Allen-Bradley 440N-Z21S17H, 440N-Z21S16B, 440N-Z21S16A, 440N-Z21S16J, 440N-Z21S17A Installation Instructions Manual

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Page 1

SensaGuard

18 mm Plastic Barrel

Installation Instructions

Certifications

IMPORTANT:

SAVE THESE INSTRUCTIONS FOR FUTURE USE

Note: Refer to Technical Specifications for Certification information and ratings.

Page 2

Table of Contents

Installation Instructions 3

Warnings 3

Technical Specification 3

Operating Characteristics 3

Outputs (internally fused) 3

Environmental 3

Protection 4

Dimensions 4

Mode of Operation 4

Status Indicators 4

Mounting Information 4

Nut Torque Specification 4

Minimum Distance Between Sensors 5

Misalignment Curve 5

Wiring Diagram 5

Recommended Mating Cable 5

Diagnostics 5

Troubleshooting 6

Application Wiring Examples 8

List of Recommended Relays 12

Maintenance 12

Repair 12

Declaration of Conformity 12

PA-75056-180-01(A), September 2006

2 SensaGuardTM18 mm Plastic Barrel Installation Instructions

Page 3

Installation Instructions

Installation must be in accordance with the following steps and stated specifications and should be carried out by suitable competent personnel. The unit is not to be used as a mechanical stop. Guard stops and guides must be fitted. Adherence to the recommended maintenance instructions forms part of the warranty.

This device is intended to be part of the safety related control system of a machine. Before installation, a risk assessment should be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics of the machine to which it is to be fitted. Refer to Technical Specifications for Certification information and ratings.

ATTENTION: The presence of spare actuators compromise the integrity of the safety sys-

tems. Personal injury or death, property damage or economic loss can result. Appropriate management controls, working procedures and alternative protective measures should be introduced to control their use and availability.

WARNING: Do not defeat, tamper, remove or bypass this unit. Severe injury to personnel

could result. The sensor MUST be connected to a Class 2 SELV 24V DC, +10% / -15% power supply.

Technical Specification

Safety Ratings CAT4/SIL3 Safety Certifications TÜV, CE Safety Standards IEC60947-5-3, IEC61508, EN954 Certifications cULus Standards UL 508 PFHd 1.119 - 10

-9

Operating Characteristics

Sensing Distance (Actuator) 18 mm 30 mm

Assured Make (mm) 15 25

Assured Break (mm) 25 35 Typical misalignment (±7 mm in both axes) Maximum output current (all outputs, mA) 200 Input Current 50 mA (no load supply current) Operational Current, Min. ≤ 1 mA DC Off-state Current < 0.5 mA DC Maximum # of switches, connected in series Unlimited. See unit response time section Operating Voltage 24V DC +10% / -15%

Class 2 SELV power supply Frequency of operating cycle 1 Hz Response Time (Off) 54 ms Case Material Valox

DR 48

Actuator Material Valox

DR 48

Outputs (internally fused)

OSSD 2 Auxiliary 1

Environmental

Operating Temperature -10…+55°C (+14…+131°F) Operating Humidity 5% -95% relative Washdown rating NEMA 3, 4X, 12,13, IP 69K Shock & Vibration IEC68-2-27 30 g, 11 ms/IEC 68-2-6

10…55Hz Radio Frequency IEC 61000-4-3

IEC 61000-4-6

PA-75056-180-01(A), September 2006

SensaGuardTM18 mm Plastic Barrel Installation Instructions 3

Page 4

Protection

Short-Circuit Protection Incorporated Current limitation Incorporated Overload Protection Incorporated False Pulse Protection Incorporated Transient Noise Protection Incorporated Reverse Polarity Protection Incorporated Overvoltage protection Incorporated Thermal shutdown/restart Incorporated Electrical Life 10 x 10

Dimensions - mm (inches)

Mode of Operation

Status indicators:

• “Power/Fault” LED illuminates Green - The unit is ready for operation.

• “Power/Fault” LED illuminates Red: - Door/Guard open. The unit is not ready for operation.

• “Power/Fault” LED illuminates flashes Red or Green: - Unit failure. See Diagnostic section below.

Mounting Information

Use non-removable screws, bolts, or nuts to mount the switch and actuator. Do not over torque the mounting hardware.

Position the switch and actuator so they are aligned with each other. Mount the switch and actuator to removable guard, door or gate.

Keep the switch and actuator within the sensing range below.

Nut Torque Specification

Plastic Barrel Switch: 2.26 N•M (20 in•lbs) Plastic Actuators: 2.26 N•M (20 in•lbs)

PA-75056-180-01(A), September 2006

4 SensaGuardTM18 mm Plastic Barrel Installation Instructions

30 mm Actuator

48.92

[1.926]

19.81 [0.78]

22.22 [0.875]

48.92

[1.926]

19.81 [0.78]

22.22

[0.875]

30.40

[1.197]

16.84

[0.663]

3.17

[0.125]

4.57

[0.18]

DIA

2 PLACES

Sensor

18 mm Actuator

67.06

[2.640]

2.03

[.080]

M18X1

36.47 [1.436]

13.72 [0.54]

15.87

[0.625]

36.47

[1.436]

13.72 [0.54]

15.87

[0.625]

4.57

[0.180]

DIA

19.81 [0.78]

3.17

[0.125]

15.42

[0.607]

2 PLACES

Page 5

Minimum Distance Between Sensors

Misalignment Curve

18 mm Unit with 18 mm Target 18 mm Unit with 30 mm Target

Note: There must be a minimum spacing of 4 mm

(0.157 in) if actuator and sensor face approaches laterally. This will prevent false triggering due to the side lobe areas.

Wiring Diagram

Pin # Wire Color Signal

1 White Aux Outputs 2 Brown +24V 3 Green NA 4 Yellow OSSD 2, +24V Input 5 Grey OSSD 1 6 Pink OSSD 2 7 Blue 0V 8 Red OSSD 1, +24V Input

Recommended mating cable, 2 m (6.5 ft). 889D-F8AC-2. Lengths are available up to 30 m (98.4 ft)

Diagnostic

Unit Indicators (per IEC 60073)

State Status Troubleshooting

Off Not Powered NA

Device Output Red Not Safe, OSSD not active NA

LED Green Safe, OSSD active NA

Green flash Power up test or OSSD Check 24V DC or OSSD inputs

inputs not valid (yellow and red wire)

Red Flash 1 Hz Flash Recoverable Fault Recoverable fault —check OSSD

4 Hz Flash Non-recoverable Fault outputs are not shorted to GND,

24V DC or each other. Cycle power.

PA-75056-180-01(A), September 2006

SensaGuardTM18 mm Plastic Barrel Installation Instructions 5

18 mm Actuator

75 mm

Sensor

Senso

30 mm Actuator

100 mm

Sensor

Senso

Lateral Misalignment Tolerance—mm (in

)

Face to Face Distance—mm

-15

(-0.59)

-10

(-0.39)

-5

(-0.19)

(0.19)

(0.39)

(0.59)

-25

(-0.98)

-20

(-0.787)

(0.787)

(0.98

)

Side Lobe Side Lobe

Assured Sensing

Distance

OFF OFF

-30

(-1.18)

-20

(-0.787)

-10

(-0.39)

010

(0.39)20(0.787)30(1.18)

Face to Face Distance—mm

Side Lobe Side Lobe

Assured Sensing

Distance

OFF OFF

Lateral Misalignment Tolerance—mm (in)

Note: There must be a minimum spacing of 7 mm (0.275 in) if actuator and sensor face approaches laterally. This will prevent false triggering due to the side lobe areas.

476

Brown

White

Blue

Pink

Grey

Green

Red

Yellow

Note: Refer to Technical Specifications for Certification information and ratings.

Page 6

Troubleshooting

Series Circuit

PA-75056-180-01(A), September 2006

6 SensaGuardTM18 mm Plastic Barrel Installation Instructions

Ye l

Red

Brown

Gray

Pink

Blue

24VDC

Power

Supply

1606

-XL120D

Switch 1

+24

RTN

Switch 2

White

Ye l

Red

Brown

Gray

Pink

Blue

Actuator 1

Actuator 2

Switch 3

White

Ye l

Red

Brown

Gray

Pink

Blue

Actuator 3

Switch 4

White

Ye l

Red

Brown

Gray

Pink

Blue

Actuator 4

Switch 5

White

Ye l

Red

Brown

Gray

Pink

Blue

Actuator 5

+24 V

+0 V

Actuator 2 is in sensing range.

Switch

2 is functioning properly

OSSDs are energize to 24 V

Green LED is ON.

Actuator 3 is in sensing range.

Switch

3 has fault.

See Table Above—Red LED is flashing

Actuator 1 is in sensing range.

Switch

1 is functioning properly

OSSDs are energize to 24 V

Green LED is ON.

Actuator 4 is in sensing range.

Switch

4 is functioning properly.

Series inputs are 0 V.

OSSDs are de-energized to 0V .

Green LED is Flashing to indicate

Series inputs are not 24V.

Actuator 5 is in sensing range.

Switch

5 is functioning properly .

Series inputs are 0V .

OSSDs are de-energized to 0V.

Green LED is Flashing to indicate

Series inputs are not 24V.

OSSD’ s are OF

Recoverable fault

Note: Refer to Technical Specifications for Certification information and ratings.

Page 7

Unit Response Time (does not include safety relay response time)

PA-75056-180-01(A), September 2006

SensaGuardTM18 mm Plastic Barrel Installation Instructions 7

Yel

Red

White

Gray

Pink

Blue

24V DC

Power

Supply

1606

Sensor 1

+24

Sensor 2

Brown

Gray

Pink

White

Yel

Red

Blue

Sensor 3

Brown

Yel

Red

White

Gray

Pink

Blue

S21

S11 41332313S12S52

42342414A2S34S22

440R-N23126

Actuator 1

Actuator 2

Actuator 3

Initial Conditions:

All actuators are in sensing

distance.

Actuator 1 is moved out of

sensing range.

Sensor 2 drops the 24 volts

(red and yellow) from Sensor 1

OSSD outputs.

Green LED flashes.

Sensor 3 drops the 24 volts

(red and yellow) from Sensor 2

OSSD outputs.

Green LED flashes.

0 mS

54 mS 72 mS 90 mS

Actuator 1 is out of sensing

range.

Actuator 2 and 3 are in

sensing range.

Actuator 1 is moved into sensing

range.

Sensor 1 OSSD outputs are

energized.

Sensor 2 OSSD inputs (red and yellow)

transition to 24V DC from Sensor 1

OSSD outputs.

Sensor 2 OSSD outputs are energized

Sensor 3 OSSD inputs (red and

yellow) transition to 24V DC from

Sensor 2 OSSD outputs.

Sensor 3 OSSD outputs are

energized.

0 mS

360 mS 378 mS 396 mS

OFF

Note: Refer to Technical Specifications for Certification information and ratings.

Page 8

Application Wiring Examples

PA-75056-180-01(A), September 2006

8 SensaGuardTM18 mm Plastic Barrel Installation Instructions

+24V DC

MSR127RP with 1 sensor, monitored manual reset, drivin

100S or 700S safet

controllers.

A1 S11

S52 S12

23 33

S21

S22

S34

14 24 34 42

MSR127RP

Reset

GND

Blue

Gray

Pink

Yel lo w

Red

Brown

SensaGuard

Unit 1

+24V DC

GND

MSR127RP with 3 sensors in series, monitored manual reset, drivin

100S or 700S safet

controllers

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuard

Unit 1

SensaGuard

Unit 2

SensaGuard

Unit 3

A1 S11

S25 S12

23 33

S21 S22 S34 A2 14 24 34 42

MSR127RP

Reset

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

MSR127RP with 3 sensors and 1 440L light curtain in series, monitored manual reset, driving 100S or 700S safety relays.

Note: Light curtain must be last (farthest from MSR127).

GND

A1 S11

S52 S12

23 33

S21 S22 S34 A2 14 24 34 42

MSR127RP

Reset

+24V DC

Blue

Gray

Pink

Yel l ow

Red

Brown

SensaGuard

Unit 1

SensaGuard

Unit 2

SensaGuard

Unit 3

GuardShield

Blue

Gray

Pink

Yel l ow

Red

Brown

Blue

Gray

Pink

Yel l ow

Red

Brown

Blue

Gray

Pink

Yel l ow

Red

Brown

A1 S11

S52 S12

23 33

S21

S22

S34

14 24 34 42

MSR127TP

GND

MSR127RP with 1 sensor, automatic reset, drivin

100S or 700S safet

controllers

+24V DC

SensaGuard

Unit 1

Blue

Gray

Pink

Yellow

Red

Brown

Note: Refer to Technical Specifications for Certification information and ratings.

Page 9

Application Wiring Examples

PA-75056-180-01(A), September 2006

SensaGuardTM18 mm Plastic Barrel Installation Instructions 9

MSR127TP with 3 sensors in series, automatic reset, drivin

100S or 700S rela

MSR127TP

+24V DC

GND

Blue

Gray

Pink

Yel lo w

Red

Brown

SensaGuard

Unit 1

A1 S11

S52 S12

23 33

S21 S22 S34 A2 14 24 34 42

Blue

Gray

Pink

Yel lo w

Red

Brown

Blue

Gray

Pink

Yel lo w

Red

Brown

SensaGuard

Unit 3

SensaGuard

Unit 2

MSR127TP with 3 sensors and 1 440L light curtain in series, automatic reset, driving 100S or 700S safety contactors.

Note: Light curtain must be last (farthest from MSR127)

MSR127TP

GND

A1 S11

S52 S12

23 33

S21 S22 S34 A2 14 24 34 42

+24V DC

Blue

Gray

Pink

Yel lo w

Red

Brown

Blue

Gray

Pink

Yel lo w

Red

Brown

Blue

Gray

Pink

Yel lo w

Red

Brown

Blue

Gray

Pink

Yel lo w

Red

Brown

GuardShield

SensaGuard

Unit 1

SensaGuard

Unit 3

SensaGuard

Unit 2

Note: Refer to Technical Specifications for Certification information and ratings.

Page 10

Application Wiring Examples

PA-75056-180-01(A), September 2006

10 SensaGuardTM18 mm Plastic Barrel Installation Instructions

MSR200 series with 3 sensors and 1 440L light curtain, automatic reset, driving 100S or 700S safety contactors.

Note: Li

ht curtain can be attached to an

GuardShield

+24V DC

GND

440R-H23177

Y40 Y41S51S12 S20 S32 S11 S21 S31 S41 13 23 31 Y42 A1S32S20S12

S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2S62S50S42

440R-H23179

S32S20S12

S62S50S42

S32

440R-H23180

MSR221P MSR211P

MSR230P

SensaGuard

Blue

Brown

GrayPink

Blue

Brown

Yellow

Red

GrayPink

SensaGuard SensaGuard

GrayPink GrayPink

Blue

Brown Yellow Red

Blue

Brown

Yellow

Red

MSR200 series with 4 sensors and 1 440L light curtain, manual reset, driving 100S or 700S safety contactors.

Note: Li

ht curtain can be attached to an

ut.

Reset

GuardShield

+24V DC

GND

440R-H23177

Y40 Y41S51S12 S20 S32 S11 S21 S31 S41 13 23 31 Y42 A1S32S20S12

S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2S62S50S42

440R-H23179

S32S20S12

S62S50S42

S32

440R-H23180

MSR221P MSR211P

MSR230P

SensaGuard

Blue

Brown

GrayPink

Blue

Brown

Yellow

Red

GrayPink

SensaGuard SensaGuard

GrayPink GrayPink

Blue

Brown Yellow Red

Blue

Brown

Yellow

Red

Note: Refer to Technical Specifications for Certification information and ratings.

Page 11

Application Wiring Examples

PA-75056-180-01(A), September 2006

SensaGuardTM18 mm Plastic Barrel Installation Instructions 11

MSR200 series with 4 sensors, automatic reset, driving 100S or 700S safety contactors.

Yel l ow Red

+24V DC

GND

440R-H23177

Y40 Y41S51S12 S20 S32 S11 S21 S31 S41 13 23 31 Y42 A1S32S20S12

S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2S62S50S42

440R-H23179

S32S20S12

S62S50S42

S32

440R-H23180

MSR221P MSR211P

MSR230P

SensaGuardSensaGuard

Blue

Brown

GrayPink

Blue

Brown

Yel l ow

Red

GrayPink

SensaGuard SensaGuard

GrayPink GrayPink

Blue

Brown Yel l ow Red

Blue

Brown

Yel l ow

Red

MSR200 series with 4 sensors, manual reset, drivin

100S or 700S safet

contactors.

Reset

+24V DC

GND

440R-H23177

Y40 Y41S51S12 S20 S32 S11 S21 S31 S41 13 23 31 Y42 A1S32S20S12

S42 S50 S62 S34 Y1 Y2 Y3 14 24 32 Y32 Y33 Y30 A2S62S50S42

440R-H23179

S32S20S12

S62S50S42

S32

440R-H23180

MSR221P MSR211P

MSR230P

SensaGuardSensaGuard

Blue

Brown

GrayPink

Blue

Brown

Yellow

Red

Yellow Red

GrayPink

SensaGuard SensaGuard

GrayPink GrayPink

Blue

Brown Yellow Red

Blue

Brown

Yellow

Red

Note: Refer to Technical Specifications for Certification information and ratings.

Page 12

List of recommended relays

MSR126, MSR127, MSR123, MSR124, MSR131, MSR138, MSR211, MSR121, MSR320, MSR200 Family (Except MSR210), MSR300 Family, SmartGuard, 1791 DS DeviceNet™ Safety I/O

Maintenance

Every week.

Check the correct operation of the switching circuit. Also check for signs of abuse or tampering. Inspect the switch casing for damage

Repair

If there is any malfunction or damage, no attempts at repair should be made. The unit should be replaced before machine operation is allowed.

Declaration of Conformity

This is to declare that the products shown on this document conforms with the Essential Health and Safety Requirements (EHSR’s) of the European Machinery Directive (73/23/EEC as amended by 93/68/EEC). These products also conform to EN 60947-5-3, EN 1088, EN292, EN 60204-1 and have Third Party Approval.

For a comprehensive certificate please visit: www.ab.com/safety.

Publication 75056-180-01(A), September 2006

12 SensaGuardTM18 mm Plastic Barrel Installation Instructions

Check the machine is isolated and stopped whenever the interlocked guard door is open.

IMPORTANT: After installation and commissioning, the actuator, switch and switch lid fixing screws should be coated with tamper evident varnish or similar compound.