Black Max User Requirements Installation Information Operating Instructions LINK ELECTRIC & SAFETY CONTROL COMPANY 444 McNALLY DRIVE, NASHVILLE TN 37211 PH (615)-833-4168 FAX (615)-834-1984 Black Max Link Lite 305 MANUAL INCLUDES SECTIONS 1,3, &4
Link Lite Black Max Section 1 - User Requirements 1. IMPORTANT REQUIREMENTS AND RESPONSIBILITIES THAT THE USER/EMPLOYER MUST MEET WHEN USING LINK LITE BLACK MAX LIGHT CURTAINS 1.1. Machine and Machine Control Construction Requirements All light curtains depend on the electrical, mechanical, pneumatic, and/or hydraulic control components and drive systems of the machine to stop hazardous motion when the light curtain gives a stop signal to the machine control.
Link Lite Black Max Section 1 - User Requirements 5. Machine controls must be designed for "Control Reliability", i.e., so that a single failure in electrical, pneumatic, or hydraulic components does not prevent the normal stopping of machine action when required but does prevent initiation of further machine action. supplied by Link fail in such a manner as to not stop the machine action when the Black Max provides a stop signal to the controls.
Link Lite Black Max Section 1 - User Requirements must read or provide translation of these instructions to the person. The employer must ascertain that the instructions are understood. 2. The specific duties and actions to be performed by setup and operator personnel for each job relative to both production and safety. These work practices must be in conformance with any OSHA or ANSI standards that apply. 1.3.3. Supervision 3. The machine manufacturer's operating instructions.
Link Lite Black Max Section 1 - User Requirements to maintain WARNING! Failure machines, or improper repairs or adjustments to machines on which the Link Lite Black Max is used as a safeguarding component, may result in abnormal, uncontrollable machine action(s) that cause serious injury or death even though the Black Max is functioning properly.
Link Lite Black Max Section 3 - Installation 3.2.1 Summary of Black Ma x Installation Requirements 3 INSTALLATION 3.1 General Requirements Installation of the Link Lite Black Max must include the following procedures and requirements. These procedures and requirements are discussed in more detail in sections 3.3 through 3.8.
Link Lite Black Max Section 3 - Installation selected by the user/employer to install the barriers must: Determine where barriers are 1. necessary and the location and size of barriers. Design and fabricate (or have fabri2. cated) the necessary barriers. Mount the barriers and confirm their 3. effectiveness and that pinch points or other hazards are not created between barriers and moving machine parts. Supplemental guard requirements discussed in more detail in section 3.9. 3.3 are Figure 3.
Link Lite Black Max Section 3 - Installation Ts = the stop time (in seconds) of the machine measured from the control output stop signal to the actuator(s) (valves, etc.) that govern machine motion till the machine actually stops. presses. See ANSI B11.1 1988 sections 6.3.2(15) and 4.11 and OSHA's CFR 1910.217 sections (c)(5) and (b)(14).
Link Lite Black Max Section 3 - Installation to account for the increase in M.O.S. due to blanking. Blanking is possible on Black Max units with .95" M.O.S. and 1.25" M.O.S.. Each contiguous (side by side) channel blanked increases the M.O.S. by .75". following formula. Use this formula only for M.O.S. less than 2.75 inches. Dpf = 3.4 (M.O.S. - .276) Figure 3.
Link Lite Black Max Section 3 - Installation 1. Any location and orientation of the main Black Max transmitter and receiver units must place the sensing field at a distance from the hazard greater than or equal to the safety distance required in section 3.3 of this manual, i.e. so, that hands or fingers are Ds from the hazard when the sensing field is interrupted by any part of the body.
Link Lite Black Max Section 3 - Installation the machine control as required. The Black Max is designed to detect crosstalk from other light curtains and to provide a stop signal if it occurs. It is important to install Black Max light curtains in such a manner as to avoid nuisance machine stops caused by crosstalk. 3. The mounting location or method must leave access for work pieces, tool changes, and other operational requirements. 4.
Link Lite Black Max Section 3 - Installation components of the safety system to supplement the protection provided by the main transmitter and receiver units. 8. The Black Max transmitter and receiver each have four mounting holes, two in each end mounting flange. See Figure ---, page ---, for mounting hole dimensions and patterns for various length units.
Link Lite Black Max Section 3 - Installation The mounting requirements for remote segment Black Max units are generally the same as for main transmitter and receiver units except that when used for supplemental guarding between the main sensing field and the hazard, there is no Figure 3.7. Shows remote segment units mounted on a straight side press with columns extended beyond the bed and slide. safety distance, Ds, requirement for the location of remote segment units.
Link Lite Black Max Section 3 - Installation Black Max remote segment transmitter and receiver units must always be mounted on the same side of the machine, respectively, as the main transmitter and receiver units as shown in Figure 3.10 Also, the mounting arrangement is somewhat different for the remote segement units as shown in Figures 3.9a and 3.9b. 3.4.
Link Lite Black Max Section 3 - Installation accommodate a 1/2" conduit fitting. Run a 1/2" conduit from the machine control enclosure to each main Black Max transmitter unit. Similarly, run a 1/2" conduit from the machine control enclosure to each main Black Max receiver unit. All wires required for the transmitter and receiver should be pulled through the 1/2" conduit. Use of flexible conduit with integral armor and ground wire, such as Seal Tite, is preferable.
Link Lite Black Max Section 3 - Installation Figure 3.13: Location of transmitter power connector.
Link Lite Black Max Section 3 - Installation All control wiring connections to the Link Lite Black Max are made to the eight position terminal/connector located on the relay board in the main Black Max receiver enclosure, accessible by opening the door to the receiver enclosure as shown in Figure 3.14. Run wires through the 1/2" flexible conduit from the machine control enclosure to the main Black Max receiver unit to interconnect the light curtain to the control.
Link Lite Black Max Section 3 - Installation Figure 3.14: Power and relay connections for Black Max receiver.
Link Lite Black Max Section 3 - Installation mechanical power presses, hydraulic power presses, power press brakes, etc., OSHA and ANSI allow presence sensing devices such as the Link Lite Black Max to be interconnected or interfaced with the machine control so that the protective function is bypassed (muted) during the non-hazardous portion of the stroking cycle only. Never simply use unmonitored limit switch contacts to mute the Black Max in the non-hazardous part of a machine cycle.
Link Lite Black Max Section 3 - Installation Figure 3.15: Location of relay check con-figuration jumpers.
Link Lite Black Max Section 3 - Installation screw-in plug in the large hole in the end cap, running the ribbon cable through the hole, and screwing the cable fitting into the hole. Always leave the screw-in plug in place on the unused end of the main transmitter or receiver unit to retain the NEMA 4 performance of the enclosure. In some cases, two remote segment units may be used, one off of either end of the main transmitter or receiver enclosure. This is illustrated in Figure 3.18. shown in Figure 3.
Link Lite Black Max Section 3 - Installation Figure 3.16: Use of remote segment at bottom of main transmitter.
Link Lite Black Max Section 3 - Installation Figure 3.17: Remote segment unit used at top of main transmitter.
Link Lite Black Max Section 3 - Installation Figure 3.18: Use of two remote segment units with main transmitter.
Link Lite Black Max Section 3 - Installation Figure 3.19: Location of the transmitter power level switch and power level table.
Link Lite Black Max Section 3 - Installation NOTE! The receiver unit of the Black Max light curtain is designed to supply a stop signal when far too much light is received from the transmitter. 3.7 Aligning The Black M ax Transmitter(s) and Receiver(s) After setting the proper transmitter power level, make sure that both the Black Max transmitter and receiver enclosure doors are closed and screwed shut. If the mounting instructions in section 3.
Link Lite Black Max Section 3 - Installation receiver units. Verify that power is on the transmitter by observing that the green "POWER" LED in the front center of the transmitter unit is on. Verify that power is on the receiver by observing that either the green "CLEAR" LEDS or the red "STOP SIGNAL" LEDS in the front center of the receiver unit are on. Don't start the machine for this alignment procedure. Leave all motors off. sent by the Black Max receiver unit to the machine control. 2.
Link Lite Black Max Section 3 - Installation connect the mounting ears to the transmitter unit to lock the transmitter into angular alignment. 7. Loosen the bolts that connect the mounting ears to the receiver unit and repeat the procedure of step 6 with the receiver to bring the receiver into angular alignment. brackets (or surface) to which the transmitter and receiver are to be mounted are in reasonable alignment.
Link Lite Black Max Section 3 - Installation Perform the following checkout steps: indicator light behind the acrylic receiver lens lights as its channel is blocked, and that the red "STOP SIGNAL" lights on the receiver door stay continuously on as the bar or strip is lowered from top to bottom. 1. Turn on power to the Link Lite Black Max units by turning the main disconnect to the machine control to the on position. Do not turn on machine motor(s).
Link Lite Black Max Section 3 - Installation 9. Take the test bar or strip used in steps 4 through 6 and insert it into the sensing field between the transmitter and receiver. The machine stopping action should immediately be initiated when the sensing field is interrupted. An exception to this occurs when the Black Max is muted during a part of a machine cycle that is not hazardous.
Link Lite Black Max Section 3 - Installation the point of operation, except through the Black Max(s) sensing field(s). have a body part in the hazardous area without being detected. If remote segment Black Max units are not used to detect a person standing between the primary sensing field created by the main transmitter and receiver and the hazard (see section 3.4.2), then barriers must be installed to keep someone from passing completely through the Black Max sensing field toward the hazard. 2.
Link Lite Black Max Section 3 - Installation Figure 3.23: Illustration of barriers installed to prevent someone from reaching over the top of a Black Max sensing field or through the openings of a C frame machine.
Link Lite Black Max Section 3 - Installation Figure 3.24: A Black Max with supplemental barrier to prevent standing between light curtain and hazard. Figure 3.25: Example of a Black Max on a press brake with supplemental barriers. Figure 3.26: Use of Black Max remote segment units in the horizontal position to protect inside primary sensing field, and barriers to prevent entry from the side.
Link Lite Black Max Section 4 - Operating Instructions 4 1. Link Lite Black Max light curtain presence sensing devices are designed and manufactured to comply with OSHA and ANSI standards for construction of point of operation devices.
Link Lite Black Max Section 4 - Operating Instructions 2. The main Black Max sensing field must be located far enough away from the hazardous area that machine action will be stopped before a persons hand that passes through the light curtain sensing field can reach the closest hazard. This safety distance is required by both OSHA and ANSI. The minimum safety distance, DS, is determined by a formula which is explained in section 3.3 of the installation section of this manual.
Link Lite Black Max Section 4 - Operating Instructions 5. Any task associated with a machine or production system using a Black Max as a safeguarding component that requires a person to enter into the hazardous area so that he is not protected by the Black Max or other safeguarding components must be done in accordance with OSHA's lockout/tagout regulations, CFR1910.147, where all hazardous energy is locked out on the machine or production system by each person involved in the task.
Link Lite Black Max Section 4 - Operating Instructions sensing field can be blanked. Sensors in remote extension Black Max units used for supplemental safeguarding cannot be blanked. WARNING! If muting is used, and the muting means is improperly installed or adjusted, the Black Max stop signal may be bypassed in a hazardous portion of the machine cycle. Serious injury or death can result from improper muting. 4.
Link Lite Black Max Section 4 - Operating Instructions extend through the sensing field without preventing the machine or production system from operating. No more than seven (7) sensors can be fixed blanked on a standard Black Max unit. Any combination of seven sensor channels can be blanked. NOTE! The Black Max always gives a stop signal unless the blanking mode selector switch is in the RUN position. Always remove the key from the switch when blanking mode selection is complete.
Link Lite Black Max Section 4 - Operating Instructions NOTE! When FIXED BLANKING is used, removal of the object(s) that blocks the transmitter light from the receiver sensor channel will automatically unblank the sensor channel. NOTE! Because fixed blanking provides "windows" in the Black Max sensing field, you must follow the safe blanking requirement of section 4.2.4 when it is used.
Link Lite Black Max Section 4 - Operating Instructions obstructed to prevent a person from reaching through the blanked area. Otherwise item 4 of this list applies. For any combination of VARIBLANK and FIXED BLANKING that uses two or more side by side sensor channels in FIXED BLANKING, the fixed blanked area must be obstructed to prevent a person from reaching through the fixed blanked area and the safety distance, Ds, must be increased by 2.55 inches. Otherwise, item 4 of this list applies. 4.2.
Link Lite Black Max Section 4 - Operating Instructions 4.3 each Black Max receiver channel and verify that the red LED indicator seen through the red acrylic strip next to the channel numbers turns on (except for channels with fixed blanking).
Link Lite Black Max Section 4 - Operating Instructions about half way between the transmitter and receiver units. step 2. If they are on, have an authorized person use the RUN/PROGRAM/SELECT switch to turn them off while leaving any FIXED BLANKING necessary for the setup. 6. Initiate machine action and insert the test bar into the Black Max sensing field in the hazardous portion of the cycle or stroke. The machine should stop with normal reaction time.
Link Lite Black Max Section 4 - Operating Instructions scribed in section 3.8 of this manual must be performed before placing the machine back into production. WARNING! After repair or re-installation of a Link Lite Black Max or the machine or machine control is repaired, rebuilt, or modified, the functional checkout of the Black Max installation and the machine on which it is installed described in section 3.
