Pinnacle Systems DR User Manual
Installation Manual
for the
DIN-rail Controller Module
Rev. 4-8
DIN-rail Controller Module
Installation Manual
Pinnacle Systems, Inc.
3715 Swenson Avenue
St. Charles, IL 60174
P/N: 28-022r4-8
Customer Service: 630-443-8542 (CST)
(Please have Model #, Serial #, and Software Rev # Available)
Sales and Marketing: 800-569-7697 (EST)
www.pinnaclesystems.com • sales@pinnaclesystems.com • service@pinnaclesystems.com
Proper Usage and Limitations
The information disclosed herein includes proprietary
rights of the manufacturer. Neither this document nor
the information disclosed herein shall be reproduced
or transferred to other documents, used or disclosed
to others for manufacturing purposes, or for any other
purposes, except as specifi cally authorized in writing by
the manufacturer. If this manual is supplied in connection
with the sale or delivery of manufacturer’s equipment, it
is to be used solely for maintenance, repair, or installation
of such equipment.
The MicroGuard was manufactured in the United States.
The Installation Manual was printed in the United States.
You must read and fully understand the following
information pertaining to the proper use and limitations of
your Microguard:
• The MicroGuard must be installed by qualifi ed
personnel only.
• The MicroGuard must NOT be used on full
revolution presses or any machine that cannot be
commanded to stop at any time.
• You must NOT wire the Safety Output contacts of
the MicroGuard to an external relay unless you
use the External Relay Checking feature.
• The mechanical power press on which the
MicroGuard is installed must meet ANSI B11.12009 and OSHA 1910.217 regulations. These
include inspection and maintenance procedures
that must be followed to comply with the
regulations. The manufacturer will NOT take
responsibility for improperly maintained machinery.
• Point of operation safeguarding is defi ned in ANSI
B11.19-2003. This regulation is used to determine
a safe distance to place your MicroGuard. The
manufacturer takes no responsibility for injury as
a result of improper safeguarding or improper safe
distances.
• The MicroGuard may not be able to safely stop
a press which has a faulty stopping mechanism.
The manufacturer cannot be held responsible
for an improperly maintained or faulty stopping
mechanism.
• The MicroGuard must be checked before put into
operation. Follow instructions provided in this
manual for procedures on how to do this.
• The MicroGuard should never be modifi ed or
repaired except by qualifi ed personnel and upon
authorization of the manufacturer. Never operate
machinery that is not in full working order.
• Make sure that all maintenance people,
machine operators, die-setters, foreman, and
supervisors have read and understood this
manual and all procedures have been and will
be followed.
• All procedures in this manual must be followed.
The manufacturer cannot take responsibility for
operation if all procedures and warnings in this
manual are not followed.
Warranty
Manufacturer warrants that this product will be free
from defects in material and workmanship for a period
of two years from the date of shipment thereof. Within
the warranty period, the manufacturer will repair or
replace (at our discretion) any product that is disclosed
as defective upon examination by the manufacturer and
is returned with shipping charges prepaid. This warranty
will not apply to any product that has been subjected to
misuse, negligence, accident, restriction, and use not
in accordance with manufacturer’s instructions or which
will have been altered or repaired by persons other than
the authorized agent or employees of the manufacturer.
Disclaimer
The provisions of the warranty are the sole obligations
of the manufacturer and exclude all other warranties of
merchantability , expressed or implied. Further, there are
no warranties that extend beyond the above warranty.
Limitation of Liability
In the event of any claim for breach of any obligations of
the manufacturer under any order, whether expressed
or implied, and particularly in the event of any claim
of a breach of the warranty or warranties contained in
the paragraph “Warranty” or of any other warranties,
expressed or implied which might despite the paragraph
entitled “Disclaimer,” be determined to be incorporated
in any order, the company shall under no circumstances
be liable for any consequential or special damages,
either in law or in equity, or for losses or expenses or
claims for the same arising from the use of, or inability
to use, the products of the manufacturer for any purpose
whatsoever.
We have designed our equipment to the very highest
performance and safety standards known to the current
technological state of the art. However, the installation,
usage, suitability, and fi tness of our equipment for any
purpose, known or unknown, is interdependent upon
the performance of other equipment not manufactured,
installed, or secured or maintained by the manufacturer.
We cannot and do not accept responsibility for any
overall system performance when factors, such as these,
are beyond our control.
We will not supply individual component parts of any
circuit board but will supply the individual circuit board
complete. Individual detectors or emitters are available
as a complete tested unit.
WARNING: The entire machine safety system must
be tested at the start of every shift. Machine testing
should include: (1) proper machine operation and
stopping capability; and (2) verifi cation of proper
installation and settings of all point of operation
guards and devices before the operation is released
for production.
FILL THIS INFORMATION OUT IMMEDIATELY
Purchase Date: _____________________________
__________________________________________
Model No.: _________________________________
__________________________________________
Options: ___________________________________
__________________________________________
Purchased From: ____________________________
Serial No.: _________________________________
Microprocessor Revision No.: __________________
This information will be needed in the event you
need assistance.
Table of Contents
Introduction
Theory of Operation ...............................................................................................................................................iv
The System ............................................................................................................................................................iv
System Safety ........................................................................................................................................................iv
Safety Features ......................................................................................................................................................iv
Specifi cations .......................................................................................................................................................1
Standard Features
Auxillary Relay Output ............................................................................................................................................2
Emergency Stop Input ............................................................................................................................................2
External Relay Check .............................................................................................................................................2
Fault Relay Output ..................................................................................................................................................2
Resettable Latching Relays ....................................................................................................................................2
MicroGuard DIN-rail Serial Port ..............................................................................................................................3
Remote Latching Reset ..........................................................................................................................................3
Safety Relay Outputs ..............................................................................................................................................3
Optional Features
Analog Output .........................................................................................................................................................5
Auto Blank ...............................................................................................................................................................5
Cincinnati Interface .................................................................................................................................................6
DeviceNet ...............................................................................................................................................................6
Floating Blank .........................................................................................................................................................6
Guarding Mute-Out .................................................................................................................................................7
Remote Diagnostics Display ...................................................................................................................................7
Remote Indicator Lights ..........................................................................................................................................7
Remote Key Switch .................................................................................................................................................7
Installation Procedures
Resetting Faults ......................................................................................................................................................8
System Check .........................................................................................................................................................8
Aligning Pylons .......................................................................................................................................................9
Aligning Mirrors .......................................................................................................................................................9
Operations ............................................................................................................................................................10
ANSI Standard B11.19.2003 .................................................................................................................................11
Safeguarding with Mechanical Guards .................................................................................................................12
Light Curtain Test Procedure.................................................................................................................................12
Wiring ....................................................................................................................................................................13
Controller Module Setup .......................................................................................................................................16
Swivel Bracket Dimensions ...................................................................................................................................17
Pylon Dimensions (by model) (Swivel) .................................................................................................................18
Additional cable information (Swivel) ....................................................................................................................18
Fixed Bracket Dimensions ....................................................................................................................................19
Pylon Dimensions (by model) (Fixed) ...................................................................................................................19
Additional cable information (Fixed) ......................................................................................................................19
- i -
Table of Contents
Dimensions
Controller Module ..................................................................................................................................................20
RSD Mounting Dimensions ...................................................................................................................................21
Accessories
Cornering Mirrors ..................................................................................................................................................22
Pedestal Mounting ................................................................................................................................................23
Swing-Arm Mounting Bracket ...............................................................................................................................23
Appendix A: Diagnostics & Troubleshooting
Obstruction or Misalignment ...............................................................................................................................A-1
Error Conditions ..................................................................................................................................................A-1
Status Display Messages ....................................................................................................................................A-2
Fault Display Messages ......................................................................................................................................A-2
Appendix B: Regulations and Guidelines
OSHA Regulations ..............................................................................................................................................B-1
Machine Control Reliability Requirements ..........................................................................................................B-1
Safety Guidelines and Management
Operational Safety ..........................................................................................................................................B-2
Power Press Guarding ....................................................................................................................................B-2
Power Press Care through Inspection and Maintenance ................................................................................B-3
Safety Enforcement ........................................................................................................................................B-3
Supervisor Training .........................................................................................................................................B-3
Operator Training ............................................................................................................................................B-3
Appendix C: Replacement Parts
Pylons .................................................................................................................................................................C-1
Appendix D: USB Diagnostic Codes
Master Controls USB Port ........................................................................................................................D-1 to D-2
- ii -
Table of Contents
Figures
Figure 1: 4 Sided Guarding with Dual Stud Guard Brackets, TRM Mirrors and Model #8000 Pedestals ...........9
Figure 2: Minimum Object Sensitivity and D(pf) ...............................................................................................11
Figure 3: DIN-rail Controller Module Wiring Diagram ........................................................................................15
Figure 4: Internal Circuit Board View ................................................................................................................16
Figure 5a: Swivel Bracket Dimensions ................................................................................................................17
Figure 5b: Swivel Bracket Dimensions, pylon dimensions (by model), and additional cable information ...........18
Figure 6: Fixed Bracket Dimensions, pylon dimensions (by model), and additional cable information .............19
Figure 7: DIN-rail Controller Module Dimensions ..............................................................................................20
Figure 8: RSD Plain Plate Dimensions .............................................................................................................21
Figure 9: RSD Plate with Floating or Auto Blank Dimensions ..........................................................................21
Figure 10: Cornering Mirror Dimensions .............................................................................................................22
Figure 11: Pedestal Dimensions .........................................................................................................................23
Figure 12: Swing-Arm Mounting Bracket ............................................................................................................23
Tables
Table 1: DIN-rail Serial Port Diagnostics ...........................................................................................................4
Table 2a: .5” Beam Spacing Pylons (Minimum Object Sensitivity, Depth Penetration Factor, Floating size) ......6
Table 2b: 1” Beam Spacing Pylons (Minimum Object Sensitivity, Depth Penetration Factor, Floating size) .......6
Table 3: Truth Table ...........................................................................................................................................7
Table 4: Mechanical Guards ............................................................................................................................12
Table 5a-f: Controller Module Wiring ...................................................................................................................13
Table 6: Internal Jumper Settings with Different Pylon Lengths ......................................................................16
Table 7: Cornering Mirror Dimensions .............................................................................................................22
- iii -
Introduction
The MicroGuard DIN-rail Controller Module is an infrared
safety light curtain that is designed to the European
IEC 61496 standard. IEC-61496 standard defines
requirements for infrared light curtains used in safety
applications. When properly installed, it protects the
machine operator by passing an invisible infrared light
beam across an area to be guarded and examining
whether or not the light beam(s) are blocked. If the light
beams are blocked, safety outputs will automatically
open up and a “STOP” command will be sent to the
guarded machine.
The system is composed of a sending unit (Emitter), a
receiving unit (Receiver), and a Controller Module. The
entire system is control reliable (per IEC 61496) in that
a single fault anywhere within the MicroGuard DIN-rail
itself will not prevent the safety outputs from opening
up when anything blocks the infrared light beam(s). All
failures are reported on the Diagnostics Display and/or
via the RS-232 or RS-485 Serial Port.
The Diagnostics Display aids in installation by showing
where beam blockage is occurring, as well as reporting
selected installed options and fault reports.
Theory of Operation. The MicroGuard protects an area
by projecting a curtain of infrared light. It forms a curtain
by utilizing infrared Emitters in line on .5” or 1” centers.
This close spacing makes it impossible to place a body
part through the curtain without detection (assuming
proper installation procedures were followed). For every
infrared Emitter, there is an infrared Detector directly
opposite. When an obstruction is placed between
them, the beam is broken and the absence of a beam is
observed by the Controller Module which de-energizes
the safety relays and opens the connected circuit.
All the beams are scanned sequentially (one at a time)
until the entire curtain has been scanned. The two
computers compare data with each other every scan
of the light curtain and will drop out the safety relays if
any signal is incorrect or the compared data does not
match. Cooperation from both computers is required to
energize safety relays and either computer can disable
both safety relays if a fault is detected.
and transistor receivers also spaced .5” or 1” apart.
The Controller Module contains diverse redundant
technology that includes two different microprocessors,
self-checking circuitry, power supply, safety output
contacts, and a diagnostics display.
System Safety. The MicroGuard employs diverse
redundant technology that provides a backup for every
system that could cause an unsafe condition. Upon
power up, all systems are checked before activating
the output relays. Once the unit passes the initial
tests and activates the system, it is then tested by
both microprocessors and other circuits once per scan
of the light curtain. All signals are presented to both
microprocessors, but are isolated from one another
to prevent a failure of one microprocessor should the
other crash. Other circuits detect short circuits, open
circuits, proper voltage, proper oscillation, etc. The
use of special dual force-guided safety relays assure
that if one fails, the other can safely shut down the unit.
Additionally , watchdog circuits on the relays prevent an
unsafe condition even if both microprocessors failed.
All the standard and optional features that run on the
MicroGuard are designed with safety in mind:
The Floating Blank option allows only one object
to be placed into the light curtain’s fi eld of view.
Even if the object is smaller than the allowed size,
a second object will cause the unit to go RED.
The Auto Blank option programs in the exact size
and location of an object automatically and thus
can detect any movement in the object and shut
down the light curtain, which must be reset with
a key.
The External Relay Check can detect either an
opening or a short in the external relay or its
wiring. The standard Cincinnati Interface provides
a means to assure that the light curtain can open
up its output relays between press cycles.
Safety Features. The MicroGuard was designed to
meet the European IEC 61496 standard parts 1 and 2,
CSA, UL 1998, UL Subject 491, OSHA, ANSI, and RIA.
The System. The MicroGuard employs infrared
technology in a small sealed NEMA 4 aluminum housing
which provides harmless invisible protection and an
unobstructed view of the guarded area. The Microguard
consists of three parts: an Emitter pylon(s), Receiver
pylon(s), and Controller Module. The Emitter pylon(s)
contains infrared light emitting diodes spaced .5” or 1”
apart down the entire length of the pylon. The Receiver
pylon(s) contains an equal number of infrared detector’s
• Control-reliable design prevents a failure to
danger condition from ever occurring (assuming
all installation procedures are followed properly).
• System redundancy assures that there are at least
two ways to detect a system failure, two ways
to shut down the safety outputs, and two safety
outputs. The redundant systems are confi gured
differently to prevent any possible inherent circuit
- iv -
- v -
Introduction
problems from occurring simultaneously in both
redundant circuits.
• Force-guided relays allows dry relay contacts to
be monitored for contact welding and/or circuit
failure.
• Watchdog timers on both computers and both
safety relays assures that a system lock-up will
automatically drop out the safety relays.
• Through the use of shielded cables, chokes,
surge suppressers, and optically-coupled inputs,
immunity to EMI/RFI fi elds is greatly increased.
• The MicroGuard DIN-rail was designed to meet
the European IEC 61496 standard parts 1 and 2
(part 2 requires use of optional 2 degree pylons),
CSA, UL 1998, UL491, UL991, OSHA, ANSI, and
RIA.
• Surface mount technology is used throughout for
increased reliability.
- v -
- vi -
Specifi cations
DIN-rail Controller Module
Input Power
24vdc +/- 20% (7 watts max)
Input Fuse
1 amp fast blow (pico size)
Relay Outputs
K1, K2 Safety N.O.
8A@250v resistive
(4A@120vac recommended max)
130V surge suppression devices are installed
inside the Controller Module. This limits the
recommended maximum voltage to 120VAC.
Please consult factory if you need to switch higher
voltages.
K3 Aux N.O. & N.C.
8A@250v resistive
(4A@120vac recommended max)
K4 Fault N.O.
8A@250v resistive
(4A@120vac recommended max)
Indicators
External:
OK/CLEAR Green LED
BLOCK/FAULT Red LED
BLANKING ACTIVE Y ellow LED
BLOCKED Red LED
Internal:
D1 +5v Yellow D3 +12v Red
D14 K2 relay Green D13 K1 relay Green
D16 K3 relay Green D15 K4 relay Green
D19 +5v Yellow D18 -5v Green
Temperature Range
0 to 50°C (up to 95% humidity, non-condensing)
Dimensions
Controller Module: 5.87” length X 2.95” width X
4.33” height DIN-rail mount is 35.5mm (1.4”) wide.
Pylons: 1.45” square.
Beam Spacing
.5” (12.7mm) standard
1” [25.4mm] (optional). The Floating Blank option
changes the effective beam spacing.
Minimum Object Sensitivity:
.5” (12.7mm) beam spacing is .55” (14mm)
1” (25.4mm) beam spacing is 1.18” (30mm)
Response Time < 30 mSec total
Scanning Frequency 5.9 KHz
Shock Tested to withstand high vibration applications
Self-Checking every 20 milliseconds
Scanning Distance All units are supplied standard
with a 20’ scanning capability. Extended range units
are available and must be specifi ed (35’ maximum).
Maximum Operating Distance Stated as last two
digits in model number
Construction
Controller Module: DIN-rail mountable
polycarbonate housing providing IP40 protection,
UL94V-1.
Pylons: Painted aluminum extrusion with
polycarbonate IR lens and Viton seals providing
NEMA 12, 13 protection. An optional polycarbonate
tube provides NEMA 4 protection.
Cables: Shielded PVC 22 AWG stranded.
Standard length: 20’ Emitter; 8’ Receiver
1
7
Standard Features
DIN-rail Controller Module
Standard Features
DIN-rail Controller Module
Auxiliary Relay Output
Description: Use this relay for horns, lights, and signals
back to PLC’s. Relay K3 is not monitored and driven off
of the K2 relay . It should not be placed into a “stop” circuit
by itself. Both N.O. and N.C. terminals are provided.
POWER / RELAY terminal #8: N.C., terminal #9:
common, terminal #10: N.O. Follow the same directions
as for contact ratings.
Emergency Stop Input
Description: A built-in hardwired Emergency Stop Safety
Input which utilizes two normally-closed emergency stop
contacts to achieve a Category 4 safety level, per EN
954-1. If either or both emergency stop contacts open,
power to the safety output relays is removed, causing
the relays to de-energize and send a stop signal to the
guarded machine.
Application: This protects against a safety switch
contact failure or wiring fault. A contact failure or wiring
short will inhibit the system reset, causing the system’s
Diagnostics Message Display to indicate an Emergency
Stop Input failure.
Usage: See Figure 3 DIN-rail Controller Module Wiring
Diagram for proper wiring of the E-Stop inputs. If you
choose not to use this feature, you must still wire the
two inputs closed (the DIN-rail is pre-wired from the
factory). To reset an E-Stop fault, hit the F1 key on the
top of the DIN-rail controller or Ground Terminal #3 on
the Input/Output connector (the same input is used for
the Latching Relay Reset).
External Relay Check
Description: This feature allows the MicroGuard
DIN-rail to monitor a pair of external relays in series.
The external relays must be force-guided and have an
extra pole that is normally closed. The primary pole of
a force-guided relay maintains identical position to the
secondary pole even when one of the poles is welded.
The secondary pole is used to monitor your external
relays.
Application: If your application requires you to switch
to high current in your “stop” circuit, then you will need
to use external relays. You will want to monitor those
external relays in case of contact welding.
To Activate Feature: Install Jumper (see Installation
Procedures, “Controller Module Setup”) on across pins
labeled EXT. The display should read “rdyE” when this
feature is active.
Usage: POWER / RELAY terminal #13: +pos input
(+24vdc max), terminal #14: -neg input (ground)
The secondary poles must be N.C. when the curtain is
in a “RED” condition. The monitored external contacts
must close and the primary contacts must open in a
“RED” condition within 250mSec’s or an error will occur .
If the curtain is “GREEN,” the monitored secondary
contacts should open up and the primary contacts will
close. An error will occur if the monitored contacts do
not open up. The primary poles of your external relays
must be N.O. (they are placed in your “stop” circuit).
Bring +24vdc to T erminal #13, run GND through the N.C.
contact of both external relays in series to Terminal #14.
Messages: (see Appendix A: Diagnostics &
Troubleshooting for details)
“External contact welded or wire cut”
“External contact short”
NOTE: Use only shielded cable between external relays
and external relay checking input.
Fault Relay Output
Description: Relay K4 is not monitored and has its
own driver circuitry . It should not be placed into a “stop”
circuit by itself. The fault output is a dry contact N.O.
(held closed when clear, opens when there is a fault).
Use this relay for horns, lights, and signals back to PLC’s.
POWER / RELAY terminal #11 & 12. Follow the same
note found above for contact ratings.
Resettable Latching Relays
Description: When power is applied to the MicroGuard
DIN-rail unit, it will stay in a “RED” condition until the
Latching Reset Input is reset.
Application: This is used for guarding an area against
intrusion; without this feature the curtain would stay
“RED” only as long as the curtain’s fi eld of view was
blocked. If you are perimeter guarding, you may need
this.
To Activate Feature: Install Jumper (see Installation
Procedures, “Controller Module Setup”) on across pins
labeled CLOSE. The display should read “rdyL” when
this feature is active. Y ou may want to remove this jumper
during installation.
Usage: Install your own N.O. push button between
ground and terminal #3 of INPUTS/OUTPUTS following
the Wiring section of this manual. You must cycle the
button to reset the curtain.
2
3
Standard Features
DIN-rail Controller Module
MicroGuard DIN-rail Serial Port
Description: Make your connection via the DB-9 pin
connector at the Controller Module. You need a DB-9
male cable (straight, not zero modem). The baud rate
is 4800. A character is sent every time the status of the
curtain changes (see T able 1 for descriptions). The unit
does not receive commands at this time.
Application: To monitor status of the light curtain via
RS-232 or RS-485 serial communication port.
To Activate Feature: This feature is always active as
RS-232. You must specify if you wish RS-485 because
it requires a software change as well as an addition of a
terminator added to the circuit board.
Remote Latching Reset
Description: When the curtain is blocked, the unit will
issue a “STOP” command and remain in this condition
until the curtain is clear and the Latching Input is cycled.
This feature must be enabled.
Usage: Install a N.O. button from I/O Terminal #3 to
Power/Relay Terminal #2.
To Activate: Install jumper across pins labeled “close”.
Standard Features
DIN-rail Controller Module
Safety Relay Outputs
Description: Safety Relays are N.O. (closed when
green, open when blocked or power removed). Both K1
and K2 relays each have their own driver circuitry and
relay monitoring circuitry, are fully independent of each
other, and have their own output terminals.
POWER / RELAY: K1 (Terminal #4 & 5)
K2 (Terminal #6 & 7)
WARNING: You must use both K1 and K2 relays
in your “stop” circuit(s). If you have only one “stop”
circuit, you must place K1 and K2 relays in series.
If you have two “stop” circuits, each relay will have
its own “stop” circuit.
NOTE: Safety relays are rated at 8A @ 250vac resistive
at room temperature. Inductive loads and high ambient
temperatures de-rate that value substantially. It is not
recommended that more than 4A@120vac be used
through the internal safety relay contacts.
3
4
Standard Features
DIN-rail Controller Module
Standard Features
DIN-rail Controller Module
Table 1: DIN-rail Serial Port Diagnostics
DIAGNOSTICS DISPLAY DESCRIPTION
A RDY Ready (GREEN light)
B 01 > (numbers on screen show where Blockage of curtain fi eld (RED) relays are off.
blockage occurred)
C SIZE Auto Blank object size to large.
D MOVE Auto Blank object moved.
E PENT Curtain penetrated and locked out (RED)
F Waiting for reset button to be pushed (scrolling or error code).
G Reset button has been pushed.
H CINN Cincinnati Interface active (+24v).
I MUTE Mute Out in active muting state (outputs bypassed).
J Emitter turned off (occurs after you remove blockage to check for external
infrared sources).
K Blockage of curtain fi eld but waiting for relays to turn off.
L 01 > (numbers on screen show where No blockage, relays off, trying to turn on.
blockage occurred)
M CPU responding with last order from another CPU.
U MUTE-OUT SWITCH FAULT Signal inputs that control Mute function where either in MUTE at power up or both
high or low (same state for too long).
V OPEN EMITTER PYLON LED in pylon failed or cable to pylon off or bad.
W SHORT IN EMITTER PYLON LED in pylon shorted.
X EMITTER LENGTH FAULT Physical length of pylon does not match settings in box.
Y RECEIVER LENGTH FAULT Physical length of pylon does not match settings in box.
Z EXT RELAY CONTACT WELD / WIRE CUT External relay input signal open all the time or at the wrong time.
[ EXT RELAY CONTACT SHORTED External relay input signal short all the time or at the wrong time.
\ INT RELAY CONTACT STUCK ON Internal relay closed, but should be open.
] INT RELAY CONTACT STUCK OFF Internal relay open but should be closed.
^ NO DATA LINE DETECTED Slave could not detect data line from Master
_ NO CLOCK LINE DETECTED Slave could not detect clock line from Master
‘ No G LINE DETECTED Slave could not detect G line from Master
a EXT INFRARED SOURCE DETECTED Receiver pylon indicating seeing signals when none were transmitted by Emitter
pylon.
b RELAY BAD OR MISSING No RED or GREEN light on box lit up.
c RAM FAILURE Ram would not clear.
d HAD POWER ON RESET Slave processor has reset itself.
e HAD CLOCK/WATCHDOG FAILURE Oscillator or Watchdog failure.
f DATA TRANSFER CORRUPTED Checksum error between Master and Slave CPU’s.
g SERIAL TRANSFER INCOMPLETE Slave and Master could not talk to each other.
h DATA FROM RECEIVER PYLON NOT Data coming from Receiver pylon not correct.
CORRECT
i EMITTER ON AT WRONG TIME LED in Emitter pylon was on but not supposed to be.
j RECEIVER IS OSCILLATING A phototransistor in the Receiver pylon was Oscillating.
k NO MORE CODES Displayed after all stored fault codes are displayed.
l INITIATE EEPROM New EEPROM was tested and initialized for initial use
m Master wants Slave to store new AB data
n AB DATA CORRUPTED Stored Auto Blank pattern has been corrupted.
o RESET BUTTON HELD DOWN TOO LONG Reset button has been held down too long or is broken.
p NO ACK FROM EEPROM Cannot talk to EEPROM memory.
q ESTP Emergency Stop Input
4
5
Optional Features
DIN-rail Controller Module
Analog Output
Description: Ouput can be set up for either 0 to 10V or
–10V to 10V and proportional to the area blocked. You
must specify the details of the output (see Installation
Procedures, “Figure 3: Controller Module Wiring
Diagram”).
Application: Various
To Activate Feature: This feature must be ordered and
requires exchanging computer chips (see Installation
Procedures, “Figure 3: Controller Module Wiring
Diagram”).
Auto Blank [patent # 5,243,183]
Description: With the obstruction in place, turn the
key switch from “OFF” to any mode of operation. If the
object(s) do not exceed the total allowable size, the unit
will energize the safety outputs.
Application: Permits you to automatically program
the location of an obstruction (i.e., a conveyor, table,
work piece, etc.).
Standard Operation: If the obstruction is moved or
removed, the unit will issue a “MOVE” fault and will
re-energize the safety outputs when the obstruction
is returned to the original position. Standard operation
allows for a total of eight beams to be blocked anywhere
in the curtain (they do not have to be next to each other).
Optional Operation: If the obstruction is moved or
removed, the unit will issue a “MOVE” fault and lockup,
requiring you to re-program the obstruction.
Troubleshooting: If you get a “MOVE” fault when
the obstruction did not move, it is possible that you
are just barely covering a beam and either vibration or
refl ections are causing the beam to become uncovered.
The uncovered beam then causes a fault.
To Activate Feature: This feature must be ordered
and requires exchanging the computer chips (see
Installation Procedures, “Figure 3: Controller Module
Wiring Diagram”).
WARNING: Leave key switch in OFF/RESET
position while installing, setting up, and testing the
light curtain. Use Auto Blank only after you are
able to get a clear signal from the curtain with no
obstruction.
MODE Description
OFF/
RESET Normal operation (no blanking)
#1 Mode 2, but guard must be reset if unit is
penetrated. The auto blank obstruction must
remain in its exact location permanently . Any
movement in the Auto Blank obstruction and/
or additional guard penetration will latch the
light curtain in a RED condition and must be
reset via the keyswitch.
NOTE: If no obstructions were programmed
in, the guard will still latch in a RED condition
should the guard be penetrated.
#2 Standard Auto Blank operation. The Auto
Blank obstruction must remain in its exact
location permanently. This works like Mode
1 except guard penetrations will not latch in
a RED condition.
#3 Mode 2, plus one beam fl oat. This mode
works like Mode 2 with the addition of a
Floating Blank which is set to allow one
beam fl oat (see Optional Features, “Floating
Blank”).
NOTE: If no obstructions were programmed
in, the guard will still allow one beam fl oat.
Programming: To program, turn the keyswitch into
the OFF/RESET position and place the obstruction(s)
in the guarded area. Now, turn the keyswitch into the
desired mode of operation. The exact size and location
of the object(s) are now in memory. The Penetration
Depth Factor D(pf) must be set to account for the
one beam fl oat (see Optional Features, “Floating Blank,
Tables 2a and 2b”).
Diagnostics Display
AB Auto Blank detected an object (the number
indicates the size of the object).
RDY No objects programmed in, keyswitch in
Mode 1 or 2.
FB No objects programmed in, keyswitch in
Mode 3
SIZE Obstruction size exceeded a total of eight
beams.
PENT Penetration of the light curtain occurred
while keyswitch was in Mode 1.
MOVE Auto Blank obstruction moved.
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