User Manual SafeShield™ Safety Light Curtain Hardware
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.
SafeShield Safety Light Curtain Hardware User Manual Conditions required for proper use of the SafeShield Safety Light Curtain Please make sure you read and understand these requirements before you select and install the SafeShield safety light curtain. SafeShield 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 personnel on a variety of machinery.
SafeShield Safety Light Curtain Hardware User Manual Table of Contents Agency Approvals Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Configurable Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation and Mounting . . . . . . . . . . . . . . . . . . . . . . . .
SafeShield Safety Light Curtain Hardware User Manual Introduction SCD Please read this chapter carefully before working with this documentation and the SafeShield safety light curtain. These operating instructions are designed to address the technical personnel of the machine manufacturer or the machine operator in regards to safe mounting, installation, configuration, electrical installation, commissioning, operation and maintenance of the SafeShield safety light curtain.
SafeShield Safety Light Curtain Hardware User Manual 〉 Green The green LED is off. Instructions for taking action are shown by an arrow. Read carefully and follow the instructions for actions. ! Software notes show the location in the SCD where you can make the appropriate settings and adjustments. Go to the menu View, Dialog box of the SCD and activate the item File cards to view the named dialog fields as required. Alternatively, the Software Assistant will guide you through the appropriate setting.
SafeShield Safety Light Curtain Hardware User Manual General Protective Notes and Protective Measures ATTENTION: Safety notes Please observe the following procedures in order to ensure the correct and safe use of the SafeShield safety light curtain.
SafeShield Safety Light Curtain Hardware User Manual SafeShield Safety Light Curtain Function That Can Be Configured Without Cascading Connection With Cascading Connection Special Features " Emergency stop can be connected to the device Reset button can be connected directly to the device # " Output for “Reset required” on the device # " Signal output (ADO) " " External device monitoring (EDM) " " Reduced resolution " " Blanking " " Teaching in blanked areas # " PSDI mode # # B
SafeShield Safety Light Curtain Hardware User Manual Examples of Range of Use The SafeShield safety light curtain operates correctly as a protective device only if the following conditions are met: • The control of the machine must be electrical. • The dangerous state of the machine must be transferable at any time into a safe state. • Sender and receiver unit must be so mounted that objects penetrating the hazardous area are safely identified by the SafeShield safety light curtain.
SafeShield Safety Light Curtain Hardware User Manual Display Yellow -- Meaning Emergency stop active Supply voltage OK System error. Disconnect the supply voltage to the SafeShield safety light curtain for at least 3 seconds. If the problem persists, replace the unit. The device is in the test mode.
SafeShield Safety Light Curtain Hardware User Manual Restart Interlock ATTENTION: Always configure the application with restart interlock! Ensure that there is always a restart interlock. The SafeShield safety light curtain is unable to verify if the restart interlock of the machine is operable. If you deactivate both the internal and the machine’s restart interlock, the operators of the machine will be at an acute risk of injury.
SafeShield Safety Light Curtain Hardware User Manual Only the external restart interlock prevents the machine from restarting. After pressing the reset button for the SafeShield safety light curtain, the operator must also press the restart button for the machine. If the reset button and the restart button are not pressed in this specified sequence, the dangerous state remains unchanged.
SafeShield Safety Light Curtain Hardware User Manual ATTENTION: You must not use the signal output for safety-relevant functions! You are only allowed to use the signal output for signalling. You must never use the signal output for controlling the application or with safety-relevant functions.
SafeShield Safety Light Curtain Hardware User Manual Fixed Blanking Floating Blanking Fixed blanking Fixed blanking with increased size tolerance Floating blanking with complete object monitoring An object of fixed size must be at a specific point in the protective field. On one side of the fixed blanking an object of limited size is allowed to move through the protective field. An object of fixed size must be within An object of limited size is allowed in a a specific area of the protective field.
SafeShield Safety Light Curtain Hardware User Manual Blanked area, sides protected by mechanical barriers Figure 9: Example of mechanical protection of fixed or floating blanking ➢ After modifying the blanking, check the protective field with the test rod. Instructions can be found in the “Daily Functional Checks of the Protective Device on page 31. Fixed Blanking ➢ Also pay attention to the warnings in the related chapter.
SafeShield Safety Light Curtain Hardware User Manual Table 10. For this reason the moving area must always be greater than the effective resolution at the edges of the area. Unlike the normal size tolerance for blanking, the increased size tolerance allows the blanked object on a specific side of the area to be larger than the blanked area.
SafeShield Safety Light Curtain Hardware User Manual ! Device symbol SafeShield safety light curtain Host (receiver), context menu Configuration draft, Edit, file card Blanking of the related system, option Type of blanking = fixed + increased size tolerance. Here you can adjust the position of the increased size tolerance and the size of this area in millimeters directly. Table 10. For this reason the moving area must always be greater than the effective resolution at the edges of the area.
SafeShield Safety Light Curtain Hardware User Manual Object monitoring ATTENTION: During operation with “Blanking” combined with “Size tolerance,” the safety distance that corresponds to the modified resolution is to be observed. Description Complete The blanked area must be completely covered by the object within the size tolerance. If this is not the case, then the safety light curtain switches to red. Partial The blanked area does not need to be covered by an object.
SafeShield Safety Light Curtain Hardware User Manual ATTENTION: During operation with “Reduced resolution” or “Blanking” the safety distance that corresponds to the modified resolution is to be observed. Resolution modified to: (please mark) Reduction ATTENTION: Prevent teach-in areas or operating modes where it is not intended to be used! A successfully completed teach-in process changes the size and, for fixed blanking, also the position of the blanked areas.
SafeShield Safety Light Curtain Hardware User Manual • The system response time does not change under reduced resolution. • You cannot combine the function Reduced resolution with the function Floating blanking with partial object monitoring (see page 17). • With reduced resolution, the 7-segment display ATTENTION: Test the protective device after teach-in! ➢ Test the entire protective device for effectiveness (see “Test Notes” on page 31).
SafeShield Safety Light Curtain Hardware User Manual • During the test the sender indicates . • The test is successful, if the SafeShield safety light curtain receiver switches to red, i.e. the output signal switching devices (OSSDs) are deactivated. In a cascade this only applies for the host. Notes SafeShield safety light curtain-Sender and receiver are selftesting and do not require any external sender test.
SafeShield Safety Light Curtain Hardware User Manual • Resolution of the light curtain and/or beam separation • Other parameters that are stipulated by the standard depending on the application Safety distance S (Ds) Protective field height Hazardous point components involved in stopping the hazardous motion of the machinery. For a mechanical power press it is the stopping time measured at approximately the 90º position of the crankshaft rotation.
SafeShield Safety Light Curtain Hardware User Manual ➢ First, calculate S using the following formula: S = 2000 × T + 8 × (d – 14) [mm] Tr = Response time of the presence-sensing device and its interface Where … Tbm=Additional response time allowed for brake monitor to compensate for wear T = Stopping/run-down time of the machine + response time of the protective device after light path interruption [s] d = Resolution of the light curtain [mm] S = Safety distance [mm] The reach/approach speed is already
SafeShield Safety Light Curtain Hardware User Manual Figure 21: Graph, minimum distance from reflective surfaces Steps for Mounting the Device ATTENTION: Special features to note during mounting: • Always mount the sender and receiver parallel to one another. • During mounting, make sure that sender and receiver are aligned correctly. The optical lens systems of sender and receiver must be located in exact opposition to each other; the display elements must be mounted at the same height.
SafeShield Safety Light Curtain Hardware User Manual Sender and receiver can be mounted in two different ways: • Mounting with swivel mount bracket • Mounting with side bracket Note ➢ Mount the bolts marked with ➊ to ➍ on the operator side of the system to ensure that they remain accessible after mounting and to allow you to readjust the light curtain later, if necessary.
SafeShield Safety Light Curtain Hardware User Manual Notes • The two outputs are protected against short-circuits to 24V DC and 0V. When the light path is clear, the signal level on the outputs is HIGH DC (at potential), when the light beams are interrupted or there is a device fault the outputs are LOW DC. • The SafeShield safety light curtain meets the interference suppression requirements (EMC) for industrial use (interference suppression class A).
SafeShield Safety Light Curtain Hardware User Manual Pin Wire Color Sender Receiver Pin Sender/ Receiver PC-Side RS-232-D-Sub 1 Brown 24V DC input (voltage supply) 24V DC input (voltage supply) 1 Not assigned 2 RxD Pin 3 2 Blue 0V DC (voltage supply) 0V DC (voltage supply) 3 0V DC (voltage supply) Pin 5 3 Grey OSSD1 (output signal Test input: 0V: external test active switching device 1) 24V: external test inactive 4 TxD Pin 2 4 Pink Reserved OSSD1 (output signal switching devic
SafeShield Safety Light Curtain Hardware User Manual Notes • The plug alignment (direction of turn) in the housing may vary from device to device. You can identify the correct pin assignment by the position of the pins in relation to each other as shown in the drawings. • If you do not connect any further safety light curtain to an extension connection, then you must also not connect any cable to pins 9 and 10.
SafeShield Safety Light Curtain Hardware User Manual Teach-In Key-Operated Switch Equivalent Complementary Switching Pin 3 Pin 7 Pin 4 Pin 6 Pin 3 Pin 7 Pin 4 Pin 6 Pin 4 Pin 3 Pin 7 Pin 6 Switch for deactivating the blanking Teach-in key-operated switch Figure 32: Connection of an external teach-in key-operated switch Notes • For teach-in a reset button must be connected to the SafeShield safety light curtain (see “Reset Button” on page 28).
SafeShield Safety Light Curtain Hardware User Manual ! If you connect the signal output, then you must configure it with the aid of the SCD prior to commissioning. Details can be found in the “Signal Output (ADO)” section on page 29. Notes Device configuration after replacement! If you replace a safety light curtain on which the signal output (ADO) is connected, then you must transfer the configuration to the device again.
SafeShield Safety Light Curtain Hardware User Manual ➢ Switch the power supply off and then back on again and check via the 7-segment display whether the alignment is correct after tightening the clamping bolts (Table 18). The display values have the following meaning: Display ➢ If any modifications have been made to the machine or the protective device, or if the safety light curtain has been changed or repaired, the system must be checked again as specified in the checklist in the annex.
SafeShield Safety Light Curtain Hardware User Manual Note In all three tests, the receiver of the SafeShield safety light curtain must show the red LED only. ➦ • PC/Notebook with Windows 9x/NT 4/2000 Professional/XP and a serial interface (RS-232). PC/Notebook not included • Connecting cable for connecting PC and SafeShield safety light curtain 442L-ACRS232 ➢ To configure the device, please read the user manual for the SCD software and use the online help function of the programme.
SafeShield Safety Light Curtain Hardware User Manual The system state lock-out Error Displays of the 7-Segment Display In case of certain faults or an erroneous configuration, the system can go into the lock-out status. The 7-segment display on the safety This section explains the meaning of the error displays of the 7segment display and how to respond to the messages. Please refer to the “Status Indicators” section on page 9. light curtain then indicates device back in operation: , , , , or .
SafeShield Safety Light Curtain Hardware User Manual Display Possible Cause Remedying the Error SafeShield function ➢ Interrupt the supply of power to the module SafeShield safety light curtain and to the function module for at least 3 seconds. ➢ If the problem persists, replace the function module. Overcurrent at ➢ Check the contactor. Replace, if switching output 1 necessary. ➢ Check the wiring for short-circuit to 0V. Short-circuit at ➢ Check the wiring for short-circuit to switching output 1 24V.
SafeShield Safety Light Curtain Hardware User Manual Technical Specifications Data Sheet Minimum General System Data Protective field height, depending on type Resolution, depending on type Protective field width Resolution 14mm Resolution 30mm Protection class (IEC 536:1976) Enclosure rating (IEC 60_529) Typical Maximum 300mm to 1800mm 14mm and 30mm 0m 0m III IP 65 19.
SafeShield Safety Light Curtain Hardware User Manual Minimum Input voltage11) LOW (inactive) Input current LOW Operation time control switch input Output Reset required 24V lamp output Switching voltage HIGH (active) Switching voltage LOW (inactive) Signal output (ADO) Switching voltage HIGH (active) Switching voltage LOW (inactive) Switching current Emergency stop Changeover time Latency time Cable resistance Cable capacitance Teach-in key-operated switch/ switch for deactivating the blanking Cable resist
SafeShield Safety Light Curtain Hardware User Manual Response Time Example The response time depends on the following parameters: • Number of beams • Beam coding • Configuration of floating blanking • Number of cascaded systems Calculating the response time for a cascaded system without beam coding in which fields are configured with floating blanking: How to determine the response time of the system: ➢ Read the response times of the individual systems (shown on type label).
SafeShield Safety Light Curtain Hardware User Manual Number of Beams 10 15 20 23 25 30 35 38 40 45 50 53 55 60 68 75 80 83 90 100 105 120 135 140 150 160 165 180 200 220 240 Without Beam Coding 9ms 10ms 10ms 10ms 10ms 11ms 11ms 11ms 11ms 12ms 12ms 12ms 12ms 13ms 13ms 14ms 14ms 14ms 15ms 16ms 16ms 17ms 18ms 19ms 19ms 20ms 20ms 22ms 23ms 24ms 26ms Table of Weights With Beam Coding 11ms 12ms 13ms 14ms 14ms 15ms 16ms 17ms 17ms 18ms 19ms 20ms 20ms 21ms 22ms 24ms 25ms 25ms 27ms 29ms 30ms 33ms 36ms 37ms 39ms 40
SafeShield Safety Light Curtain Hardware User Manual Dimensional Drawings SafeShield Safety Light Curtain with Cascading Connection SafeShield Safety Light Curtain Without Cascading Connection 11 (0.43) 34 (1.32) 40 (1.57) 48 (1.89) 20 22.4 (0.79) (0.88) 14 (0.55) 10 (0.39) 1 6 (0.24) 3.5 (0.14) 2.2 (0.09) 10.5 (0.41) Sliding nut groove for side mounting L2 74 (2.91) 75 (2.95) approx. 140 (5.51) (conn. range) 56.3 (2.22) approx. 100 (3.94) (connector range) 36.2 (1.
SafeShield Safety Light Curtain Hardware User Manual Swivel Mount Bracket Mounting Bracket 440L-AF6102 44.4 (1.75) Slider nut 3.8 (0.15) M5 M5 x 18 13 (0.51) 8 (0.31) 44 (1.73) 10 (0.39) 30.6 (1.2) 75 (2.95) 42 (1.65) Catalog No. 442L-AF6106 Figure 39: Dimensional drawing, swivel mount bracket (mm) Side Bracket 19 (0.75) 18 (0.71) 50 (1.97) 15 (0.59) 9 (0.35) 5.5 (0.22) 34.5 (1.36) 6 (0.24) Catalog No. 442L-AF6107- Figure 40: Dimensional drawing, side bracket (mm) 40 5.3 (0.21) 24 (0.
SafeShield Safety Light Curtain Hardware User Manual Accessories Corner Mirror L5 L1 L2 L3 18 (0.71) L4 0.275 Dia. 6 Places Mounting Bracket 440L-AM120BRK 85.6 (3.73) 9.4 (0.73) (2) 6.8 (0.27) Dia. 11.1 (0.44) Dia. Shown 440L-AM1201500 43.5 (1.71) L1 L2 L3 L5 76 (3.0) 38 (1.5) 3˚ 0.275 Dia. 4 Places 15.4 (0.51) 172 (6.77) 123.4 (4.86) 63.5 (2.5) 89 (3.5) 152.5 (6.0) 12.7 (0.5) 39 (1.54) 39 (1.54) 171 (6.
SafeShield Safety Light Curtain Hardware User Manual Mounting Stand—440L-AMSTD Laser Alignment Tool 19.05 (0.75) 66.8 (2.63) 25.4 (1.0) 1828.8 (72) 12.19 (0.48) 63.5 (2.5) 62.48 (2.46) 4 (0.15) 11.1 (7/16) Dia. Laser Alignment Tool (LAT)— 440L-ALAT 12.7 (1/2) Dia. 19.05 (0.75) 6.35 (0.25) 25.4 (1.0) 76.2 (3.0) 381.0 (15) 304.8 (12) 6.35 (0.
SafeShield Safety Light Curtain Hardware User Manual Ordering Information Delivery SafeShield Safety Light Curtain Delivery, sender • Sender unit • 4 sliding nuts for side bracket Delivery, receiver • Receiver unit • 4 sliding nuts for side bracket • Test rod with diameter corresponding to the physical resolution of the safety light curtain • Label “Important Information” • Operating instructions on CD-ROM • SCD software on CD-ROM • Information label “Operator’s notes” 43
SafeShield Safety Light Curtain Hardware User Manual System without Cascading Connection For use as single system or as last guest of a cascadable system.
SafeShield Safety Light Curtain Hardware User Manual Additional Front Screen (Weld Shield) Accessories Part Connection cable for standard type and cascadable devices: Straight female—2 (6.5) Straight female—5 (16.4) Catalog Number Straight female—10 (32.8) 889M-F12AH-10 Straight female—15 (49.2) 889M-F12AH-15 Straight female—20 (65.6) 889M-F12AH-20 Straight female—30 (98.4) 889M-F12AH-30 Right angle female—2 (6.
SafeShield Safety Light Curtain Hardware User Manual Appendix Checklist for the Manufacturer Checklist for the manufacturer/OEM for the installation of electro-sensitive protective equipment (ESPE) The details on the items listed below must be available at the latest when the system is commissioned for the first time, depending, however, on the various applications the requirements of which must be reviewed by the manufacturer/OEM.
SafeShield Safety Light Curtain Hardware User Manual Declaration of Conformity EC Declaration of Conformity The undersigned, representing the following supplier Rockwell Automation/Allen-Bradley 2 Executive Drive Chelmsford, MA 01824 -- USA and the authorized representative established within the Community Rockwell Automation, Subsidiary of Rockwell International GmbH Düsselberger Straße 15 D-42781 Haan, Germany herewith declare that the Products Product identification (brand and catalogue number/part nu
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