Banner EZ-SCREEN User Manual
EZ-SCREEN® Type 2 Light Screen Instruction Manual
122452 rev. B 3/2/2011
Original Instructions
Contents
Contents
About This Document ............................................................................................................................4
Important . . . Read This Before Proceeding! ...................................................................................................................4
Introduction ............................................................................................................................................5
Features ..........................................................................................................................................................................5
System Description ..........................................................................................................................................................5
Appropriate Applications and Limitations ........................................................................................................................7
Control Reliability and Safety Categories .........................................................................................................................8
Operating Features ..........................................................................................................................................................9
Mechanical Installation ........................................................................................................................12
Pre-Installation Considerations ......................................................................................................................................12
Mounting System Components ......................................................................................................................................23
Electrical Installation and Testing ......................................................................................................26
Routing Cordsets ............................................................................................................................................................26
Initial Electrical Connections ..........................................................................................................................................27
Initial Checkout Procedure .............................................................................................................................................28
Electrical Connections to the Guarded Machine ...........................................................................................................34
Reference Wiring Diagrams ...........................................................................................................................................40
System Operation .................................................................................................................................43
Security Protocol ...........................................................................................................................................................43
Reset Procedures ..........................................................................................................................................................43
Status Indicators ............................................................................................................................................................44
Use of Warnings and Cautions ................................................................................................................................4
EC Declaration of Conformity (DOC) ......................................................................................................................4
Examples: Appropriate Applications .......................................................................................................................8
Examples: Inappropriate Applications ....................................................................................................................8
Trip/Latch Output ....................................................................................................................................................9
Wiring Options for Emitter/Receiver Swapability ..................................................................................................10
Manual Reset/Remote Test Input and EDM .........................................................................................................10
Status Indicators ...................................................................................................................................................11
Calculating the Safety Distance (Minimum Distance) ............................................................................................13
Reducing or Eliminating Pass-Through Hazards ..................................................................................................17
Supplemental Safeguarding .................................................................................................................................17
Other Considerations .............................................................................................................................................18
Overview of Emitter/Receiver Mounting Hardware ................................................................................................23
Mounting and Initial Alignment of Emitter/Receiver Pairs ......................................................................................24
Configuring the System for Initial Checkout ..........................................................................................................29
Initial Power-Up ....................................................................................................................................................29
Optical Alignment ..................................................................................................................................................31
Trip Test ................................................................................................................................................................32
OSSD Output Connections ...................................................................................................................................34
FSD Interfacing Connections ................................................................................................................................35
Machine Primary Control Elements ......................................................................................................................36
Manual Reset/Remote Test Input and EDM .........................................................................................................36
Preparing for System Operation ...........................................................................................................................38
Commissioning Checkout .....................................................................................................................................38
Generic Emitter Wiring Diagram ...........................................................................................................................40
Generic Wiring to FSDs (manual reset) ................................................................................................................41
Generic Wiring — Interface Module (2-Channel EDM, Manual Reset) ................................................................42
Receiver Resets ...................................................................................................................................................43
Emitter Resets ......................................................................................................................................................44
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Contents
Emitter ..................................................................................................................................................................44
Receiver ................................................................................................................................................................44
Normal Operation ..........................................................................................................................................................45
System Power-Up .................................................................................................................................................45
Run Mode .............................................................................................................................................................45
Manual Reset Procedure ......................................................................................................................................46
Periodic Checkout Requirements ..................................................................................................................................46
Troubleshooting and Maintenance .....................................................................................................47
Troubleshooting and Lockout Conditions ......................................................................................................................47
Recovery Procedures ....................................................................................................................................................47
Receiver (System Reset) ......................................................................................................................................47
Emitter Reset ........................................................................................................................................................47
Electrical and Optical Noise ...........................................................................................................................................49
Sources of Electrical Noise ...................................................................................................................................49
Sources of Optical Noise ......................................................................................................................................49
Servicing and Maintenance ............................................................................................................................................49
Cleaning ................................................................................................................................................................49
Warranty Service ..................................................................................................................................................50
Disposal .................................................................................................................................................................50
Checkout Procedure Schedule ...........................................................................................................51
Schedule of Checkouts ..................................................................................................................................................51
Specifications and Accessories .........................................................................................................52
Specifications .................................................................................................................................................................52
General Specifications ..........................................................................................................................................52
Emitter Specifications ...........................................................................................................................................53
Receiver Specifications ........................................................................................................................................53
Emitter and Receiver Dimensions .........................................................................................................................54
Bracket Dimensions ...............................................................................................................................................55
Accessories ...................................................................................................................................................................57
Cordsets ................................................................................................................................................................57
Interface Modules ..................................................................................................................................................60
Contactors ............................................................................................................................................................60
Lens Shield ............................................................................................................................................................60
EZ-LIGHT™ for EZ-SCREEN® ...........................................................................................................................61
MSA Series Stands (Base Included)* ...................................................................................................................62
MSM Series Corner Mirrors ..................................................................................................................................62
SSM Series Corner Mirrors ...................................................................................................................................63
Accessory Mounting Brackets ..............................................................................................................................64
Alignment Aids ......................................................................................................................................................65
Replacement Parts ...............................................................................................................................................65
Documentation ......................................................................................................................................................65
Standards and Regulations .................................................................................................................66
U.S. Application Standards ............................................................................................................................................66
OSHA Regulations .........................................................................................................................................................66
International/European Standards ..................................................................................................................................66
Sources of Standards and Regulations ..........................................................................................................................67
Contact Us .....................................................................................................................................................................67
Glossary ................................................................................................................................................68
3
EZ-SCREEN® Type 2 Light Screen Instruction Manual
About This Document
Important . . . Read This Before Proceeding!
It is the responsibility of the machine designer, controls engineer, machine builder and/or maintenance electrician to apply and maintain
this product in full compliance with all applicable regulations and standards. The product can provide the required safeguarding function
only if it is properly installed, properly operated, and properly maintained. This manual attempts to provide complete installation, operational, and maintenance instruction. Reading the manual completely is highly recommended. Please direct any questions regarding the
application or use of the product to the Banner Engineering Applications at the locations listed here.
For more information regarding U.S. and international institutions that provide safeguarding application and safeguarding product performance standards, see the following sections.
WARNING: User Responsibility
The user is responsible to:
• Carefully read, understand and follow the information in all documentation for this product.
• Perform a risk assessment of the specific machine guarding application.
• Determine what safeguarding devices and methods are appropriate per the requirements defined in
EN ISO 13849-1 and other appropriate standards.
• Create and confirm each configuration and then verify that the entire safeguarding system (including
input devices and output devices) is operational and working as intended.
• Periodically re-verify as needed, that the entire safeguarding system is working as intended.
Failure to follow any of these recommendations can potentially create a dangerous condition that
may lead to serious injury or death.
Use of Warnings and Cautions
This manual contains numerous WARNING and CAUTION statements:
• Warnings refer to situations that could lead to significant or serious personal injury or death.
• Cautions refer to situations that could lead to slight personal injury or potential damage to equipment.
Warnings are intended to remind the machine designer, control engineer, machine builder, maintenance electrician, or end user how to
avoid misapplication of this product and effectively apply the EZ-SCREEN Type 2 to meet the various safeguarding application requirements. You must read and abide by the warnings.
EC Declaration of Conformity (DOC)
Banner Engineering Corp. herewith declares that the EZ-SCREEN Type 2 Light Screen is in conformity with the provisons of the Machinery Directive (Directive 2006/42/EC) and all essential health and safety requirements have been met. For more information, visit
www.bannerengineering.com/EZSCREEN.
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Introduction
Features
• An optoelectronic safeguarding device
• Creates a screen of synchronized, modulated infrared sensing beams. Choose from 10
sizes, in 150 mm (6") increments: defined areas from 150 mm to 1.8 m (6" to 71")
• Compact package for smaller production machines
• Models available with Trip or Latch output operation (automatic or manual start/restart)
• 30 mm (1.18") resolution
• Remote Test input terminals for simulating a "blocked" condition
• Operating range up to 15 m (50')
• Type 2 per IEC 61496-1/-2; Category 2 PLd per EN ISO 13849-1
• FMEA tested according to IEC 61496-1, Type 2 requirements
• Receiver LEDs provide system status and emitter/receiver alignment indications
• Highly immune to EMI, RFI, ambient light, weld flash, and strobe light
• Two-piece design
• Vibration-tolerant, factory burned-in emitter and receiver circuitry for toughness and dependability
System Description
NOTE: A “System” as referred to in this manual may be defined as an emitter and its receiver, plus their ca-
bling.
Banner EZ-SCREEN Type 2 emitters and receivers provide a redundant, microprocessor-controlled, opposed-mode optoelectronic "curtain of light," or "light screen." EZ-SCREEN Type 2 typically is used for point-of-operation safeguarding, and is suited to safeguard a
variety of lower-risk machinery.
The EZ-SCREEN Type 2 is a two-piece (“two-box”) system – comprising an emitter and a receiver, but no external controller. The external device monitoring (EDM) function ensures the fault detection capability required by EN ISO 13849-1 Category 2.
The EZ-SCREEN Type 2 emitters have a row of synchronized modulated infrared (invisible) light-emitting diodes (LEDs) in a compact
metal housing. Receivers have a corresponding row of synchronized photodetectors. The light screen created by the emitter and receiver
is called the “defined area”; its width and height are determined by the length of the sensor pair and the distance between them. The lowprofile housing provides maximum sensing within minimum space; its defined area (sensing area) is equivalent to the height of the housing. The maximum range is 15 m (50'), which decreases if corner mirrors are used. Resolution is 30 mm (1.18")..
Both emitter and receiver feature LEDs to provide continuous indication of the System’s operating status, alignment and error conditions.
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Quick-Disconnect
Cables
M12 QD
Fittings
Defined
Area
Emitter
Specified Test Piece
Synchronization
Beam
Receiver
Status
Indicators
EZ-SCREEN® Type 2 Light Screen Instruction Manual
In typical operation, if any part of an operator’s body (or any opaque object) of more than a pre-determined cross section is detected, the
solid-state Output Signal Switching Device (OSSD) safety outputs will turn OFF. These safety outputs are connected to the guarded
machine’s Final Switching Devices (FSDs) that control the machine primary control elements (MPCEs), which immediately stop the motion of the guarded machine.
Both OSSD outputs must be connected to the machine control so that the machine’s safety-related control system interrupts the circuit or
power to the MPCEs (Machine Primary Control Elements), resulting in a non-hazardous condition. Each OSSD is capable of sourcing
0.5A at +24V dc.
The OSSD safety outputs are not capable of performing a “handshake” communication with the Muteable Safety Stop Interface (MSSI) or
Universal Safety Stop Interface (USSI) found on other Banner Engineering safety products.
EZ-SCREEN Type 2 is extensively FMEA (Failure Mode and Effects Analysis) tested to IEC 61496-1/-2 requirements. The design of the
EZ-SCREEN Type 2 has considered all single faults such that a loss of a critical safety function will result in a stop command and a
lockout condition. In the event of an accumulation of undetected faults, a remote external test (or check) is required to maintain the safety
function.
Electrical connections are made through M12 (or Euro-style) quickdisconnects. An optional hookup that provides sensor interchangeability (or “swapability”) – the ability to install either sensor at either
QD connection – is possible. Using a parallel connection (color-forcolor), the emitter cable can be connected to the receiver cable,
providing the ability to swap the emitter and receiver position, similar to a popular feature of Banner MINI-SCREEN® safety light
screens. This hookup option provides advantages during installation, wiring, and troubleshooting.
All models require a supply voltage of +24V dc ±20%.
Figure 1. Banner EZ-SCREEN Type 2: emitter, receiver, and
two interconnecting cables
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
Appropriate Applications and Limitations
WARNING: Read this Section Carefully Before Installing the System
If all mounting, installation, interfacing, and checkout procedures are not followed properly, the EZSCREEN Type 2 cannot provide the protection for which it was designed. The user has the responsibility
to ensure that all local, state, and national laws, rules, codes, or regulations relating to the installation and
use of this control system in any particular application are satisfied. Extreme care should be taken to ensure that all legal requirements have been met and that all technical installation and maintenance instructions contained in this manual are followed.
The user has the sole responsibility to ensure that this EZ-SCREEN Type 2 is installed and interfaced to
the guarded machine by Qualified Persons, in accordance with this manual and applicable safety regulations.
The Banner EZ-SCREEN Type 2 is intended for lower-risk machine guarding applications and other safeguarding applications, as determined by a risk assessment. It is the user’s responsibility to verify whether the safeguarding is appropriate for the application and is
installed, as instructed by this manual, by a Qualified Person (as defined in the Glossary).
CAUTION: Install System Only on Appropriate Applications
Banner EZ-SCREEN Type 2 are for use only on machinery that can be stopped immediately after a stop
signal is issued at any point in the machine's stroke or cycle, such as part-revolution clutched machines.
Under no circumstances may the EZ-SCREEN Type 2 be used on full-revolution clutched machinery or in
unsuitable applications as those listed. If there is any doubt about whether or not your machinery is
compatible with the EZ-SCREEN Type 2, contact Banner's Application Engineers at the factory.
CAUTION: Use of EZ-SCREEN Type 2
EZ-SCREEN Type 2 meets the Type 2 requirements of IEC 61496 and Category 2 PLd requirements of
EN ISO 13849-1. DO NOT use EZ-SCREEN Type 2 unless it is installed, tested, and inspected in accordance with this manual. DO NOT use EZ-SCREEN Type 2 where Control Reliability is required, or where
Category 3, Category 4, or Type 4 AOPD (active opto-electronic protective device) have been mandated,
or where a risk assessment has determined that frequent access by personnel to the hazard could result
in an irreversible or serious injury (for example, OSHA reportable injury).
Typical use is for safeguarding in situations where the consequence of an accident will result in only slight
(normally reversible) injuries that are typically treated by the normal healing processes and minor medical
treatment (that is, first aid, as defined by OSHA 29CFR1904.7).
Failure to follow these instructions could result in serious bodily injury or death.
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
Examples: Appropriate Applications
EZ-SCREEN Type 2 are typically used, but is not limited to, the following applications (dependent on machine risk assessment):
• Small assembly equipment
• Automated production equipment
• "Table-top" robotic work cells
• Component insertion/"pick-and-place" machines
• Small packaging machines
• Equipment and process protection (non-personnel safety
• Applications that could result in only slight (normally reversible) injuries (such as bump, bruise, knock-down, trapping but not crushing, minor cuts and abrasions, etc.)
Examples: Inappropriate Applications
EZ-SCREEN Type 2 may NOT be used with the following machinery or inappropriate applications:
• As a primary safeguard in frequently accessed hazardous situations that could result in serious injuries (normally irreversible, including death).
• In any case where Control Reliability, Category 3, Category 4, or Type 4 AOPD (active opto-electronic protective device) have been
mandated. See EN ISO 13849-1, IEC 61496-1, or other appropriate standard.
• Any machine that cannot be stopped immediately after a stop signal is issued, such as single-stroke (or “full-revolution”) clutched
machinery.
• Any machine with inadequate or inconsistent machine response time and stopping performance.
• Any machine that ejects materials or component parts through the defined area.
• In any environment that is likely to adversely affect photoelectric sensing efficiency. For example, corrosive chemicals or fluids or
unusually severe levels of smoke or dust, if not controlled, may degrade sensing efficiency.
• As a tripping device to initiate or reinitiate machine motion (PSDI applications), unless the machine and its control system fully comply
with the relevant standard or regulation (see ISO 12100-2, IEC 60204-1, IEC 61496-1, or other appropriate standard).
If an EZ-SCREEN Type 2 is installed for use as a perimeter guard (that is, where a pass-through hazard may exist), the dangerous
machine motion can be initiated by normal means only after the safeguarded area is clear of individuals and the EZ-SCREEN Type 2 has
been manually reset.
Control Reliability and Safety Categories
To summarize the expected safety circuit performance in high-risk situations, requirements of Control Reliability (OSHA 29CFR1910.217,
ANSI B11.19, and ANSI/RIA R15.06) and Category 3 and Category 4 (EN ISO 13849-1) demand that a reasonably foreseeable, single
failure does not lead to the loss of the safety function, and does not prevent a normal or immediate stop from occurring. The failure or the
fault must be detected at or before the next demand of safety (e.g., at the beginning or end of a cycle, or when a safeguard is actuated).
The safety-related part of the control system then must issue an immediate stop command, or prevent the next machine cycle or hazardous situation until the failure or fault is corrected.
The effect of ANSI/RIA R15.06, ANSI B11.19, and EN ISO 13849-1 is to set a baseline for situations in which a minimum level of performance has been mandated or in cases where a risk assessment has determined a need for Control Reliability, Category 3 or Category
4 level of performance.
In lower-risk safety applications, safeguards and safety circuits do not require the level of performance and fault tolerance described by
Control Reliability, Category 3 or Category 4. Applications involving situations that could result in a slight or normally reversible injury
(e.g., only requiring first aid, as defined by OSHA 29CFR1904) can be solved by EN ISO 13849-1 Category 2.
EN ISO 13849-1 Category 2 does not require the same level of performance and fault tolerance as required by Control Reliability, Category 3 or Category 4. Safety-related parts of control systems designed to Category 2 “shall be designed so that their function(s) are
checked at suitable intervals by the machine control system.” This allows a single fault to lead to the loss of the safety function between
the check [test] of the system, but the loss of safety function is detected by the check. By comparison, in a system designed to EN ISO
13849-1 Category 4, a single fault or an accumulation of faults will not lead to a loss of the safety function.
While EN ISO 13849-1 generally applies to the machine level, IEC61496-1/-2 specifies requirements for the design, construction and
testing for two levels or “types” of active opto-electronic protective devices (AOPDs) or light curtains (light screens). “Type 2” and “Type
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
4” describe differing requirements to ensure that appropriate safety-related performance is achieved. The appropriate type is dependent
on the overall degree of risk reduction, as determined by the machine’s Risk Assessment (see ISO 14121, ANSI B11.19, ANSI/RIA
R15.06).
A Type 2 AOPD relies on periodic testing to detect a failure to danger. Between tests, a single fault can result in the loss of the safety
function. While this level of performance and fault tolerance is generally not allowed in Category 4 situations, it is acceptable in the lowerrisk situations described by Category 2.
While the EZ-SCREEN Type 2 conducts continual internal self-tests and all single faults have been considered, the installation should
provide an additional periodic test/check of the EZ-SCREEN Type 2 and its interface to ensure the integrity of the safety function (see
Manual Reset/Remote Test Input and EDM on page 36). A component failure detected by periodic test/check must cause a “stop”
signal to be sent to the guarded machine and put the System into a Lockout condition.
Recovery from this type of Lockout condition requires:
• Replacement of the failed component (to restore the safety function)
• The appropriate reset procedure.
Operating Features
The Banner EZ-SCREEN Type 2 Light Screen models described by this manual feature standard selectable functions:
• Trip or Latch Output (depending on model)
• External Device Monitoring (EDM) via the Test/Retest input
The System Response Time (Tr) can be determined by the model number on the emitter and receiver.
Trip/Latch Output
Whether a receiver features Trip or Latch Output determines whether the System will enter RUN mode automatically after power-up, or if
it will require a manual reset first. If the System has Trip Output, other measures must be taken to prevent a pass-through hazard.
For Latch Output models, the EZ-SCREENEZ-SCREENEZ-SCREEN Type 2 requires a manual reset for the OSSD outputs to turn ON,
after power is applied and all beams are clear.
• For Trip Output models, the OSSD outputs will turn ON after power is applied and the receiver passes its internal self-test/synchronization and recognizes that all beams are clear. Trip Output models will also automatically reset after all beams are cleared.
• For Latch Output models, the EZ-SCREEN Type 2 requires a manual reset for the OSSD outputs to turn ON, whenever power is
applied and all beams are clear.
WARNING: Use of Trip/Latch Output
Application of power to the EZ-SCREEN Type 2, the clearing of the defined area, or the reset of a Latch
condition MUST NOT initiate dangerous machine motion. Machine control circuitry must be designed so
that one or more initiation devices must be engaged (i.e., a conscious act) to start the machine – in addition to the EZ-SCREEN Type 2 going into RUN mode. Failure to follow these instructions could result in an
increased risk of harm.
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D
C
A
B
EZ-SCREEN® Type 2 Light Screen Instruction Manual
Wiring Options for Emitter/Receiver Swapability
Each EZ-SCREEN Type 2 sensor can be connected to its own power supply or, color-for-color to the other sensor’s cable. The color-forcolor hookup allows the emitter and receiver positions to be interchanged without rewiring (functionality known as sensor " swapability").
Model CSB.. splitter cordsets and DEE2R.. double-ended cables facilitate interconnection between an EZ-SCREEN Type 2 receiver and
emitter, providing a single "homerun" cable for optional swapable hookup.
Individual Cordsets Splitter Cordsets
EZ-SCREEN Type 2
A
Key Description
C
Bn
Or/Bk
Or
Wh
Bk
Bu
Gn/Ye
Vi
B
+24V dc
n.c.
n.c.
OSSD2
OSSD1
0V dc
Ground
Reset/Test & EDM
Key Description
A Emitter
B Receiver
C QDE-8..D Cordsets
A Emitter
B Receiver
C DEE2R.. Cordsets
D CSB.. Cordsets
Manual Reset/Remote Test Input and EDM
A single input provides the means to reset the system from a latch or lockout condition, to externally test the light screen and its interface,
and to monitor external devices (EDM) for proper operation. If the System is in Run condition with outputs ON, operating the switch
results in a test. If the System is Latched or Locked Out, operating the switch results in a reset.
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Power/Fault LED (Green)
Alignment LEDs
(Yellow)
Status Blocked LED (Red)
Status Clear LED (Green)
EZ-SCREEN® Type 2 Light Screen Instruction Manual
External Device Monitoring (EDM)
This feature allows the EZ-SCREEN Type 2 system to monitor the status of external devices such as MPCEs. The EDM used in this
system is similar to Power Monitoring employed by MINI-SCREEN safety light screens. A normally closed and a normally open contact
from each monitored device are wired in series-parallel to detect if one of the devices fails.
Status Indicators
Status indicators on both the emitter and receiver are clearly visible on each sensor’s front panel.
Figure 2. EZ-SCREEN Type 2 emitter and receiver status indicators
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
Mechanical Installation
The effective use of the EZ-SCREEN Type 2 as a safety guarding device depends on two things:
• the suitability of the application
• the proper mechanical and electrical installation and interfacing to the guarded machine.
WARNING: Read this Section Carefully Before Installing the System
If all mounting, installation, interfacing, and checkout procedures are not followed properly, the EZSCREEN Type 2 cannot provide the protection for which it was designed. The user has the responsibility
to ensure that all local, state, and national laws, rules, codes, or regulations relating to the installation and
use of this control system in any particular application are satisfied. Extreme care should be taken to ensure that all legal requirements have been met and that all technical installation and maintenance instructions contained in this manual are followed.
The user has the sole responsibility to ensure that this EZ-SCREEN Type 2 is installed and interfaced to
the guarded machine by Qualified Persons, in accordance with this manual and applicable safety regulations.
This section has two main subsections:
• Considerations in designing the layout of the application
• Mounting the hardware
Pre-Installation Considerations
This subsection describes important considerations before you begin installing the EZ-SCREEN Type 2. The two primary factors that
influence the layout of the EZ-SCREEN Type 2 System’s mechanical installation the most are the Safety Distance (See Calculating the
Safety Distance (Minimum Distance) on page 13) and eliminating pass-through hazards (see Reducing or Eliminating Pass-Through
Hazards on page 17). Additionally, you will find information on the following in this section:
• Emitter and receiver orientation (see Emitter and Receiver Orientation on page 21)
• Dealing with the affects of adjacent reflective surfaces (see Adjacent Reflective Surfaces on page 19)
• Using corner mirrors (see Use of Corner Mirrors on page 20)
• Installing multiple systems (see Installation of Multiple Systems on page 21)
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EZ-SCREEN
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Calculating the Safety Distance (Minimum Distance)
Safety Distance (Ds), also called Minimum Distance (S), is the minimum distance required between the defined area and the closest
reachable hazard point. The distance is calculated so that when an object or a person is detected (by blocking a sensing beam), the EZSCREEN Type 2 will send a stop signal to the machine, causing it to stop by the time the person can reach any machine hazard point.
The distance is calculated differently for domestic U.S. and European installations. Both methods take into account several factors, including a calculated human speed, the total system stopping time (which itself has several components), and the depth penetration factor. After the distance has been determined, record the calculated distance on the Daily Checkout Card
WARNING: Proper Safety Distance
Banner EZ-SCREEN Type 2 emitters and receivers must be mounted at a distance from the nearest hazard such that an individual cannot reach the hazard before cessation of hazardous motion or situation.
Failure to establish and maintain the minimum distance could result in increased risk of harm.
Figure 3. Safety distance and hard guarding
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
EZ-SCREEN Type 2 Models With Response Times
Models (see note below) Defined Area Height Number of Beams Response Time (Tr)
LS2..30-150Q8 150 mm (5.9") 8 11 ms
LS2..30-300Q8 300 mm (11.8") 16 13 ms
LS2..30-450Q8 450 mm (17.7") 24 14 ms
LS2..30-600Q8 600 mm (23.6") 32 16 ms
LS2..30-750Q8 750 mm (29.5") 40 17 ms
LS2..30-900Q8 900 mm (35.4") 48 19 ms
LS2..30-1050Q8 1050 mm (41.3") 56 21 ms
LS2..30-1200Q8 1200 mm (47.2") 64 22 ms
LS2..30-1350Q8 1350 mm (53.1") 72 24 ms
LS2..30-1500Q8 1500 mm (59") 80 25 ms
LS2..30-1650Q8 1650 mm (65") 88 27 ms
LS2..30-1800Q8 1800 mm (70.9") 96 29 ms
NOTE: The .. in the model numbers is one of the following:
• E = Emitter
• TR = Trip-Output Receiver
• LR = Latch-Output Receiver
• TP = Trip-Output Emitter/Receiver Pair
• LP = Latch-Output Emitter/Receiver Pair
Pair model numbers end in 88 (for example, LS2TP30-150Q88) to indicate that both the transmitter and receiver have an 8-pin connector.
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EZ-SCREEN
® Type 2 Light Screen Instruction Manual
Formula and Examples
The Safety (separation) distance formula for U.S. applications:
Ds = K x (Ts + Tr) + Dpf
The minimum distance formula for European applications:
S = (K x T) + C
where:
U.S. Applications
Ds
the safety distance, in mm (inches).
K
1600 mm per second (or 63" per second), the
OSHA 29CFR1910.217, ANSI B11.19, ANSI/RIA
R15.06 recommended hand-speed constant
(See Note 1 below)
Ts
the overall stop time of the machine (in seconds)
from the initial “stop” signal to the final ceasing of
all motion, including stop times of all relevant
control elements (e.g., IM-T-.. Interface Modules)
and measured at maximum machine velocity
(See Note 3 below).
Tr
the maximum response time, in seconds, of the
EZ-SCREEN Type 2 emitter/receiver pair (depending on model).
Dpf
the added distance – in this case, 78 mm (3") –
due to depth penetration factor as prescribed in
OSHA 29CFR1910.217, ANSI B11.19, ANSI/RIA
R15.06 for U.S. applications .
European Applications
S
the minimum distance, in mm, from danger zone
to light screen center line; minimum allowable
distance is 100 mm ( 175 mm for non-industrial
applications), regardless of calculated value.
K
hand-speed constant (see Note 2); 2000 mm/s
(for minimum safety distances < 500 mm) 1600
mm/s (for minimum safety distances > 500 mm)
T
the overall machine stopping response time (in
seconds), from the physical initiation of the safety
device and the machine coming to a stop (or the
hazard removed). This can be broken down into
two parts: Ts and Tr where T = Ts + Tr
C
the additional distance, in mm, based on intrusion of hand or object towards danger zone prior
to actuation of a safety device.
Calculate using the formula:
C = 8 x (d - 14)
where d is the resolution of the light curtain (for d
< 40 mm). For EZ-SCREEN Type 2, d = 30 mm
and C = 128 mm (5").
Notes:
1. The OSHA-recommended hand speed constant K has been determined by various studies and, although these
studies indicate speeds of 1600 mm/sec. (63"/sec.) to more than 2500 mm/sec. (100"/sec.), they are not conclusive determinations. Consider all factors, including the physical ability of the operator, when determining the value
of K to be used.
2. The recommended hand speed constant K, derived from data on approach speeds of the body or parts of the
body as stated in ISO 13855.
3. Ts is usually measured by a stop-time measuring device. If the machine manufacturer's specified stop time is
used, at least 20% should be added to allow for possible clutch/ brake system deterioration. This measurement
must take into account the slower of the two MPCE channels, and the response time of all devices or controls
that react to stop the machine. See Notice Regarding MPCEs. If all devices are not included, the calculated separation distance (Ds) will be too short and serious injury could result.
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
Examples
Example: U.S. Applications, Model LS2..30-600
K = 63" per second (the hand speed constant set by
OSHA)
Ts = 0.32 (0.250 second is specified by the machine
manufacturer; plus 20% safety factor; plus 20 ms
for interface module IM-T-9A response)
Tr = 0.016 second (the specified response time of an
LS2..30-600 EZ-SCREEN Type 2)
Dpf = 3"
Substitute the numbers into the formula as follows:
Ds = K x ( Ts + Tr ) + Dpf
Ds = 63 x (0.32 + 0.016) + 3 = 24.2"
Mount the EZ-SCREEN Type 2 emitter and receiver so that no
part of the defined area will be closer than 24.2" to the closest
reachable hazard point on the guarded machine.
WARNING: Determine Correct Stop Time
Example: European Applications, Model LS2..30-600
K = 1600 mm per second
T = 0.336 (0.250 second specified by machine manufac-
turer; plus 20% safety factor; plus 20 ms interface
module response), plus 0.016 second (the specified
LS2..30-600 response time)
C = 8 x (30-14) = 128 mm
Substitute the numbers into the formula as follows:
S = (K x T ) + C
S = (1600 x 0.336) + 128 = 665.6 mm
Mount the EZ-SCREEN Type 2 emitter and receiver so that no
part of the defined area will be closer than 665.6 mm to the closest reachable hazard point on the guarded machine.
Stop time (Ts) must include the response time of all devices or controls that react to stop the machine. If all devices are not included, the calculated safety distance (Ds) will be too short. This can lead to
an increased risk of harm. Be sure to include the stop time of all relevant devices and controls in your
calculations.
If required, each of the two Machine Primary Control Elements (MPCE1 and MPCE2) must be capable of
immediately stopping the dangerous machine motion, regardless of the state of the other. These two channels of machine control need not be identical, but the stop time performance of the machine (Ts, used to
calculate the safety distance) must take into account the slower of the two channels.
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EZ-SCREEN® Type 2 Light Screen Instruction Manual
Reducing or Eliminating Pass-Through Hazards
A pass-through hazard is associated with applications where personnel may pass through a safeguard (which issues a stop command to
remove the hazard), and then continues into the guarded area, such as in perimeter guarding. Subsequently, their presence is no longer
detected, and the related danger becomes the unexpected start or restart of the machine while personnel are within the guarded area.
In the use of light screens, a pass-through hazard typically results from large safety distances calculated from long stopping times, large
minimum object sensitivities, reach-over, reach-through, or other installation considerations. A pass-through hazard can be generated
with as little as 75 mm (3") between the defined area and the machine frame or hard guarding.
Eliminate or reduce pass-through hazards whenever possible. While it is recommended to eliminate the pass-through hazard altogether,
this may not be possible due to machine layout, machine capabilities, or other application considerations.
One solution is to ensure that personnel are continually sensed while within the hazardous area. This can be accomplished by using
supplemental safeguarding, such as described by the ANSI B11.19 of safety requirements or other appropriate standards.
An alternate method is to ensure that once the safeguarding device is tripped it will latch, and will require a deliberate manual action to
reset. This method of safeguarding relies upon the location of the reset switch as well as safe work practices and procedures to prevent
an unexpected start or restart of the guarded machine.
WARNING: Use of EZ-SCREEN Type 2 for Perimeter Guarding
If an EZ-SCREEN Type 2 is installed in an application that results in a pass-through hazard (e.g., perimeter guarding), either the EZ-SCREEN Type 2 System or the Machine Primary Control Elements (MPCEs)
of the guarded machine must cause a Latched response following an interruption of the defined area.
The reset of this Latched condition may only be achieved by actuating a reset switch that is separate from
the normal means of machine cycle initiation.
Lockout/Tagout procedures per ANSI Z244.1 may be required, or additional safeguarding, as described by
ANSI B11.19 safety requirements or other appropriate standards, must be used if a passthrough hazard
can not be eliminated or reduced to an acceptable level of risk. Failure to observe this warning could
result in an increased risk of harm.
Supplemental Safeguarding
As described in Calculating the Safety Distance (Minimum Dis-
tance) on page 13, the EZ-SCREEN Type 2 must be properly posi-
tioned such that an individual can not reach through the defined
area and access the hazard point before the machine has stopped.
Additionally, the hazard can not be accessible by reaching around,
under, or over the defined area. To accomplish this, supplemental
guarding (mechanical barriers, such as screens or bars), as described by ANSI B11.19 safety requirements or other appropriate
standards, must be installed. Access will then be possible only
through the defined area of the EZ-SCREEN Type 2 System or
through other safeguarding that prevents access to the hazard
(see Figure 4. An example of supplemental safeguarding on page
17).
The mechanical barriers used for this purpose are typically called
"hard guarding'; there must be no gaps between the hard guarding
and the defined area. Any openings in the hard guarding must
comply with the safe opening requirements of ANSI B11.19 or other appropriate standard.
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Figure 4. An example of supplemental safeguarding
EZ-SCREEN® Type 2 Light Screen Instruction Manual
Figure 4. An example of supplemental safeguarding on page 17 shows an example of supplemental safeguarding inside a robotic work
cell. The EZ-SCREEN Type 2, in conjunction with the hard guarding, is the primary safeguard. Supplemental safeguarding (such as a
horizontal-mounted safety light screen as an area guard) is required in areas that can not be viewed from the reset switch (i.e., behind
the robot and the conveyor). Additional supplemental safeguarding may be required to prevent clearance or trapping hazards (for example, the safety mat as an area guard between the robot, the turntable, and the conveyor).
WARNING: The Hazard Must Be Accessible Only through the Defined Area
The installation of the EZ-SCREEN Type 2 System must prevent any individual from reaching around, under, over or through the defined area and into the hazard without being detected. Mechanical barriers (for
example, hard guarding) or supplemental safeguarding may be required to comply with this requirement,
and is described by ANSI B11.19 safety requirements or other appropriate standards.
Other Considerations
Reset Switch Location
A key-actuated reset switch provides some operator or supervisory control, as the key can be removed from the switch and taken into the
guarded area. However, this does not prevent unauthorized or inadvertent resets due to spare keys in the possession of others, or additional personnel entering the guarded area unnoticed. When considering where to locate the reset switch, follow the guidelines in the
Warning below.
WARNING: Reset Switch Location
When considering where to locate the reset switch, you must follow the guidelines outlined in this section.
If any areas within the guarded area are not visible from the reset switch, additional safeguarding must be
provided, as described by the ANSI B11.19 series or other appropriate standards.
Failure to follow these instructions could result in an increased risk of harm
All reset switches must be:
• Outside the guarded area
• Located to allow the switch operator a full, unobstructed, view of the entire guarded area while the reset is performed
• Out of reach from within the guarded area
• Protected against unauthorized or inadvertent operation (such as through the use of rings or guards).
Important: Resetting a safeguard must not initiate hazardous motion. Safe work procedures require a startup procedure to be followed and the individual performing the reset to verify that the entire hazardous area is
clear of all personnel, before each reset of the safeguard is performed. If any area can not be observed from
the reset switch location, additional supplemental safeguarding must be used: at a minimum, visual and audible warnings of machine start-up.
18 www.bannerengineering.com - tel: 763-544-3164 122452 rev. B
d
d
d
Operating Range
(R)
Emitter Receiver
Do not position reflective surfaces
within the shaded area
top view
side view
EZ-SCREEN
® Type 2 Light Screen Instruction Manual
Adjacent Reflective Surfaces
WARNING: Avoid Installation Near Reflective Surfaces
Avoid locating the defined area near a reflective surface; it could reflect sensing beam(s) around an object
or person within the defined area, and prevent its detection by the EZ-SCREEN Type 2.
Reflections will result in incomplete guarding and could result in an increased risk of harm.
A reflective surface located adjacent to the defined area may deflect one or more beams around an object in the defined area. In the
worst case, an optical short circuit may occur, allowing an object to pass undetected through the defined area.
This reflective surface may result from shiny surfaces or glossy paint on the machine, the workpiece, the work surface, the floor or the
walls. Beams deflected by reflective surfaces are discovered by performing the trip test and the periodic checkout procedures. To eliminate problem reflections:
• If possible, relocate the sensors to move the beams away from the reflective surface(s), being careful to maintain adequate separation distance.
• Otherwise, if possible, paint, mask or roughen the shiny surface to reduce its reflectivity.
• Where these are not possible (as with a shiny workpiece), mount the sensors in such a way that the receiver's field of view and/or the
emitter's spread of light are restricted.
• Repeat the trip test (see Trip Test on page 32) to verify that these changes have eliminated the problem reflection(s). If the workpiece is especially reflective and comes close to the defined area, perform the trip test with the workpiece in place.
122452 rev. B www.bannerengineering.com - tel: 763-544-3164 19
For 0.2 to 3 m (8" to 10') Operating range: d = 0.26 m (10")
For Operating range > 3 m (> 10'): d = 0.0875 x R (m or ft)
Figure 5. Adjacent reflective surfaces
Recommended sensor
configuration angle
Emitter
Emitter
Receiver
Receiver
Mirror Mirror
A
45° < A < 120°
EZ-SCREEN® Type 2 Light Screen Instruction Manual
Use of Corner Mirrors
EZ-SCREEN Type 2 Systems may be used with one or more cor-
SSM and MSM Series Glass-Surface Mirrors
ner mirrors. The use of glass-surface corner mirrors reduces the
maximum specified emitter/receiver separation by approximately 8
percent per mirror, as follows:
Corner Mirrors Max. Emitter / Receiver
Range
1 13.8 m (45')
2 12.7 m (42')
3 11.7 m (38')
4 10.8 m (35')
Mirrors are not allowed for applications that would allow personnel undetected access into the safeguarded area.
If mirrors are used, the difference between the angle of incidence from the emitter to the mirror and from the mirror to the receiver must
be between 45° and 120°. If placed at a sharper angle, as shown in the example, an object in the light screen may deflect beam(s) to the
receiver, preventing the object from being detected (that is, "false proxing"). Angles greater than 120° result in difficult alignment and
possible optical short circuits.
WARNING: Avoid Retroreflective Installation
Do not install emitters and receivers in "retroreflective" mode, with less than a 45° angle of incidence, as
shown.
Sensing could be unreliable in this configuration; an increased risk of harm could result.
20 www.bannerengineering.com - tel: 763-544-3164 122452 rev. B
Figure 6. Never use EZ-SCREEN Type 2 sensors in a retroflective mode.
Receiver
Emitter
Receiver
Emitter
Receiver
Emitter
Receiver
Emitter
Receiver
Emitter
EZ-SCREEN
® Type 2 Light Screen Instruction Manual
Emitter and Receiver Orientation
The emitter and receiver must be mounted parallel to each other and aligned in a common plane, with both cable ends pointing in the
same direction. Never mount the emitter with its cable end oriented opposite the cable end of the receiver. If this occurs, voids in the light
screen may allow objects or personnel to pass through the defined area undetected.
The emitter and receiver may be oriented in a vertical or horizontal plane, or at any angle between horizontal and vertical, as long as they
are parallel and their cable ends point in the same direction. Verify that the light screen completely covers all access to the hazard point
that is not already protected by hard guarding or other supplemental guarding.
a) Both cable ends down. b) Both cable ends up. c) Orientation parallel to floor with both ca-
ble ends pointing in the same direction.
Figure 7. Examples of Correct Emitter/Receiver Orientation
a) Cable ends point in opposite directions.
Problem: Voids in defined area
b) Emitter and receiver not parallel to each other.
Problem: Reduced excess gain
Figure 8. Examples of incorrect Emitter/Receiver Orientation
Installation of Multiple Systems
Whenever two or more EZ-SCREEN Type 2 emitter and receiver pairs are adjacent to one another, optical crosstalk may potentially take
place between systems. To minimize optical crosstalk, alternate the positions of emitters and receivers, (see Figure 9. Installation of
multiple systems on page 22).
When two or more systems are installed in the same plane (as shown in Figure 9. Installation of multiple systems on page 22), optical
crosstalk may occur between sensor pairs whose emitter and receiver lenses are oriented in the same direction. In this situation, eliminate optical crosstalk by mounting these sensor pairs exactly in line with each other within one plane, or by adding a mechanical barrier
between the pairs.
122452 rev. B www.bannerengineering.com - tel: 763-544-3164 21
R
E
R
E
R2
E2
R1
E1
R 3
E 3
R 1
E1
R2
E 2
A
EZ-SCREEN® Type 2 Light Screen Instruction Manual
WARNING: Proper Orientation of System Emitters and Receivers
EZ-SCREEN Type 2 System emitters and receivers must be installed with their corresponding cabled
ends pointing in the same direction (for example, both cabled ends facing up). Failure to orient them properly will impair the performance of the EZ-SCREEN Type 2 System and will result in incomplete guarding,
and could result in an increased risk of harm.
E
R
R
E
E = Emitter R = Receiver E = Emitter R = Receiver
a. Two systems in a horizontal plane b. Two or three systems stacked (or alternate receiver/emitter po-
sitions)
E1 = Vertical Emitter E2 = Horizontal Emitter
R1 = Vertical Receiver R2 = Horizontal Receiver
A = Opaque Shield
E1 = Emitter #1 E2 = Emitter #2 E3 = Emitter #3
R1 = Receiver #1 R2 = Receiver #2 R3 = Receiver #3
c. Two systems at right angles d. Multiple systems
Figure 9. Installation of multiple systems
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