Pinnacle Systems MG User Manual
Installation Manual
for the
Metal Box Controller Module
Rev 9-6
Metal Box Controller Module
Installation Manual
Pinnacle Systems, Inc.
3715 Swenson Avenue
St. Charles, IL 60174
P/N: 28-006r9-6
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 specically 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 qualified
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.
• Th e me chanical powe r p ress o n w hic h t he
MicroGuard is installed must meet ANSI B11.1-
1988 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 dened 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 modified or
repaired except by qualied 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 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.
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) verification of proper
installation and settings of all point of operation
guards and devices before the operation is released
for production.
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.
Fill this Information out Immediately
(It will be needed in the event you need assistance)
Purchase Date: _______________________________
Purchased From: ______________________________
Model No.: ___________________________________
Serial No.: ___________________________________
Options: _____________________________________
Microprocessor Revision No.: ____________________
Table of Contents
Introduction ...........................................................................................................................................................iv
Theory of Operation ...............................................................................................................................................iv
The System ............................................................................................................................................................iv
System Safety ........................................................................................................................................................iv
Immunity to EMI/RFI ...............................................................................................................................................v
CE Approved ...........................................................................................................................................................v
Specications .......................................................................................................................................................1
Standard Features
Auxillary Output Contact ........................................................................................................................................2
Cincinnati Interface .................................................................................................................................................2
External Relay Check .............................................................................................................................................2
Standard Output Contacts .....................................................................................................................................3
Fault Relay Output .................................................................................................................................................3
Optional Features
Auto Blank ...............................................................................................................................................................4
Emergency Stop Input ............................................................................................................................................5
DeviceNet ...............................................................................................................................................................5
Floating Blank .........................................................................................................................................................5
Depth Penetration Factor ........................................................................................................................................5
Guarding Mute-Out .................................................................................................................................................6
Latching Relays ......................................................................................................................................................6
Installation Procedures .....................................................................................................................................7
Resetting the MicroGuard .......................................................................................................................................8
Alignment Procedure ..............................................................................................................................................9
Operations ............................................................................................................................................................10
ANSI Standard B11.19.2003 .................................................................................................................................11
Safeguarding with Mechanical Guards .................................................................................................................12
Light Curtain Testing Procedure ............................................................................................................................12
Controller Module Setup .......................................................................................................................................13
Single Pylon Set Controller Module Jumper Settings ...........................................................................................14
Multiple Pylon Set Controller Module Jumper Settings .........................................................................................15
Wiring ....................................................................................................................................................................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
Dimensions
Physical Dimensions of Swivel Bracket ................................................................................................................17
Physical Dimensions of Swivel Bracket ................................................................................................................18
Physical Dimensions of Fixed Bracket ..................................................................................................................19
Controller Module ..................................................................................................................................................20
- i -
Table of Contents
Accessories
Cornering Mirrors ..................................................................................................................................................21
Pedestal ................................................................................................................................................................22
Swing-Arm Mounting Bracket ...............................................................................................................................22
Appendix A: Diagnostics & Troubleshooting
Diagnostic Indicator Lights ................................................................................................................................. A-1
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 .................................................................................................................................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
Controller Module Replacement Parts ................................................................................................................C-1
Pylon Replacement Parts ...................................................................................................................................C-2
Appendix D: USB Diagnostic Codes
Model MG or DR USB Diagnostic Codes ................................................................................................D-1 to D-2
- ii -
Table of Contents
Figures
Figure 1: Wiring External Relays ........................................................................................................................2
Figure 2: Bottom Board Inside Control Box .........................................................................................................6
Figure 3: 4 Sided Guarding with Dual Stud Guard Brackets, TRM Mirrors and Model #8000 Pedestals ...........9
Figure 4: Minimum Object Sensitivity and D(pf) ................................................................................................ 11
Figure 5: Controller Module (Lower Board) .......................................................................................................13
Figure 6: Controller Module Jumper (Upper Board) ..........................................................................................14
Figure 7: Multi-pylon Controller Module Connector/Jumper Detail ...................................................................15
Figure 8: Controller Module Wiring Diagram .....................................................................................................16
Figure 9a: Swivel Bracket Dimensions ................................................................................................................17
Figure 9b: Swivel Bracket Dimensions, pylon dimensions (by model), and additional cable information ...........18
Figure 10: Fixed Bracket Dimensions, pylon dimensions (by model), and additional cable information .............19
Figure 11: Controller Module Dimensions ...........................................................................................................20
Figure 12: Cornering Mirror Dimensions .............................................................................................................21
Figure 13: Pedestal Dimensions .........................................................................................................................22
Figure 14: Swing-Arm Mounting Bracket Dimensions .........................................................................................22
Figure 15: Controller Module Replacement Parts .............................................................................................C-1
Figure 16: Pylon Replacement Parts ................................................................................................................C-2
Tables
Table 1a: .5” Beam Spacing Pylons .....................................................................................................................5
Table 1b: 1” Beam Spacing Pylons ......................................................................................................................5
Table 2: Mechanical Guards ............................................................................................................................12
Table 3: Controller Module Connection Chart (Lower Board) ..........................................................................13
Table 4: Single Pylon Set Controller Module Jumper Chart ............................................................................14
Table 5: Multiple Pylon Set Controller (DUAL - SC) Module Length Jumper Chart .........................................15
Table 6: Controller Module Dimensions ...........................................................................................................20
Table 7: Cornering Mirror Dimensions (MGM & TRM) .....................................................................................21
- iii -
Introduction
The Microguard is the latest in infrared safety curtain
technology. Contained in the main housing (Controller
Module) is a diverse redundant architecture that is
designed to detect internal failures in the Emitter
pylon(s), Receiver pylon(s), and the Controller Module
which will immediately send a “STOP” command to
the machine, thus being “FAIL-SAFE.” Failures are
immediately reported on the diagnostic message display
for immediate evaluation.
Diverse redundancy means that there are at least two
ways to detect a system failure, two ways to shut it down,
and that the two methods of detection and shut down
use different techniques. This eliminates the chance
an inherent fault in one circuit will effect the other. For
example: The stop circuit output contacts run through
two relays and both are monitored for correct position
through a second set of contacts on each relay. A special
circuit monitors those contacts, but a different circuit (a
test circuit) monitors the rst circuit to make sure that it
is functioning correctly. Two different microprocessors
isolated from one another each monitor the same signals
and monitor each other. Either microprocessor can turn
off the output relays, but it requires both to turn them on.
Special watchdog circuits on the microprocessors and
on the output relay circuits prevent an unsafe condition
by turning off both outputs relays should either or both
microprocessors become erratic.
With the aid of advanced microprocessor technology, the
MicroGuard can not only detect a fault in the light curtain
but spell out the exact problem. This advancement is
a great help during alignment, use, and servicing of the
light curtain. It not only can detect shorted and open
infrared emitters, but indicate which emitters have failed,
allowing the faulty board to be replaced.
Built into the MicroGuard is an optically coupled external
relay check which can detect open or short circuits,
a Cincinnati Interface, provision for auxiliary output
contacts, and external voltage check input. The power
supply is designed to accommodate most voltage
requirements, from DC to AC (see Specications).
is placed between them, the beam is broken and the
absence of a beam is observed by the Controller Module
which de-energizes the output relays and opens the
circuit it is connected to.
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
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 curtains eld of view. Even if the
object is smaller than the allowed size, a second object
will cause the unit to go RED.
As the MicroGuard is a single function device, that of
sensing an unauthorized intrusion into a guarded area
while simultaneously determining that it is capable of
sensing such an intrusion, any internal malfunction will
manifest itself with a RED condition shut down.
Theory of Operation. The MicroGuard guards an area
by projecting a curtain of infrared light across it. It forms
a curtain by utilizing infrared emitters in line very close
together on .5” or 1” centers. This close spacing makes
it impossible to place a body part through the curtain
without detection. For every infrared emitter there is an
infrared detector directly opposite. When an obstruction
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 both an open 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 i t s o u t p u t r e l a ys
between press cycles.
- iv -
Introduction
Immunity to EMI/RFI. The entire system is shielded,
including the pylon cables. The use of MOV’s, lters,
and chokes make it immune to the noise found in the
industrial environment. Even the software embedded
into the dual microprocessors is written to cope with a
noisy environment.
CE Approved. CE approval was third party certied by
UL / DEMKO to IEC61496-1,-2. CE approved units offer
+/-2deg beam angle, which is tighter than the standard
Microguard.
- v -
Specications
Metal Box Controller Module
Input Power
18 to 33 VDC @ 10 W (optional)
90 to 140 VAC @ 12 W (standard)
128 to 240 VAC @ 12 W (optional)
All AC voltages work with 50 or 60 Hz
Fuses
AC power: 1 AMP Slow Blow (250VAC)
DC power: 1 AMP Fast Blow
Output Circuits (all isolated)
Terminals #12-13: N.O. (held closed when Green)
control reliable dry STOP circuit, wired through K1 &
K2 relays. 4A @ 120vac recommended max
Terminals #14-15: N.O. (held closed when Green)
control reliable dry STOP circuit, wired through K1 & K2
relays. 4A @ 120vac recommended max
Term inal s #9- 1 0-11: N.O. (hel d clo s ed wh en
Green) – common – N.C. (held open when Green)
dry auxi liar y cir cuit , wir ed th roug h K3 rela y.
4A @ 120vac recommended max
Alarm + - : N.O. (held closed when powered and NO
FAULTS) dry auxiliary circuit, wired through K4 relay.
4A @ 120vac recommended max
NOTE: For Older Control boxes prior to October 2007:
Both terminals #12-13 and #14-15 must be used to
achieve a control reliable STOP circuit. Newer control
boxes can use either or both sets of terminals.
Indicators
External:
Construction:
Control Unit: All 18 Gauge painted steel
NEMA 12 lockable box with sealed front
panel and sealed cable entry ttings (8 lbs.).
Pylons: Heavy-duty aluminum extrusion
NEMA 4. Replaceable IR lens.
Sealed bulkhead positive locking circular
connectors. (Optional polycarbonate
protective tube guards).
Cables: Emitter 20’/ Receiver 8’ (supplied
standard). Shielded PVC 22 AWG cable
(optional cable lengths available).
Temperature Range 32° to 120° F
Dimensions
Controller Module: (see Dimensions)
Pylons: 1.45” (36.83mm) square (see
Dimensions)
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.
OK/CLEAR Green
BLOCK/FAULT Red
AUTO/FLOAT ACTIVE Yellow
SLAVE DISAGREEMENT Red
The Diagnostics Display is a four-digit
alphanumeric with scroll
Internal:
+12V (RED) D2 CINN INT. (GRN) D10
+5V (YEL) D4 EXT RELAY (GRN) D11
+5V (YEL) D3 -5V (GRN) D17
FAULT RELAY (GRN) D21
Self-Checking every 20 milliseconds
Scanning Distance All units are supplied standard
with a 20’ (6.1m) scanning capability. Extended
range units are available and must be specied -- 50’
maximum (15.2m).
Maximum Operating Distance Stated as last two
digits in model number.
1
Standard Features
Metal Box Controller Module
Auxiliary Output Contact (K3)
Description: K3 relay uses the same driver circuitry
as the K1 relay, but has its own relay checking circuitry.
This means that you should never use the K3 relay in
series with the K1 relay unless you use K2 in another
stop circuit.
Usage: K3 has both N.O. and N.C. outputs off the
same common. This can be used in conjunction with
the standard output contacts. Never just use K3 by
itself or with K1.
N.O. contact is closed when the curtain is GREEN.
N.C. contact is open when the curtain is GREEN.
Cincinnati Interface
Description: Provided to allow an external device to
determine if the light curtain is still capable of shutting
down the safety control circuit. The Cincinnati Interface
allows an external device to override the light curtain,
initiate a RED condition, and open up the standard
output relay contacts.
Application: Cincinnati Press, PLC
Usage:
Type1: The press interface provides 24VDC when it
wants the guard to de-energize (go RED). Connect this
press signal to Terminal #5 and Ground to Terminal #6.
Type 2: The press interface provides Ground when it
wants the guard t de-energize (go RED). Connect this
signal to Terminal #6 and attach nothing to Terminal #5.
You must install the jumper J8 (bottom board).
(see Installation Procedures, “Controller Module Setup”)
External Relay Check
Description: Allows the MicroGuard to monitor a pair
of external relays in series using the external relays
secondary set of DRY contacts, provided that they are
N.C. and captive contacts. This captive or force-guided
contact will maintain the identical position as the primary
set of contacts on the external relays, except that the
secondary set of contacts are wired up to signal the
reverse of the primary. (i.e., primary are N.O., secondary
are N.C.) The circuit looks for both closure and opening
of the external relay contacts. This system is the only
safe External Relay Check.
Application: Monitoring external relay contacts for
shorts or opens.
Usage: Follow Figure 1 for wiring your external relays.
You must rst activate this feature by using the spare
jumper and placing it across J19 labeled EXT (door
board). This system requires that both N.C. relay
contacts be wired in series then back to the terminals
inside the Controller Module. Relay contacts must be
DRY contacts. Both external relay contacts must be
closed when the light curtain is RED within .25 sec or an
Figure 1: Wiring External Relays
12 13 14 15
2
error will occur (this detects an open or a contact weld).
When the light curtain goes GREEN it will record the
opening of the external relay. If the light curtain goes
RED again without ever sensing the opening of the
external relays, an error will occur (this detects a short
or failed relay) and cause the light curtain to lock up and
must be powered down to clear the error. A Red LED
(D14) will light up when external contact is closed (see
Installation Procedures, “Controller Module Setup.” )
Captive Contact Denition: one pole inside the relay
always maintains the identical position to the other pole.
(i.e., if one pole contact welds closed, the other pole
remains closed even when the relay coil is de-energized.
NOTE: Use shielded cable for relay check inputs.
Standard Output Contacts (K1 & K2)
Description: Both K1 and K2 relays each have there
own relay driving circuitry and relay checking circuitry
and are fully independent of each other having there
own output terminals. The MicroGuard checks the
position of all the relays and shuts them all down if any
are found in the wrong position. In order for the system
to remain safe during a single failure of one relay, you
must be using the relays such that the second relay can
still shut the system down if the rst one ever fails. This
can either be by wiring both relays in series or using both
relays separately in two control circuits.
Usage: K1 and K2 have separate outputs and both
must be used either together in series with your stop
circuit or separately in two stop circuits. K1 and K2
outputs are N.O. and close when the curtain is GREEN
only.
Standard Features
Metal Box Controller Module
Fault Relay Output
Description: It will not change states due to curtain
blockage.
Application: Can be used to signal a remote station
of an unexpected machine shut down.
Usage: The fault relay provides a dry contact that is
open when good and closed when a fault or loss of
power occurs. Use the alarm contacts on the power
supply board. The dry contact is isolated up to 120VAC.
To Actviate: Install jumper on J17 (bottom board)
top 2 pins. Install jumper on J9 (door board) between
Latch and Close pins (left side). This feature will disable
remote latching. D21 will light up to show the relay is
active.
3
Optional Features
Metal Box Controller Module
Auto Blank [patent # 5,243,183]
Description: Allows user to program the exact size and
location of an object (i.e., a conveyor, table, work piece,
etc.) automatically and can detect any movement in the
object causing the light curtain to shut down.
Application: With the obstruction in place, turn the
key swith 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.
Standard Operation: If the obstruction is moved or
removed, the unit will issue a “MOVE” fault, but 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
reections 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, “Controller Module Setup”).
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.
The term “Auto Blank” is an abbreviation which stands
for Automatic Programmable Beam Blanking. Auto
Blanking is controlled by a multi-position keyswitch and
has three distinct modes of operation:
1) Must be reset if auto blank obstruction moves
or g uard 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) Must be reset if auto blank obstruction moves.
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 with oating blank. This mode works
like Mode 2 with the addition of a Floating Blank
which is set to allow a one beam float (see
Optional Features, Floating Blank”).
NOTE: If no obstructions were programmed in, the
guard will still allow a one beam 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 Depth Penetration
Factor D(pf) must be set to account for the one beam
oat (see Optional Features, “Floating Blank”).
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.
IMPORTANT: Place Auto Blank keyswitch into
OFF/RESET position and remove any obstructions
while aligning light curtain. Do not use Auto Blank
until light curtain is correctly aligned (see Installation
Procedures, “Alignment Procedure”).
The keyed selector switch is designated to be supervisory
controlled. After installation, the safety key should be
removed and controlled only by the safety supervisor or
authorized plant personnel.
4
Optional Features
Metal Box Controller Module
Emergency Stop Input(s)
Description: This option utilizes two normally-closed
emergency stop contacts to achieve a Catagory 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
Diagnostic Message Display to indicate an Emergency
Stop Input Failure.
Usage: Wire one N.C. contact between Terminal #1 and
#4. Wire the second N.C. contact between Terminal #3
and #4 (located on power supply board). This option
cannot be used with Mute-Out. Alterative option: Wire
rst N.C. contact between Terminal #6 and #4. Wire
second N.C. contact between Terminal #7 and #8. This
option cannot be used with Cincinnati or External relay
checking features. To reset ESTOP: Close both ESTOP
inputs, then use the latching relay reset input to clear
ESTOP fault (cycle closure between Terminal #2 and 4).
DeviceNet
Description: Optional external board that is mounted
to the door board inside the Metal Box Controller
Module. External board comes with its own directions.
™
Depth Penetration Factor is the number used to
compute the distance the light curtain should be placed
from the point of operation (see Installation Procedures,
“ANSI Standard B11.19-2003”).
Diagnostics Display:
RDY Keyswitch is in the lowest position (Floating
Blank is off).
FB Indicates Floating Blank active and the
number of blocked beams.
OBST A second object found in the curtain (only
one obstruction is allowed to oat).
Table 1a: .5” Beam Spacing Pylons
Display
Minimum
Object
Sensitivity, S
D(pf) Depth
Penetration
Factor
Max. Floating
object size
less than
Inches/Millimeters Inches/Millimeters Inches/Millimeters
RDY (oat off) 0.55” / 14mm 0.935” / 23.8mm 0.00” / 0.0mm
FB1 (1 beam oat) 1.18” / 30mm 3.077” / 78.2mm 0.45” / 11.4mm
FB2 (2 beam oat) 1.75” / 45mm 5.015”/129.2mm 0.95” / 24.1mm
FB3 (3 beam oat) 2.36” / 60mm 7.089”/180.2mm 1.45” / 36.8mm
FB4 (4 beam oat) 2.95” / 75mm 9.095”/231.2mm 1.95” / 49.5mm
FB5 (5 beam oat) 3.54” / 90mm 11.101”/282.2mm 2.45” / 62.2mm
FB6 (6 beam oat) 4.13” /105mm 13.107”/333.2mm 2.95” / 74.9mm
Floating Blank
Description: On a press brake, the Floating Blank permits
the work piece to be placed in the guarded area and can
be moved around as long as it does not exceed the object
sensitivity selected. A keyswitch by default allows for
zero, one, two, or three beams to be blocked anywhere
in the curtain as long as all the blocked beams are next
to each other. The customer may request different
blanking sizes for different applications. The Minimum
Object Sensitivity (MOS) and the Depth Penetration
Factor (DPF) change when the key switch position
is changed. The DPF is used to compute the safety
distance.
Location of the light curtain from the point of operation
must include the depth penetration factor D(pf)
equivalent to the beam spacing.
Minimum Object Sensitivity indicates the minimum
size required to cause the light curtain to detect an
object even if it is moving (oating). If the obstruction is
slightly smaller (less than .25”) than the stated number,
the light curtain may blink RED/GREEN when the
object is moving in the eld of view. If the obstruction
is smaller than the stated number by at least .25”, then
the light curtain will stay GREEN as long as there are
no additional obstructions.
Table 1b: 1” Beam Spacing Pylons
Minimum
Display
Inches/Millimeters Inches/Millimeters Inches/Millimeters
Rdy (oat off) 1.18” / 30mm 3.077” / 78.2mm 0.00” / 0.0mm
FB1 (1 beam oat) 2.36” / 60mm 7.089” /180.2mm 0.95” / 24.1mm
FB2 (2 beam oat) 3.54” / 90mm 11.101” /282.2mm 1.95” / 49.5mm
FB3 (3 beam oat) 4.72” / 120mm 15.113” /384.2mm 2.95” / 74.9mm
Object
Sensitivity, S
D(pf) Depth
Penetration
Factor
Max. Floating
IMPORTANT: Place Floating Blank keyswitch
in lowest position and remove any obstructions
while aligning light curtain. Do not use Floating
Blank until light curtain is correctly aligned (see
Installation Procedure, “Alignment Procedures”).
The keyed selector switch is designated to be
supervisory controlled. After installation, the safety
key should be removed and controlled only by the
safety supervisor or authorized plant personnel.
5
object size
less than
Loading...