mode a normally o
30. ort The Safedge control unit and profile should be transported within the temperature range of 10 55 C 14 131 F and should 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 resulting from rough handling or the use of knives box cutters etc 4 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Safedge Selection The following are the four most important factors influencing the selection of a suitable pressure sensitive edge or pressure sensitive bar for a specific application a Category and performance level according to ISO 13849 1 as required for the application These are based on the risk assessment for the particular application the requirements of a relevant type C standard Hazard speed This is the speed at which the hazardous surface is moving Normally one surface is moving and the other is stationary The maximum possible speed should be considered as the hazard speed If both surfaces are moving special consideration is required Stopping travel of hazardous parts This is the distance travelled by the hazardous surfaces after a stop signal has been given by the output signal switching device to the machine control system This travel depends on the hazard speed the res
31. pen spring return not latching push button must be connected across the MC MC terminals or in series with the normally closed contactors 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 powering up the control unit Profile connection to control units see 4 7 in drawing on page 16 These terminals are used to connect the profile to the Z1 Brown inner conductor Z2 White outer connector Refer to the Applications section A profile must be terminated with a 6KO resistor yellow for series connection If two profiles are connected directly to Z1 and Z2 in parallel each profile should be terminated with a 15K resistor blue Original Instructions in English Rockwell Automation Publication 4A0F UMOO2A EN P 17 Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Connection in Parallel and in Series Connecting in Series In installations involving several profiles they are normally connected in series as shown in the following illustration Uses 6K8 resistor yellow Alternative Connection Method Connecting in Parallel A maximum of two profiles can be connected in parallel to facilitate the wiring of certain applications z 15K resistor blue Commissioning and Use Sequence of Operation When the unit is installed check the following sequence of operation Manual Reset Mode 1 Turn the
32. ponse time of the machine control system and the efficiency of the machine braking system This travel can be calculated and or measured Where appropriate a suitable safety factor should be used to account for brake deterioration measurement tolerances etc Recovery of the sensor after deformation On applications where the time between successive actuations of the sensor is less than 30 s A sensor should be selected which will recover sufficiently for normal operation within the time available Selection Procedure After deciding the category and the performance level according to ISO 13849 1 the procedure is as follows a Determine the required operating speed and maximum hazard speed If the maximum hazard speed is not given it should be measured or calculated The point in the travel at which the maximum speed occurs will depend on the drive mechanism The maximum operating speed of the device should be greater than the maximum hazard speed b Determine the required minimum overtravel distance Determine the stopping travel of the hazardous parts If this is not given it should be measured and or calculated The stopping travel multiplied by a suitable safety factor of at least 1 2 gives the required minimum overtravel for the application Where other factors exist such as a braking system that is subject to deterioration a higher safety factor should be used A simple way to measure the stopping distance is to temporarily fit
33. power on a Not one LED illuminates 2 Press the reset switch a The green RUN LED illuminates b Safety contacts close c Auxiliary contacts open d Contactors energize 3 Press the profile a The green RUN LED extinguishes b The red STOP LED illuminates c Safety contacts open d Auxiliary contacts close e Contactors de energize lt 5I Se a 4 Release the profile a The red STOP LED extinguishes b System has returned to step 1a 5 If profile is pressed before reset a The red STOP LED will illuminate each time the profile is pressed but the safety contacts will not energize 18 Original Instructions in English Rockwell Automation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Automatic Reset Mode 1 Turn the power on a b c d The green RUN LED illuminates Safety contacts close Auxiliary contacts open Contactors energize I w 2 Press the profile a The green RUN LED extinguishes b The red STOP LED illuminates c Safety contacts open d Auxiliary contacts close e Contactors de energize lt SUT Se ux 3 Release the profile a System has returned to step 1a Terminal block tightening torque rating is 7 in lbs suitable for wire sizes 16 AWG Use 16 AWG minimum IMPORTANT Use copper conductors only Temperature rating of field wiring shall not be less than ambient Comp
34. rminal ve and ve or and see 4 3 in drawing on page 16 If a 24V AC DC supply is 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 mains input terminal above Where a 24V AC or DC supply is used it must be isolated from the mains supply in accordance with international electrical safety practice IEC 364 4 41 One pole should be grounded to the earth For 24V DC the negative pole should be grounded With 24V AC the ground of the power supply should be connected to the negative terminal Aux Output terminals 31 and 32 or 21 and 22 in 440F C see 4 4 in drawing on page 16 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 Safety Output terminals 13 14 23 and 24 see 4 5 in drawing on page 16 These are volt free contacts for connection to the machine safety circuits in other words 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 you are using only one contactor terminals 13 and 24 are required and terminals 14 and 23 should be jumpered together For two contactors with two independent co
35. s or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DUOO2 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Allen Bradley and Rockwell Automation are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automatio
36. unctions correctly Unit appears to work correctly but there isno Blown fuse Damaged or incorrect wiring Fault Check output fuses Inspect all wiring for pressed and then the red STOP LED illuminates output on Safedge causing the outputs to fail safe damage Check for movement on any internal relays REPLACE CONTROLLER Machine does not stop when profile is pressed Incorrect external connections Inspect all wiring to contactors for mistakes The green RUN LED goes off Machine does not stop when profile is pressed DO NOT ALLOW THE USE OF THE MACHINE The green RUN LED stays on REPLACE CONTROLLER Maintenance Carefully read this section in full before attempting any maintenance work During maintenance operations disconnect the machine s prime mover before working on the Safedge system Observe all applicable electrical safety precautions Profile Cleaning The profiles should be kept clean of deposits such as swarf fine metallic filings or shavings removed by cutting grinding or any other mechanical process debris and other foreign materials to prevent damage or dead zones It is permissible to use warm water and a mild detergent to clean the surface area Routine Maintenance Inspection and Test Recommended weekly or after repair IMPORTANT DO NOT USE SOLVENTS Stop the machine clean the profile or profiles and allow them to dry off Inspect the surface of the profile for damage Any damage that
37. utomation Publication 440F UM002A EN P Guardmaster Safedge Pressure Sensitive Safety Edge System Installation and User Manual Record of Routine Inspection and Test see Maintenance section Date Inspected by Comments Original Instructions in English Rockwell Automation Publication 440F UMOO2A EN P 23 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAOs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United State
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