Rockwell Automation 445L User Manual
GuardShield™ Micro 400
Safety Light Curtains
User Manual
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Important User Information
Because of the variety of uses for the products described in this publication, those responsible for the
application and use of this control equipment must satisfy themselves that all necessary steps have been
taken to assure that each application and use meets all performance and safety requirements, including
any applicable laws, regulations, codes and standards.
Reproduction of the contents of this copyrighted publication, in whole or part, without written permission
of Rockwell Automation, is prohibited.
Throughout this manual we use notes to make you aware of safety considerations:
The illustrations, charts, sample programs and layout examples shown in the guide are intended solely for
purposes of example. Since there are many variables and requirements associated with any particular
installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property
liability) for actual use based upon the examples shown in this publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and
Maintenance of Solid-State Control (available from your local Rockwell Automation sales oce), describes
some important dierences between solid-state equipment and electromechanical devices that should be
taken into consideration when applying products such as those described in this publication.
It is recommended that you save this user manual for future use.
Identies information about practices or circumstances that can cause an explosion in
a hazardous environment, which may lead to personal injury or death, property
damage, or economic loss.
Identies information that is critical for successful application and understanding of
the product.
Identies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss. Attentions help you identify a
hazard, avoid a hazard, and recognize the consequences.
SHOCK HAZARD
Labels may be on or inside the equipment (for example, drive or motor) to alert people
that dangerous voltage may be present.
BURN HAZARD
Labels may be on or inside the equipment (for example, drive or motor) to alert people
that surfaces may reach dangerous temperatures.
WARNING
IMPORTANT
ATTENTION
GuardShield™ Micro 400 Safety Light Curtain User Manual
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Conditions required for proper use of the
GuardShield Micro 400 Safety Light Curtain
Please make sure you read and understand these requirements before you select and install the
GuardShield Micro 400 safety light curtain. GuardShield safety light curtains are point of operation
and perimeter access safeguarding devices. These safety light curtains are intended to be used to
to provide point of operation and perimeter access safeguarding of personnel on a variety of
machinery.
GuardShield Micro 400 safety light curtains are presence sensing devices and will not protect
personnel from heat, chemicals, or ying parts. They are intended to signal a stop of hazardous
machine motion when the sensing eld is broken.
The GuardShield Micro 400 family of safety light curtains are general purpose presence sensing
devices which are designed to protect personnel working on or near machinery.
It is the responsibility of the employer to properly install, operate and maintain the product as
well as the machinery on which the GuardShield Micro 400 presence sensing device is installed.
The installation of GuardShield Micro 400 safety light curtains must comply with all applicable
federal, state, and local rules, regulations, and codes.
GuardShield Micro 400 safety light curtains must be properly installed by qualied personnel.
GuardShield Micro 400 safety light curtains can only be used on machinery which can be stopped
anywhere in its stroke or cycle.
GuardShield Micro 400 safety light curtains should never be used on full revolution clutched
machinery.
The eectiveness of the GuardShield Micro 400 safety light curtains depends upon the integrity
of the machine control circuit. The machinery on which the GuardShield Micro 400 presence
sensing device is installed should have control circuitry that is fail safe in design.
All stopping mechanisms for the machinery should be inspected regularly to ensure proper
operation. The protected machinery must have a consistent reliable and repeatable stopping
time.
ATTENTION
Failure to read and follow these instructions can lead to misapplication or
misuse of the GuardShield Micro 400 safety light curtains, resulting in personal
injury and damage to equipment.
Original instructions
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GuardShield™ Micro 400 Safety Light Curtain User Manual
Save these instructions for use at a future time.
Generally recognized technical regulations and quality
assurance system ISO 9000 are carefully applied during the
development and production of Allen-Bradley/Guardmaster
products.
This technical description must be followed when installing
and commissioning the GuardShield Micro 400. Inspection
and commissioning must be carried out by a qualified
person.
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Important Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Principles for Safe Use and Symbols Used. . . . . . . . . . . . . . . . . . 4
Specialist Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Range of Uses of the Device . . . . . . . . . . . . . . . . . . . . . . . .4
Proper Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Protective Notes and Protective Measures. . . . . . . . . 5
Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Principles of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
The GuardShield Light Curtain. . . . . . . . . . . . . . . . . . . . . .6
Cascading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Examples of Range of Use . . . . . . . . . . . . . . . . . . . . . . . . . .6
Safety Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Determining the Safety Distance. . . . . . . . . . . . . . . . . . . . 8
US Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OSHA Safety Distance Calculation Formula . . . . . . . . . . . . . . . . 8
The ANSI Safety Distance Formula. . . . . . . . . . . . . . . . . . . . . . . . . 8
European Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . 9
Minimum Distance from Reflecting Surfaces . . . . . . . . . . . . . . . 9
Installation and Mounting. . . . . . . . . . . . . . . . . . . . . . . . 10
Correct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Incorrect Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and Alignment Procedure. . . . . . . . . . . . . 11
Standard GuardShield Micro 400 . . . . . . . . . . . . . . . . . . . . . . . . . 11
Multiple GuardShield Micro 400 . . . . . . . . . . . . . . . . . . . . . . . . . .11
Cascaded GuardShield Micro 400. . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting and Alignment of Cascading GuardShield . . . . . . 13
Micro 400 IP69K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mounting Brackets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
External test signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bringing into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Corrective Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Instructions—Maintenance . . . . . . . . . . . . . . . . 18
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Six-Month Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Product Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Catalog Number Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . .21
GuardShield Micro 400 Products . . . . . . . . . . . . . . . . . . 21
Standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Cascades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
IP69K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
GuardShield Micro 400 Standard . . . . . . . . . . . . . . . . . . . . . . . . .23
GuardShield Micro 400 Cascades . . . . . . . . . . . . . . . . . . . . . . . . .23
GuardShield Micro 400 IP69K. . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GuardShield Micro 400 Special Safety Light Curtain Systems.
28
Systems with Reinforced Profiles. . . . . . . . . . . . . . . . . . . . . . . . . .28
Perimeter Systems (PAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Special Patchcords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Special Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
This manual covers the operation and installation
of the:
• GuardShield Micro 400 POC,
• GuardShield Micro 400 IP69K systems, and
• GuardShield Micro 400 special configurations in the appendix
IMPORTANT
Rockwell Automation reserves the right to make changes or
revisions to the material contained in this publication and cannot
be held liable for incidental or consequential damages resulting
from the furnishing, performance or use of this material.
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Original instructions
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GuardShield™ Micro 400 Safety Light Curtain User Manual
IMPORTANT
These installation instructions are designed to
address the technical personnel of the machine
manufacturer and or the installer of the safety
system regarding the proper mounting,
configuration, electrical installation,
commissioning, operation and maintenance of
the GuardShield Micro 400 safety light curtain.
These installation instructions do not provide
instruction for the operation of machinery to
which the GuardShield Micro 400 safety light
curtain is, or will be, integrated. Only qualified
personnel should install this equipment.
Introduction
The GuardShield Micro 400 is an economical three box
(transmitter, receiver and controller) Type 4 safety light curtain
offered in a small profile (15 x 20 mm (0.59 x 0.79 in.)) housing.
The protective heights are offered from 150…1200 mm
(5.9…47.24 in.) in 150 mm (5.9 in.) increments. The compact
housing size allows the GuardShield Micro 400 to be mounted in
areas where standard safety light curtains may not be able to be
mounted due to space constraints. It is also possible to recess the
GuardShield Micro 400 transmitter and receiver into machine
frames.
Micro 400 System
The Micro 400 requires a dedicated controller, either an MSR41
which has ON/OFF functionality or an MSR42 which offers
advanced functionality of fixed and floating blanking, manual
restart and muting. The MSR42 can also be used as a multi
function safety module, allowing the connection of additional
safety light curtains, safety laser scanner — any safety device with
PNP type outputs.
The Micro 400 transmitter and receiver are offered with 8-pin M12
connectors at the end of 500 mm (20 in.) integrated cables. The
patchcords to connect the transmitter and receiver to the
controller are the same part number and are offered in a variety of
lengths. These patchcords are configured on one end with M12
connectors which mate to the integrated pigtail connectors and
RJ45 connectors on the opposite end which plug into to the MSR
41 or MSR42 controllers.
Micro 400 Cascading
The GuardShield Micro 400 is also offered in a “cascadeable”
configuration. GuardShield Cascadeable Micro 400 safety light
curtains allow the interconnection of multiple segments of the
Micro 400 safety light curtain with a common pair of safety
outputs. This cascadeable configurability of the GuardShield
Micro 400 reduces overall system wiring and allows the
GuardShield Micro 400 to be fitted into a variety of applications
where the safety distances for mounting the light curtain may
allow personnel to stand between the light curtain’s sensing field
and the hazard or where multiple-sided guarding is required and
the use of corner mirrors is not possible.
A GuardShield Cascadeable Micro 400 safety light curtain system
is comprised of one or two pair of Cascadeable Micro 400 light
curtains as well as a standard Micro 400 pair as the last segment
pair in the cascaded system.
GuardShield Micro 400 cascaded pairs are offered in both 14 mm
(0.55 in.) and 30 mm (1.18 in.) resolutions in limited protected
heights. It is possible to mix 14 mm (0.55 in.) and 30 mm (1.18 in.)
resolution pairs in a Cascaded Micro 400 system.
When connecting two cascadeable segments together, the
resultant cable length between segments is 1000 mm (40 in.).
If an additional length between segment pairs is required,
Rockwell offers an M12 to M12 patchcord in 1, 3, and 5 m (3.3, 9.8,
and 16.3 ft) lengths (445L-AC8PC1 or 445L-AC8PC3).
Note: The maximum Cascaded Micro 400 system length can not
exceed 10 m (32.8 ft) as measured between the RJ45
connection at the MSR 41 or MSR 42 Controller to the last
beam in the standard Micro 400, including all cable
lengths. The maximum number of beams in a cascaded
Micro 400 system can not exceed 255 beams.
Micro 400 Washdown Option
The GuardShield Micro 400 is offered with the transmitter and
receiver sealed in clear polycarbonate tubes with an
environmental rating of IP69K. These IP69K Micro 400 light
curtains are factory sealed and are ordered as pairs. They are
offered in a 14 mm (0.55 in.) resolution in protected heights of
150, 300, 600, 900, and 1200 mm (5.9, 11.8, 23.6, 35.4, and 47.2 in.).
The required MSR41 or MSR42 controllers maintain the IP20 rating
and must be mounted in a suitable enclosure.
The Micro 400 IP69K transmitter and receiver are both offered
with
8-pin M12 connectors at the end of 500 mm (20 in.) integrated
cables. The patchcords to connect the transmitter and receiver to
the controller are the same part number and are offered in 1, 2, 3,
5, and 8m (3.3, 6.6, 9.8, 16.4, and 26.2 ft) lengths.
These patchcords are configured on one end with M12
connectors which mate to the integrated pigtail connectors and
RJ45 connectors on the opposite end which plug into to the
MSR42 or MSR41 controller.
Micro 400 Specials
In addition to the standard GuardShield Micro 400 configurations,
the GuardShield Micro 400 is also offered in special configurations
as described in the Appendix.
The GuardShield Micro 400 family of safety light curtains are
general purpose presence sensing devices, designed for use on
hazardous machinery providing point of operation (POC), as well
as, perimeter (PAC) detection.
Note: The standard GuardShield Micro 400 must always be the
last segment in a Cascaded Micro 400 system
A cascadeable pair of GuardShield Micro 400 light curtains has a
500 mm (20 in.) pigtail with a female M12 quick disconnect on the
bottom of the Micro 400 light curtain and a 500 mm (20 in.) pigtail
with a male M12 quick disconnect attached to the top of the
Micro 400 transmitter and receiver.
The GuardShield Cascadeable Micro 400 system operates as a
single light curtain pair with a common set of OSSDs. Each
segment pair is connected in series making the complete system’s
response time the sum of each segment pair, plus the response
time of the MSR41 or MSR42 and other safety devices in the stop
circuit.
Original instructions
Important Requirements
The GuardShield Micro 400 requires a dedicated controller. The
MSR41 controller is used for on/off applications and the MSR42
can also be used as a multi-functional safety module, allowing the
connection of additional safety light curtains, safety laser scanner,
or any safety device with two Output Signal Switch Devices
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GuardShield™ Micro 400 Safety Light Curtain User Manual
Identifies information about practices or
circumstances that can lead to personal
injury or death, property damage, or
economic loss. Attentions help you identify a
hazard, avoid a hazard, and recognize the
consequences.
Identifies information that is critical for
successful appilcation and understanding of
the product.
ATTENTION
The GuardShield Micro 400 must not be used
with machines that cannot be stopped
electrically in an emergency.
The safety distance between the GuardShield
Micro 400 and a dangerous machine
movement has to be maintained at all times.
Additional mechanical protective devices
have to be installed in a way that hazardous
machine elements cannot be reached without
passing through the protective field.
The GuardShield Micro 400 has to be installed
in a way that operators can only access the
hazard through the sensing field of the Micro
400.
Improper installation can result in serious
injury.
Never connect the outputs to +24V DC. If the
outputs are connected to +24V DC, they are in
ON-state and cannot stop hazardous spots at
the machine/application.
Never expose the GuardShield Micro 400 to
flammable or explosive gases.
Regular safety inspections are imperative (see
maintenance).
(OSSD) outputs, or two contacts, such as E-Stops and enabling
switches.
There are a number of operating modes that can be configured
with the MSR42 controller. EDM, Start/Restart interlock, fixed and
floating blanking and muting are possible.
Safety Precautions
Principles for Safe Use and Symbols Used
The following instructions are preventive warnings to ensure the
safe and proper operation of the GuardShield Micro 400 light
curtains. These instructions are an essential part of the safety
precautions and therefore have to be observed at any time.
Throughout this manual we use the labels ATTENTION and
IMPORTANT to alert you to the following:
ATTENTION
ATTENTION helps you
• Identify a hazard
•Avoid a hazard
• Recognize the consequences
IMPORTANT: Identifies information that is especially important
for successful application and understanding of the product.
IMPORTANT
Specialist Personnel
The GuardShield Micro 400 safety light curtain must be installed,
commissioned and serviced only by a qualified person. A qualified
person is defined as a person who:
• Has undergone the appropriate technical training
and
• Who has been instructed by the responsible machine operator
in the operation of the machine and the currently valid safety
guidelines
and
• Who has read and has ongoing access to these installation
instructions
4
Range of Uses of the Device
The GuardShield Micro 400 safety light curtain is classified as
electro-sensitive protective equipment (ESPE). It fulfills the
requirements of a Type 4 ESPE defined by IEC 61496-1 and CLC/TS
61496-2 and is, therefore, allowed for use with controls in safety
category Type 4 in compliance with EN ISO 13849, SIL CL3 in
accordance with EN62061 or up to PLe in accordance with EN ISO
13849.
These devices are suitable for:
• Point of operation protection (finger and hand protection)
• Hazardous area protection
Access to the hazardous point must be allowed only through the
protective field. The machine/system is not allowed to start as
long as personnel are within the hazardous area. Refer to the
“Examples of Range of Use” on page 6 for an illustration of the
protection modes.
Depending on the application, mechanical protection devices
may be required in addition to the safety light curtain.
Original instructions
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GuardShield™ Micro 400 Safety Light Curtain User Manual
Safety Notes
Please observe the following items in order to
ensure the proper and safe use of the
GuardShield Micro 400 safety light curtain.
POC:
The physical resolution of the GuardShield Micro 400 POC is
• 14 mm (0.55 in.) or
• 30 mm (1.18 in.).
The protective field height of standard GuardShield Micro 400 is
between 150 mm (5.91 in.) and 1200 mm (47.2 in.).
The maximum protective field width is 0…5 m (16.4 ft).
Cascadable Micro 400
The physical resolution of cascadable GuardShield Micro 400 POC
is
• 14 mm (0.55 in.) or
• 30 mm (1.18 in.).
The protective field height of cascadable GuardShield Micro 400 is
between 300 mm (11.82 in.) and 1200 mm (47.2 in.). The
maximum protective field width is 0…5 m (16.4 ft).
Micro 400 IP69K Option
The physical resolution of the GuardShield Micro 400 IP69K is
14 mm (0.55 in.). The protective field height of GuardShield Micro
400 IP69K is between 300 mm (11.8 in.) and 1200 mm (47.2 in.).
The maximum protective field width is 0…5 m (16.4 ft).
The Micro 400 IP69K option has the Micro 400 light curtains
factory sealed in polycarbonate enclosures.
The GuardShield Micro 400 require a controller to operate in
conjunction with one of the following safety controllers
• MSR41 ON/OFF functionality
• MSR42 multi-function module
Proper Use
The GuardShield Micro 400 safety light curtain must be used only
as defined in the “Range of Uses of the Device.” It must be used
only by qualified personnel and only on the machine where it has
been installed and initialized by qualified personnel.
If the device is used for any other purposes or modified in any
way, warranty claims against Allen-Bradley/Guardmaster shall
become null and void.
General Protective Notes and Protective Measures
IMPORTANT
The national/international rules and regulations apply to the
installation, use and periodic technical inspections of the safety
light curtain, in particular:
• Machine Directive 2006/42/EC
• Low Voltage Directive 2006/95/EC
• Use of Work Directive (2009/104/EC)
• The work safety regulations/safety rules
• Other relevant health and safety regulations
Manufacturers and users of the machine with which the safety
light curtain is used are responsible for obtaining and observing
all applicable safety regulations and rules.
• The notices, in particular the test regulations of these
installation instructions (e.g. on use, mounting, installation or
integration into the existing machine controller) must be
observed.
• The tests must be carried out by specialist personnel or
specially qualified and authorized personnel and must be
recorded and documented to ensure that the tests can be
reconstructed and retraced at any time.
• The installation instructions must be made available to the
user of the machine where the GuardShield Micro 400 safety
light curtain is installed. The machine operator is to be
instructed in the use of the device by specialist personnel and
must be instructed to read the installation instructions.
Product Description
This section provides information on the special features and
properties of the safety light curtain. It describes the structure
and functions of the unit, in particular the different operating
modes.
Please read this section before mounting, installing and
commissioning the unit.
Special Features
• Slim design 15 x 20 mm (0.59 x 0.79 in.)
• Built in diagnostic LEDs
•HW configurable with MSR41
• HW and SW configurable with MSR42
• M12 connector on 20 inch pigtails
• Maintenance free and cost effective
Principle of Operation
The GuardShield Micro 400 safety light curtain consists of a nonmatched pair of optic units, i.e., transmitter and receiver with the
same protected height and resolution. The controller
functionality of the Micro 400 light curtains are through a
separate control module.
• MSR41 ON/OFF functionality
• MSR42 multi-function module
The maximum distance between transmitter and receiver is
referred to as the protective field width or range. The protective
field height is the distance between the first and last beam in the
device.
The transmitter emits sequential pulses of infrared light which are
received by the GuardShield Micro 400 receiver and processed by
the connected controller. The synchronization of the timing of the
emission and reception of infrared light pulses is accomplished by
the connected MSR controller.
The connected controller has safety outputs [Output Signal
Switching Devices (OSSDs)] and nonsafety auxiliary outputs.
When the GuardShield Micro 400 transmitter and receiver are
properly connected and aligned, the OSSDs of the connected
controller are current sourcing +24V DC. Interruption of the
sensing field causes the controller to switch the sourced current
OFF (0V DC).
Original instructions
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GuardShield™ Micro 400 Safety Light Curtain User Manual
Operating mode as manual or automatic restart
(reset), EDM (external device monitoring),
blanked beams or overriding of the
GuardShield Micro 400 are controlled from the
connected safety controller (e.g. MSR42). For
details see user manual of the connected safety
controller.
Tra ns mi tt er
(white)
Receiver
(blue marking)
Restoring the GuardShield Micro 400 sensing field, (in Guard only
configuration) causes all safety outputs (OSSDs) of the connected
controller to switch to the active high state (resume current
sourcing +24V DC).
IMPORTANT
The GuardShield Light Curtain
The GuardShield Micro 400 safety light curtain consists of a
transmitter and a receiver.
Figure 1: Components of the GuardShield Micro 400
The protective field is between the bottom of the top end cap and
the area above the status LEDs.
The width of the protective field is derived from the length of the
light path between transmitter and receiver and must not exceed
the maximum rated width of the protective field 0…5 m (0…16.4
ft).
Cascading
The GuardShield, Micro 400 POC is also available in cascading
segments which allow a number of GuardShield Micro 400
transmitters and receivers to be interconnected. This product
configurability allows the GuardShield Micro 400 to protect
multiple sides of a machine or simply adds flexibility when
positioning the GuardShield Micro 400 in various applications.
Patchcords
Last segment pair
must be a standard
Micro 400 pair
Figure 2: Up to three GuardShield Micro 400 segments can be interconnected. For limitations
see text.
Standard GuardShield Micro 400 cascading segments are offered
in protective heights from 300…1200 mm (11.8…47.2 in.) in both
14 mm (0.55 in.) and 30 mm (1.18 in.) resolutions.
A maximum of three GuardShield Micro 400 light curtains can be
interconnected (maximum two cascades plus one standard
GuardShield Micro 400). The maximum number of beams in a
cascading system is 255 beams. The individual segments can have
mixed resolutions, i.e., 14 mm and 30 mm as long as the pairs
have the same protective heights and resolutions. The maximum
cable length from the control unit to the last beam can be 10 m.
Cascading segments cannot be used as standalone light curtain
pairs.
However, if using multiple cascaded pairs or only one, the last pair
in the cascaded system must be a standard GuardShield Micro
400 light curtain.
The following limitations need to be considered:
• A maximum of 255 light beams per controller
• 10 m maximum total length for light curtains, extension
modules and connection cable combined (Figure 2)
• Only a Rockwell patchcord (445L-AC8xxx) may be used
between the light curtains and the controller. A patchcord is
required to connect the M12 connector of the Micro 400 to
either the MSR41 or MSR42 controller. The patchcord has an
8-pin M12 on one end and an RJ45 connector on opposite end.
6
Examples of Range of Use
The GuardShield Micro 400 safety light curtain operates as a
proper protective device only if the following conditions are met:
• The control of the machine must be electrical.
• The controlled machine must be able to be stopped any where
in the machines stroke or cycle.
• The transmitter and receiver must be mounted such that
access to the hazard is only through the light curtain’s
protective field.
• If used as an access device, the restart button must be located
outside the hazardous area such that it can not be operated by
a person working inside the hazardous area.
• The statutory and local rules and regulations must be observed
when installing and using the device.
Original instructions
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IMPORTANT
Additional measures may be necessary to
ensure that the ESPE does not fail to danger
when other forms of light radiation are present
in a particular application (i.e., use of cableless
control devices on cranes, radiation from weld
spatter or effects from strobe lights).
The protective system must be tested for
proper operation after each and every change
to the configuration.
IMPORTANT
The response time of the GuardShield Micro 400
light curtain system is dependent on the
opera ting mode of the connected safety controller.
With the help of an optical interface (445LAF6150) it is also possible, to delay the response
time of the connected safety light curtain
system, when the GuardShield Micro 400 is
connected to the MSR42 controller.
If a controller unit is reconfigured, a new
configuration control document must be
printed and has to be kept close to the
controller. Also the corresponding control unit
has to be marked with the provided label.
IMPORTANT
When making changes to the configuration of
the GuardShield Micro 400 system, it is
necessary to recalculate the safety distance and
potentially relocate the GuardShield Micro 400
light curtains at the proper distance from the
hazard.
IMPORTANT
The device can be operated in a fixed and/or
floating blanking mode if an MSR42 controller
is used. The resolution will increase according
configuration control document. The light
curtain stick has to be clearly labeled with the
configured resolution.
Safety Functions
The GuardShield Micro 400 safety light curtain offers a variety of
functions, which are integral to the system.
Operating modes, functions and features of the GuardShield
system are activated through HW or SW of the corresponding
connected MSR41 or MSR42 controller. For details, please refer to
the manual of the attached controller.
IMPORTANT
Response Time
The standard response time of the light curtain (see MSR42)is
dependant on the physical resolution and the protective height and is
shown on the product label. The actual response time depends on
the connected control unit and its configuration. The response
time may be faster and can be taken from the corresponding
configuration control document, created from the configuration
software of the corresponding safety controller (e.g., MSR42).
The total light curtain system response time for a cascaded
system is the sum of the response times of each cascade plus the
response time of the standard light curtain. The declared
response times are worst case values.
A worst case response time is printed on the product label or in
the GuardShield Micro 400 Products section:
t
LC
t
C
t
Nx
Example of the total response time of a cascaded light curtain:
Response time of the standard Micro 400 light
curtain
Response time of the control unit (e.g., MSR42)
including any connected MSR45 relay modules
Sum of response times tNx of all additional
connected GuardShield Micro 400 light curtain
cascades (x = 1 or 2)
GuardShield™ Micro 400 Safety Light Curtain User Manual
A detailed explanation, including the corresponding safety
information, for configuring a MSR42 controller module may be
found in the "Configuration Tool" program manual.
Parameters which may lead to an increased response time:
• Stop delay time
•Blanking
•Muting
• Using an MSR45E relay expansion module
Blanking
There are some industrial applications where material must be fed
through the protective field (e.g., textile machines or small
assembly machines). This movement of material through the
GuardShield Micro 400’s sensing field in the standard safety mode
would result in an interruption and therefore bring the machine
to an unwanted stop. To avoid this it is possible to blank out
certain beams. This operating mode is generally known as “Fixed
Blanking.” Blanking functionality is available with the MSR42
controller and requires the optical interface module to program
this functionality.
Description Length/Resolution
+ tC + tN)
LC
)
N1
)
N2
)
LC
1200/14 mm 41.9 ms
300/14 mm 18.5 ms
600/14 mm 26.3 ms
1200/14-300/14-600/14 mm
Cascade 1 (t
Cascade 2 (t
Standard (t
System (t
Ta ble 1 :
The response time printed on the product label reflects the
double scan mode of the MSR41 and MSR42 controller.
Response time
88.7 ms + tC
Original instructions
With a MSR42 safety controller and an Optical Interface
(445L-AF6150) it is possible for authorized personnel to activate
different blanking modes. Blanking modes are broken down into
the following categories:
•Fixed blanking
•Floating blanking
7
GuardShield™ Micro 400 Safety Light Curtain User Manual
With the blanking function, the resolution and
the response time of the GuardShield Micro 400
light curtain system will be changed. If the
"Blanking" function is activated, a new, longer
response time and a new, larger resolution will
be present, which must be applied to the
calculation of the safety distance. The minimal
safety distance of the light curtain must always
be adapted to the actual operating mode. The
corresponding reaction time of a light curtain
without blanking is stated on the label of each
system. If blanking is configured, the new
reaction time, and the new resolution,
according to the configuration control
document must be entered in the appropriate
spaces on the supplied label, and attached to
the GuardShield Micro 400 light curtain (see
Figure 3). The labels are provided with the
GuardShield Micro 400 mounting kit.
Further information on "Blanking" may be
found in the “Configuration and Diagnostic
Tool” manual for the corresponding safety
controller (e.g. MSR42).
The GuardShield Micro 400 safety light curtains
must be mounted at a sufficient distance from
the pinch point or point of operation hazard to
ensure that the machine stops before a person’s
finger, hand, arm(s), or body reaches the hazard.
IMPORTANT
Regardless of the calculated safety distance,
GuardShield Micro 400 safety light curtains
should never be mounted closer than six inches
from the point of operation or pinch point
hazard.
IMPORTANT
Determining Stop Time: The measurement of
stopping time (Ts) must include the stopping
times of all devices in the stop circuit. Not
including all device and control system
elements when calculating Ts will result in an
inaccurate safety distance calculation.
IMPORTANT
Fixed blanking From beam................to beam.....
Floating blanking Resolution................................mm
Reduced resolution Reaction time...........................ms
Figure 3: Additional label for blanking. After configuring blanking, the label must be
attached and clearly visible on the receiver portion of the light curtain
IMPORTANT
Determining the Safety Distance
The light curtain must be mounted with proper safety distance
• From the point of danger
• From reflecting surfaces
In the United States there are two formulas that are used to
properly calculate the safety distance. The first, the OSHA formula,
is the minimum requirement for the calculation of the safety
distance. The second formula, the one recommended by Rockwell
Automation, is the ANSI formula, which incorporates additional
factors to be considered when calculating the safety distance.
OSHA Safety Distance Calculation Formula
The OSHA safety distance formula as specified in CFR Subpart O
1910.217 is as follows:
Ds = 63 X T
Ds Safety Distance in inches
63 Is the OSHA recommended hand speed constant in inches
Ts Is the total stop time of all devices in the safety circuit,
Note: The T
S
per second
measured in seconds. This value must include all
components involved in stopping the hazardous motion of
the machinery. For a mechanical power press it is the
stopping time measured at approximately the 90° position
of the crankshaft rotation.
number must include the response times of all
S
devices, including the response time of the safety light
curtain, the safety light curtain controller (if used), the
machine’s control circuit
to stop the hazardous motion of
and any other devices that react
the machinery. Not
including the response time of a device or devices in the
stop time calculation will result in insufficient safety
distance for the application. This may result in operator
injury.
US Safety Distance Formula
IMPORTANT
This distance, referred to as the safety distance, must be properly
calculated prior to determining the safety light curtain’s
protective height and mounting the light curtains on the
machine. Failure to properly calculate this safety distance may
result in operator injury.
8
Original instructions
The ANSI Safety Distance Formula
The ANSI safety distance formula, which is the Rockwell
Automation recommended formula, is as follows:
D
= K x (TS + TCS + Tr + Tbm) + D
S
Ds Minimum safety distance between the safeguarding device
and the nearest point of operation hazard, in inches.
K Hand speed constant in inches per second. The ANSI
standard value is 63 inches per second when the operator
begins reaching toward the point of operation hazard from
rest. NOTE: ANSI B11.19 1990 E4.2.3.3.5 states “The value of
the hand speed constant, K, has been determined by
pf
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various studies and although these studies indicate speeds
Safety distance S (Ds)
Protective field height
Point
Distance to avoid standing behind
of
danger
the safety curtain 75mm
of 63 inches/second to over 100 inches/second, they are not
conclusive determinations. The employer should consider
all factors, including the physical ability of the operator,
when determining the value of K to be used.”
Ts Stop time of the machine tool measured at the final control
element.
Tcs Response time of the control system.
GuardShield™ Micro 400 Safety Light Curtain User Manual
Note: T
and Tcs are usually measured by a stop time measuring
s
device.
Tr Response time of the presence sensing device (safety light
curtain) and its interface (MSR4x and MSR45E). This value is
generally stated by the device manufacturer or it can be
measured by the user.
Tbm Additional time allowed for the brake monitor to
compensate for variations in normal stopping time.
Dpf Depth penetration factor. It is an added distance to allow for
how far into the protective field an object, such as a finger
or hand, can travel before being detected. D
is related to
pf
the safety light curtain’s object sensitivity. Object sensitivity
is the smallest diameter object which will always be
detected anywhere in the sensing field.
Example:
In opto-electronic safeguarding, such as with a perpendicular
safety light curtain applications with object sensitivity (effective
resolution) less than 2.5 inches, the D
can be approximated
pf
based on the following formula:
(inches) = 3.4 × (Object Sensitivity – 0.276),
D
pf
but not less than 0.
European Safety Distance Formula
A safety distance must be maintained between the light curtain
and the point of danger. This safety distance ensures that the
point of danger can only be reached after the dangerous state of
the machine has been completely removed.
The safety distance as defined in EN ISO 13855 and EN ISO 13857
depends on:
• Stopping/run-down time of the machine or system. (The
stopping/run-down time is shown in the machine
documentation or must be determined by taking a
measurement.)
• Response time of the protective device, e.g. GuardShield Micro
400 (for “Response Time” see page 7).
• Reach or approach speed.
• Resolution of the light curtain and/or beam separation.
Figure 4: Safety distance from the point of danger
How to Calculate the Safety Distance S
According to EN ISO 13855 and EN ISO 13857:
-> First, calculate S using the following formula:
S = 2000 × T + 8 × (d – 14) [mm]
Where…
T = stopping/run-down time of the machine
+ response time of the protective device [s]
d = resolution of the light curtain [mm]
S = safety distance [mm]
The reach/approach speed is already included in the
formula.
-> If the result S is <= 500 mm (19.6 in.), then use the determined
value as the safety distance.
-> If the result S is > 500 mm (19.6 in.), then recalculate S as
follows:
S = 1600 × T + 8 × (d – 14) [mm]
Example:
Stopping/run-down time of the machine = 290 ms
Response time = 30 ms
Resolution of the light curtain = 14 mm (0.55 in.)
T = 290 ms + 30 ms = 320 ms = 0.32 s
S = 2000 × 0.32 + 8 × (14 – 14) = 640 mm (25.1 in.)
S > 500 mm (19.6 in.) therefore:
S = 1600 × 0.32 + 8 × (14 – 14) = 512 mm (20.1 in.)
Minimum Distance from Reflecting Surfaces
The infrared light from the transmitter may be reflected off of
shiny surfaces and be received by the system’s receiver. If this
condition occurs, it can result in an object not being detected
when it enters the GuardShield Micro 400 sensing field.
All reflecting surfaces and objects (e.g. material bins) must
therefore be located at a minimum distance a from the protective
field of the system. The minimum distance a depends on the
distance D between transmitter and receiver.
Original instructions
9
GuardShield™ Micro 400 Safety Light Curtain User Manual
Distance D (meters)
IMPORTANT
The installation of the GuardShield Micro 400
safety light curtain must be such that access to
the hazard is only possible through the sensing
field of the GuardShield. Auxiliary safeguarding
may be required in conjunction with the
GuardShield Micro 400 to meet this
requirement.
Operators cannot reach hazardous
machine parts without passing through
the protective field.
Operators must not step between the
protective field and hazardous machine
parts (by-pass prevention).
Operators can reach hazardous machine
parts without passing through the
protective field.
Operators can step between the
protective field and hazardous machine
parts.
Figure 5: Minimum dista nce from reflecting surf aces
How to Determine the Minimum Distance from the Reflecting
Surfaces:
-> Determine the distance D [m] transmitter-receiver
-> Read the minimum distance a [mm] from the graph:
The GuardShield Micro 400 safety light curtain is suitable for most
benign operating environments (IP54). Proper safety distance as
well as adequate protective height must be observed. For the
installation height and safety distance, please refer to
“Determining the Safety Distance” section on page 8.
Determine if the machinery, on which the GuardShield Micro 400
is to be mounted, meets the requirements as specified in the
beginning of this manual, i.e., machinery must be able to be
stopped anywhere in its stroke or cycle, consistently and
repeatedly.
Correct Installation
Figure 6: Graph, minimum distance from reflecting surfaces
The effective aperture angle for the GuardShield Micro 400
system is
± 2.5° at a mounting distance of > 3.0 m (9.8 ft). Calculate the
minimum distance to reflecting surfaces depending on the
distance between the transmitter and the receiver, using an
aperture angle of ± 2.5°, or take the appropriate value from the
following table:
Distance Between Transmitter and Receiver
(Range D) [m (ft)]
0.2…3.0 m (0.65…9.8 ft) 135 (5.31)
4.0 m (13.1 ft) 175 (6.88)
5.0 m (16.4 ft) 220 (8.66)
Minimum Distance
a [mm (in.)]
Table 2: Table, minimum distance from reflecting sur faces
Formula: a = tan 2.5° x D [mm]
a = minimum distance to reflecting surfaces
D = distance between transmitter and receiver
Installation and Mounting
This section describes the installation of the GuardShield Micro
400 safety light curtain.
A rigid and flat base, isolated against shock and vibration should
be selected to mount the GuardShield Micro 400 light curtain.
This in combination with the standard mounting bracket set will
keep the initial alignment during operation even in harsh
industrial environments.
Incorrect Installation
10
Original instructions
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