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LS2e30-1050Q8
Instruction Manual
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Banner LS2e30-150Q8, LS2e30-1050Q8, LS2e30-1200Q8, LS2e30-1350Q8, LS2e30-1500Q8 Instruction Manual

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EZ-SCREEN® T
Instruction Manual
ype 2 Light Screen
Original Instructions 122452 Rev. D 3 December 2014
EZ-SCREEN® Type 2 Light Screen
Contents
1 About This Document .....................................................................................................
1.1 Important . . . Read This Before Proceeding! .................................................................................4
1.1.1 Use of Warnings and Cautions ...........................................................................................4
1.1.2 EC Declaration of Conformity (DoC) .................................................................................. 4
2 Introduction .................................................................................................................. 5
2.1 Features ................................................................................................................................. 5
2.2 System Description .................................................................................................................. 5
2.3 Appropriate Applications and Limitations ..................................................................................... 6
2.3.1 Examples: Appropriate Applications .................................................................................. 7
2.3.2 Examples: Inappropriate Applications ................................................................................7
2.4 Control Reliability and Safety Categories ...................................................................................... 7
2.5 Operating Features ....................................................................................................................8
2.5.1 Trip/Latch Output ...........................................................................................................8
2.5.2 Wiring Options for Emitter/Receiver Swapability ................................................................. 9
2.5.3 Manual Reset/Remote Test Input and EDM .........................................................................9
2.5.4 Status Indicators ............................................................................................................9
3 Mechanical Installation .................................................................................................11
3.1 Mechanical Installation Considerations .......................................................................................11
3.1.1 Calculating the Safety Distance (Minimum Distance) ...........................................................11
3.1.2 Reducing or Eliminating Pass-Through Hazards .................................................................14
3.1.3 Supplemental Safeguarding ............................................................................................15
3.1.4 Other Considerations ......................................................................................................15
3.2 Mounting System Components ..................................................................................................20
3.2.1 Overview of Emitter/Receiver Mounting Hardware ..............................................................20
3.2.2 Mounting and Initial Alignment of Emitter/Receiver Pairs .....................................................21
4 Electrical Installation and Testing ................................................................................ 23
4.1 Routing Cordsets .....................................................................................................................23
4.2 Initial Electrical Connections .................................................................................................... 23
4.3 Initial Checkout Procedure ........................................................................................................25
4.3.1 Configuring the System for Initial Checkout ......................................................................25
4.3.2 Initial Power-Up ............................................................................................................26
4.3.3 Optical Alignment ......................................................................................................... 26
4.3.4 Optical Alignment Procedure with Mirrors .........................................................................28
4.3.5 Trip Test ......................................................................................................................28
4.4 Electrical Connections to the Guarded Machine ...........................................................................29
4.4.1 OSSD Output Connections ............................................................................................. 30
4.4.2 FSD Interfacing Connections .......................................................................................... 30
4.4.3 Machine Primary Control Elements and EDM Input ..............................................................31
4.4.4 Manual Reset/Remote Test Input and EDM .......................................................................31
4.4.5 Preparing for System Operation ......................................................................................33
4.4.6 Commissioning Checkout ...............................................................................................33
4.5 Reference Wiring Diagrams .......................................................................................................34
4.5.1 Generic Emitter Wiring Diagram ......................................................................................34
4.5.2 Generic Wiring to FSDs (manual reset) ............................................................................ 35
4.5.3 Generic Wiring — Interface Module (2-Channel EDM, Manual Reset) .................................... 36
5 System Operation ........................................................................................................ 37
5.1 Security Protocol ....................................................................................................................37
5.2 Reset Procedures ................................................................................................................... 37
5.2.1 Receiver Resets ............................................................................................................37
5.2.2 Emitter Resets ..............................................................................................................37
5.3 Status Indicators ....................................................................................................................37
5.3.1 Receiver ......................................................................................................................38
5.3.2 Emitter ........................................................................................................................38
5.4 Normal Operation ...................................................................................................................39
5.4.1 System Power-Up .........................................................................................................39
5.4.2 Run Mode ....................................................................................................................39
5.4.3 Manual Reset Procedure ................................................................................................ 39
5.5 Periodic Checkout Requirements ...............................................................................................39
6 Troubleshooting and Maintenance ............................................................................... 40
6.1 Troubleshooting and Lockout Conditions ....................................................................................40
6.2 Recovery Procedures .............................................................................................................. 40
6.2.1 Receiver (System Reset) ................................................................................................40
6.2.2 Emitter Reset ...............................................................................................................40
4
EZ-SCREEN® Type 2 Light Screen
6.3 Electrical and Optical Noise ......................................................................................................41
6.3.1 Sources of Electrical Noise .............................................................................................
6.3.2 Sources of Optical Noise ................................................................................................ 42
6.4 Servicing and Maintenance ....................................................................................................... 42
6.4.1 Cleaning ......................................................................................................................42
6.4.2 Banner Engineering Corp Limited Warranty ...................................................................... 42
6.4.3 Warranty Service ..........................................................................................................42
6.4.4 Manufacturing Date .......................................................................................................42
6.4.5 Disposal ....................................................................................................................... 43
41
7 Checkout Procedure Schedule .......................................................................................44
7.1 Schedule of Checkouts ............................................................................................................44
8 Specifications and Accessories .................................................................................... 45
8.1 Specifications .........................................................................................................................45
8.1.1 General Specifications ................................................................................................... 45
8.1.2 Emitter Specifications ....................................................................................................45
8.1.3 Receiver Specifications ..................................................................................................45
8.1.4 Emitter and Receiver Dimensions .....................................................................................46
8.1.5 Bracket Dimensions ....................................................................................................... 46
8.2 Accessories ........................................................................................................................... 47
8.2.1 Cordsets .......................................................................................................................48
8.2.2 Interface Modules ..........................................................................................................50
8.2.3 Contactors ...................................................................................................................50
8.2.4 Lens Shield ...................................................................................................................51
8.2.5 EZ-LIGHT® for EZ-SCREEN
8.2.6 MSA Series Stands ........................................................................................................52
8.2.7 MSM Series Corner Mirrors .............................................................................................52
8.2.8 SSM Series Corner Mirrors ............................................................................................. 52
8.2.9 Accessory Mounting Brackets ......................................................................................... 53
8.2.10 Alignment Aids ........................................................................................................... 55
8.2.11 Replacement Parts ...................................................................................................... 55
8.2.12 Documentation ...........................................................................................................55
®
...........................................................................................51
9 Standards and Regulations ........................................................................................... 56
9.1 Applicable U.S. Standards .........................................................................................................56
9.2 OSHA Regulations ................................................................................................................... 56
9.3 International/European Standards ............................................................................................. 56
9.4 Contact Us ............................................................................................................................ 56
10 Glossary .....................................................................................................................58
EZ-SCREEN®
Type 2 Light Screen
1 About This Document
1.1 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 device in full compliance with all applicable regulations and standards. The device can provide the required safeguarding function only if it is properly installed, properly operated, and properly maintained. This manual attempts to provide complete installation, operation, and maintenance instruction. Reading the manual in its entirety is highly recommended. Please direct any questions regarding the application or use of the device to Banner Engineering.
For more information regarding U.S. and international institutions that provide safeguarding application and safeguarding device performance standards, see Standards and Regulations
WARNING: User Responsibility
The user is responsible to:
• Carefully read, understand, and follow the information in all documentation for this device.
•
Perform a risk assessment of the specific machine guarding application. See ISO 12100 or ANSI B11.0.
• Determine what safeguarding devices and methods are appropriate per the requirements defined in ISO 13849-1, ANSI B11.19, 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 responsibilities may potentially create a dangerous condition that may lead to serious injury or death.
on page 56.
1.1.1 Use of Warnings and Cautions
This manual contains numerous WARNING and CAUTION statements:
• Warnings refer to potentially hazardous situations which, if not avoided, may lead to serious injury or death.
• Cautions refer to potentially hazardous situations which, if not avoided, which may lead to minor or moderate injury or potential damage to equipment. Cautions are also used to alert against unsafe practices.
These statements are intended to inform the machine designer and manufacturer, the end user, and maintenance personnel, how to avoid misapplication and effectively apply the safeguarding application requirements. These individuals are responsible to read and abide by these statements.
EZ-SCREEN Type 2 Light Screen
to meet the various
1.1.2 EC Declaration of Conformity (DoC)
Banner Engineering Corp. herewith declares that the EZ-SCREEN Type 2 Light Screen are in conformity with the provisions of the Machinery Directive 2006/42/EC and all essential health and safety requirements have been met.
Representative in EU: Peter Mertens, Managing Director Banner Engineering Europe. Address: Park Lane, Culliganlaan 2F, 1831 Diegem, Belgium.
2 Introduction
2.1 Features
EZ-SCREEN® Type 2 Light Screen
• An optoelectronic safeguarding device
• Creates a screen of synchronized, modulated infrared sensing beams. Choose from 10 sizes, in 150 mm (6 in) increments: defined areas from 150 mm to 1.8 m (6 in to 71 in)
Compact package for smaller production machines
•
• Models available with Trip or Latch output operation (automatic or manual start/restart)
• 30 mm (1.18 in) resolution
• Remote Test input terminals for simulating a "blocked" condition
• Operating range up to 15 m (50 ft)
• 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
2.2 System Description
NOTE: This manual refers to an emitter and its receiver, and their cabling
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 maximum range is 15 m (50 ft), which decreases if corner mirrors are used. Resolution is 30 mm (1.18 in).
Both emitter and receiver feature LEDs to provide continuous indication of the System’s operating status, alignment and error conditions.
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 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.
as "a System".
Quick-Disconnect
Cables
M12 QD
Fittings
Defined
Area
Emitter
Specified Test Piece
Synchronization
Beam
Receiver
Status
Indicators
EZ-SCREEN® Type 2 Light Screen
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 Euro­style) quick-disconnects. 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-for-color), 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
2.3 Appropriate Applications and Limitations
The Banner EZ-SCREEN Type 2 Light Screen is intended for lower-risk machine guarding and other safeguarding applications, as determined by a risk assessment appropriate for the application and is installed, as instructed by this manual, by a Qualified Person (as defined in the
Glossary on page 58 ).
The EZ-SCREEN Type 2 ability to perform its safeguarding function depends upon the appropriateness of the application and upon its proper mechanical and electrical installation and interfacing to the guarded machine. If all mounting,
installation, interfacing, and checkout procedures are not followed properly, the EZ-SCREEN Type 2 cannot provide the protection for which it was designed.
WARNING: Read this Section Carefully Before Installing the System
If all mounting, installation, interfacing, and checkout procedures are not followed properly, the Banner device 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. 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 Banner device is installed and interfaced to the guarded machine by Qualified Persons, in accordance with this manual and applicable safety regulations.
. It is the user’s responsibility to verify whether the safeguarding is
CAUTION: Install System Only on Appropriate Applications
EZ-SCREEN®
Type 2 Light Screen
Banner EZ-SCREEN Type 2 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 Engineering.
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.
is for use only on machinery that can be stopped immediately after a stop
2.3.1 Examples: Appropriate Applications
EZ-SCREEN Type 2 are typically used for, 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.)
2.3.2 Examples: Inappropriate Applications
Do not use EZ-SCREEN Type 2 in the following 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
• With any machine that cannot be stopped immediately after a stop signal is issued, such as single-stroke (or full­revolution) clutched machinery
• With any machine with inadequate or inconsistent machine response time and stopping performance
• With 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, IEC 60204-1, IEC 61496-1, or other appropriate standard)
If an EZ-SCREEN Type 2 is installed for use as a perimeter guard (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 EZ­SCREEN Type 2 has been manually reset.
2.4 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.
EZ-SCREEN® Type 2 Light Screen
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 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 lower-risk 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 31). 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.
2.5 Operating Features
The Banner EZ-SCREEN Type 2 Light Screen models described by this manual feature standard 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.
2.5.1 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-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 turn on after all beams are cleared following a blocked beam.
• 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 Banner device, 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 (in a conscious act) to start the machine – in addition to the Banner device going into Run mode. Failure to follow these instructions may result in serious bodily injury or death.
D
C
A
B
EZ-SCREEN® Type 2 Light Screen
2.5.2 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-for-color 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
A
Bn
Or/Bk
Or
Wh
Bk
Bu
Gn/Y
Vi
Key Description
A Emitter B Receiver C QDE-8..D Cordsets
B
C
+24V dc
n.c.
n.c.
OSSD2
OSSD1
e
0V dc
Ground
Reset/Test & EDM
Key Description
A Emitter B Receiver C DEE2R.. Cordsets D CSB.. Cordsets
2.5.3 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.
External Device Monitoring (EDM)
This feature allows the closed and a normally open contact from each monitored device are wired in series-parallel to detect if one of the devices fails.
2.5.4 Status Indicators
Status indicators on both the emitter and receiver are clearly visible on each sensor’s front panel.
EZ-SCREEN Type 2 system to monitor the status of external devices such as MPCEs. A normally
Power/Fault LED (Green)
Alignment LEDs
(Yellow)
Status Blocked LED (Red)
Status Clear LED (Green)
EZ-SCREEN® Type 2 Light Screen
Figure 2. EZ-SCREEN Type 2 emitter and receiver status indicators
EZ-SCREEN® Type 2 Light Screen
3 Mechanical Installation
EZ-SCREEN Type 2 system performance as a safety guarding device depends on:
The
•
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 Banner device 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. 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 Banner device is installed and interfaced to the guarded machine by Qualified Persons, in accordance with this manual and applicable safety regulations.
3.1 Mechanical Installation Considerations
The two primary factors that influence the layout of the EZ-SCREEN Type 2 system mechanical installation are the Safety Distance (Minimum Distance) (see Calculating the Safety Distance (Minimum Distance) on page 11) and the supplemental safeguarding/eliminating pass-through hazards (see Reducing or Eliminating Pass-Through Hazards on page
14). Other considerations include:
• Emitter and Receiver Orientation on page 17
• Adjacent Reflective Surfaces on page 16
• Use of Corner Mirrors on page 16
• Installation of Multiple Systems on page 18
WARNING: Position Components Carefully The emitter and receiver must be positioned such that the hazard cannot be accessed by
reaching over, under, around, or through the sensing field. Additional and supplemental guarding
may be required.
3.1.1 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 EZ-SCREEN Type 2 sends a stop signal to the machine, causing it to stop by the time the object or person can reach any machine hazard point.
The distance is calculated differently for 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: Safety Distance (Minimum Distance)
The Banner emitters and receivers must be mounted at a distance from the nearest hazard such that an individual cannot reach the hazard before cessation of the hazardous motion or situation. This distance can be calculated using the formulas in this section, as described by ANSI B11.19 and ISO 13855, and must be greater than 100 mm (4 in) regardless of calculated value. Failure to establish and
maintain the safety distance (minimum distance) may result in serious bodily injury or death.
Reduced Resolutions increases Dpf (or C). Increase the depth penetration factor to calculate proper minimum distance whenever Reduced Resolution is used. Always turn Reduced
Resolution Off when the larger minimum object detection size is not required.
EZ-SCREEN® Type 2 Light Screen
Figure 3. Safety distance (minimum distance) and hard (fixed) guarding
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 in) 8 11 ms LS2..30-300Q8 300 mm (11.8 in) 16 13 ms LS2..30-450Q8 450 mm (17.7 in) 24 14 ms LS2..30-600Q8 600 mm (23.6 in) 32 16 ms LS2..30-750Q8 750 mm (29.5 in) 40 17 ms LS2..30-900Q8 900 mm (35.4 in) 48 19 ms LS2..30-1050Q8 1050 mm (41.3 in) 56 21 ms LS2..30-1200Q8 1200 mm (47.2 in) 64 22 ms LS2..30-1350Q8 1350 mm (53.1 in) 72 24 ms LS2..30-1500Q8 1500 mm (59 in) 80 25 ms LS2..30-1650Q8 1650 mm (65 in) 88 27 ms LS2..30-1800Q8 1800 mm (70.9 in) 96 29 ms
NOTE: The .. in the model numbers is one of the following:
= Emitter
• E
• 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.
Formula and Examples
U.S. Applications European Applications
The Safety (Separation) Distance formula for U.S. applications:
Ds = K × (Ts + Tr) + Dpf
The Minimum Distance formula for European applications:
S = (K × T) + C
U.S. Applications European Applications
Ds
the Safety Distance, in inches
K
1600 mm per second (or 63 in per second), the OSHA 29CFR1910.217, and ANSI B11.19 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 (for example, 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 due to the depth penetration factor as prescribed in OSHA 29CFR1910.217, and ANSI B11.19 for U.S. 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 below); 2000 mm/s (for Minimum Distances < 500 mm) 1600 mm/s (for Minimum 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
C
the additional distance, in mm, based on intrusion of a hand or object towards the danger zone prior to actuation of a safety device. Calculate using the formula:
C = 8 × (d - 14)
EZ-SCREEN® Type 2 Light Screen
= Ts + Tr
where d is the resolution of the light curtain (for d < 40 mm). EZ-SCREEN Type 2, d = 30 mm and C = 128 mm (5 in).
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 in/sec.) to more than 2500 mm/sec. (100 in/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.
WARNING: Determine Correct Stop Time 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 or S) will be too short. This
can lead to serious bodily injury or death. 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.
For
EZ-SCREEN®
Examples
Type 2 Light Screen
Example: U.S. Applications, Model K = 63 in. per second (the hand speed constant set by OSHA)
Ts = 0.32 (0.250 second is specified by the machine
Tr = 0.016 seconds (the specified response time of an
Dpf =
Substitute the numbers into the formula as follows:
Ds = K x ( Ts + Tr ) + Dpf
Mount the EZ-SCREEN Type 2 emitter and receiver so that no part of the defined area will be closer than 24.2 in. point on the guarded machine.
manufacturer; plus 20% safety factor; plus 20 ms for interface module IM-T-9A response time)
LS2..30-600 EZ-SCREEN Type 2) 3 in
to the closest reachable hazard
Example: European Applications, Model K = 1600 mm per second
T = 0.336 (0.250 second specified by machine manufacturer;
C = 8 x (30 - 14) = 128 mm (14 mm resolution)
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 reachable hazard point on the guarded machine.
plus 20% safety factor; plus 20 ms interface module response time), plus 0.016 LS2..30-600 response time)
seconds (the specified
mm to the closest
3.1.2 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 pass­through hazard can be generated with as little as 75 mm (3 in) between the defined area and the machine frame or hard (fixed) 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 safety requirements in ANSI B11.19 or other appropriate standards.
An alternative 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 the Banner device for Perimeter Guarding
If a Banner device is installed in an application that results in a pass-through hazard (for example, perimeter guarding), either the Banner device 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 cannot be eliminated or reduced to an acceptable level of risk. Failure to observe this
warning may result in serious bodily injury or death.
3.1.3 Supplemental Safeguarding
As described in Calculating the Safety Distance (Minimum
Distance) on page
properly positioned such that an individual cannot reach through the defined area and access the hazard point before the machine has stopped.
Additionally, the hazard cannot 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 on page 15).
The mechanical barriers used for this purpose are typically called "hard (fixed) guarding"; there must be no gaps between the hard (fixed) guarding and the defined area. Any openings in the hard (fixed) guarding must comply with the safe opening requirements of ANSI B11.19 or other appropriate standard.
11, the
EZ-SCREEN Type 2 must be
EZ-SCREEN® Type 2 Light Screen
Figure 4. An example of supplemental safeguarding
15
Figure 4 on page
conjunction with the hard (fixed) guarding, is the primary safeguard. Supplemental safeguarding (such as a horizontal­mounted safety light screen as an area guard) is required in areas that cannot be viewed from the reset switch (for example, behind the robot and the conveyor). Additional supplemental safeguarding may be required to prevent clearance or trapping hazards (for example, a safety mat as an area guard between the robot, the turntable, and the conveyor).
shows an example of supplemental safeguarding inside a robotic work cell. The EZ-SCREEN Type 2, in
WARNING: The Hazard Must Be Accessible Only through the Defined Area
The installation of the EZ-SCREEN Type 2 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 (fixed) 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.
3.1.4 Other Considerations
Reset Switch Location
The reset switch must be mounted at a location that complies with the warning and guidelines below.
hazardous areas are not in view from the switch location, additional means of safeguarding must be provided. The switch should be protected from accidental or unintended actuation (for example, through the use of rings or guards).
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 below.
WARNING: Reset Switch Location
If any
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 serious injury or death.
All reset switches must be:
• Outside the guarded area
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
• 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 start-up 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 cannot be observed from the reset switch location, additional supplemental safeguarding must be used: at a minimum, visual and audible warnings of machine start-up.
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. Perform the trip test, as described in this manual, to detect such reflection(s) and the resultant optical short circuit.
Failure to prevent reflection problems will result in incomplete guarding and could
result in serious injury or death.
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 or machine frame), determine the worst-case resolution resulting from the optical short circuit and use the corresponding depth penetration factor (Dpf or C) in the Safety Distance (Minimum Distance) formula; or mount the sensors in such a way that the receiver's field of view and/or the emitter's spread of light are restricted from the reflective surface
• Repeat the trip test (see Trip Test on page 28) 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
Use of Corner Mirrors
Figure 5. Adjacent Reflective Surfaces
EZ-SCREEN Type 2 may be used with one or more corner mirrors. Mirrors are not allowed for applications that would allow undetected personnel access into the safeguarded area. The use of glass-surface corner mirrors reduces the maximum specified emitter/receiver separation by approximately 8 percent per mirror, as follows:
A
Emitter
Receiver
Mirror
45˚ < A < 120˚
Emitter
Receiver
Mirror
EZ-SCREEN® Type 2 Light Screen
SSM and MSM Series Glass-Surface Mirrors
Corner Mirrors Max. Emitter / Receiver Range
1 13.8 m (45 ft) 2 12.7 m (42 ft) 3 11.7 m (38 ft) 4 10.8 m (35 ft)
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° (see Figure 6 on page light screen may deflect beam(s) to the receiver, preventing the object from being detected, also know as 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 may be unreliable in this configuration and result in a serious bodily injury
or death.
17
). If placed at a sharper angle, an object in the
Figure 6. Using EZ-SCREEN Type 2 sensors in a retroreflective mode
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 in the opposite direction of 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 to each other 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 (fixed) guarding or other supplemental guarding.
WARNING: Proper Orientation of System Emitters and Receivers
EZ-SCREEN Type 2 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 serious bodily injury or death.
Receiver
Emitter
Receiver
Emitter
Receiver
Emitter
Receiver
Emitter
Receiver
Emitter
EZ-SCREEN® Type 2 Light Screen
Both cable ends down Both cable ends up Orientation parallel to floor with both
cable ends pointing in the same
direction
Figure 7. Examples of Correct Emitter/Receiver Orientation
Cable ends point in opposite directions
Problem: Voids in defined area
Figure 8. Examples of Incorrect Emitter/Receiver Orientation
Emitter and receiver not parallel to each other
Problem:
Reduced excess gain
Installation of Multiple Systems
Whenever two or more EZ-SCREEN Type 2 emitter and receiver pairs are adjacent to one another, optical crosstalk may take place between the systems. To minimize optical crosstalk, alternate the positions of the emitters and receivers (see
Figure 9 on page
When three or more systems are installed in the same plane (as shown in Figure 9 on page 19), 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.
19).
Receiver
Emitter
Scan Code 1
Receiver
Emitter
Scan Code 1
Receiver
Emitter
Scan Code 2
Receiver
Emitter
Scan Code 1
Emitter
Receiver
Horizontal Receiver
Horizontal
Emitter
Scan Code 1
Scan Code 2
Receiver 1
Emitter 1
Scan Code 1
Receiver 2
Emitter 2
Scan Code 2
Receiver 3
Emitter 3
Scan Code 2
Opaque Shield
EZ-SCREEN® Type 2 Light Screen
a. Two systems in a horizontal plane
c. Two systems at right angles
Figure 9. Installation of Multiple Systems
emitter positions)
d. Multiple systems
WARNING: Multiple Pairs of Sensors
Do not connect multiple pairs of sensors to one Interface Module (for example, IM-T-9A/-11A) or otherwise parallel OSSD outputs. Connection of multiple OSSD safety outputs to a single device
may result in serious bodily injury or death, and is prohibited.
b. Two or three systems stacked (or alternate receiver/
WARNING: Proper Orientation of System Emitters and Receivers
EZ-SCREEN Type 2 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 serious bodily injury or death.
WARNING: Synchronization
In situations where multiple systems are mounted closely together, or where a secondary emitter is in view (within ±5°), within range of an adjacent receiver; a receiver may synchronize to the signal from the wrong emitter, reducing the safety function of the light screen.
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