Rockwell Tools GUARDSHIELD SAFE 4 User Manual
Operation Manual
GuardShield
GuardShieldTM Safe 4
TM
Safe 4 PAC
Safety Light Curtain
GuardShield Safe 4 Operation Manual
2
Operation Manual GuardShield Safe 4
Please make sure you read and understand these requirements before you select and install
the GuardShield safety light curtain. GuardShield safety light curtains are point of operation
saf
eguarding devices. These safety light curtains are intended to be used to provide point of
op
eration safeguarding of personnel on a variety of machinery.
The GuardShield family of safety light curtains are general purpose presence sensing
devices which are designed to help protect personnel working on or near machinery.
The installation of the GuardShield safety light curtain must comply with all applicable
federal, state and local rules, regulations, and codes.
It is the responsibility of the employer to properly install, operate and maintain the product
as
well as the machinery on which the GuardShield presence sensing device is installed.
GuardShi
eld safety light curtains must be properly installed by qualified personnel.
GuardShi
eld safety light curtains are presence sensing devices and will not protect
personnel from heat, chemicals or flying parts. They are intended to signal a stop of
hazardous
machine motion when the sensing field is broken.
GuardShi
eld safety light curtains can only be used on machinery which can be stopped
anyw
here in it’s stroke or cycle.
GuardShi
eld safety light curtains should never be used on full revolution clutched
machinery.
The effectiveness of the GuardShield safety light curtains depend upon the integrity of the
machine control circuit. The machinery that the GuardShield presence sensing device is
ins
talled should have control circuitry that is fail safe in design.
All
stopping mechanisms for the machinery should be inspected regularly to provide proper
op
eration. 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 safety light
cu
rtains, resulting in personal
inju
ry and damage to equipment.
Conditions required for proper use of the
GuardShield Safety Light Curtain
3
GuardShield Safe 4 Operation Manual
Content
1. Approvals and Conformity 4
2. Introduction 5
2.1. System design 5
2.2. Special features 5
3. Applications 5
3.1. Typical applications 5
3.2. Applications restrictions 6
3.3. Application conditions 6
3.3.1. Corner mirrors 6
4. Principles of operation 7
4.1. Mode of operation 7
4.2. Intelligent Laser Alignment System ILAS 7
4.3. LED indicators 7
4.4. Perimeter systems 7
4.5. Muting 7
5. Installation 8
5.1. Regulations and standards 8
5.1.1. IEC Safety distance to danger point 8
5.1.2. North American Safety distance formulas 8
5.1.3. Height of protective field 9
5.1.4. Response time – light curtain 9
5.1.5. Distance to reflective surfaces 10
5.1.6. Multiple light curtain arrangement 10
5.2. Mechanical installation 10
5.2.1. Mounting brackets 10
5.2.2. Intelligent Laser Alignment System ILAS 10
5.2.3. Adjustment Procedure without ILAS 12
5.2.4. Adjustment Procedure with ILAS 12
5.2.5. Remarks to ILAS 12
5.2.6. Testing the protection field 13
5.3. Electrical Installation 13
5.3.1. Connection diagram 13
5.3.2. Test input to transmitter 14
5.3.3. Power supply 14
5.3.4. Bringing into operation 14
5.3.5. Outputs 14
5.3.6. Trouble shooting 15
6. Interfacing to safety devices 15
7. Dimensional drawings 19
7.1. System with integrated controller 19
8. Selection of a safety light curtain 20
8.1. Check list 20
8.2. Selection table 20
8.3. Accessories / Components 21
9. Inspection and service 2
9.1. Cleaning 22
9.2. Inspections 22
9.3. Decommissioning 22
10. Product labels 22
11. Technical Data 2
1. Approvals and Conformity
TÜV Rheinland Product Safety GmbH, performed the
CE - type examination according to the machinery
directive EC/98/37, appendix VI and the respective
standards ICE 61496.
The CE - conformity declaration and the product
approval certification (TÜV) is available at your
nearest ROCKWELL AUTOMATION dealer or on the
home-page www.Rockwell Automation.com.
All ROCKWELL AUTOMATION products are
developed and manufactured following generally
accepted rules in industry and in compliance with a
total quality management system ISO 9001: 2000.
ATTENTION
GuardShield Safe 4 systems are only a safety
protection device if all instructions in this manual
and in the related documents are carefully followed
and fully complied with. In addition the installer
is responsible to comply with all local laws and
standards.
ATTENTION
Failure to follow all instructions in this manual and
related documents may lead to serious injury or
death. Rockwell Automation cannot be held liable
for any injury or death due to the negligence of the
purchaser or installer.
IMPORTANT
This instruction manual is part of the light curtain
GuardShield Safe 4. It must be kept accessible
during the whole life cycle for everybody who is in
charge of installation, operation, maintenance and
2
safety control.
3
4
Operation Manual GuardShield Safe 4
Protection height
Intellig ent Laser Alig nment System ILAS
Intelligen t Laser Align ment System ILAS
Detection c apability
(resolution )
Operating range
2. Introduction
GuardShield Safe 4 safety light curtains are active
optoelectronic protective equipment AOPE type 4
with object detection capability of 14 mm or 30 mm.
GuardShield Safe 4 has built-in fully redundant selfmonitoring circuitry and complies to annex VI of the
European Machinery Directive EC/98/37 and IEC
61496 as a safety component. GuardShield Safe 4 is
a control reliability device as well as defined in ANSI
B11.19-1990, 5.5 and OSHA 29 CFR 1910.212.
2.1. System design
GuardShield Safe 4 light curtains consist of a
transmitter and a receiver (Figure 1).
The transmitter as well as the receiver of GuardShield
Safe 4 have a standard built-in intelligent laser
alignment system ILAS.
This allows a much easier adjustment during installation
and system testing compared to conventional safety
light curtains. The ILAS may also be used as a
vibration indicator at the installation.
Finger (14 mm) and hand protection (30 mm)
Large range with a compact profile type:
14 mm resolution: 0 m to 6 m
30 mm resolution: 0 m to 6 m
Tolerant to dust, soiling, pollution
Short cir
cuit protected semiconductor
outputs
Built-in d
iagnostic LEDs
Very compact design: 30 x 40 mm (1.2” x 1.6”)
Optical syn
chronisation, no electrical
cable needed between transmitter and
receiver
Ma
intenance-free and cost effective
3. Applications
3.1. Typical applications
GuardShield Safe 4 systems are used for (Figure 2):
Entry / exit safeguarding
Poin
Hazards area safeguarding
Combination of entry and area
safeguading
Combination of entry, area and point-of-
operation safeguarding
Typical areas of applications are:
Robotic assembly line
Weldi
Processing machinery
Rotation machines
Conveyor machines
Automated paint shops
Entry / exit of au
t-of-operation safeguarding
ng robots
tomatic storage facilities
Figure 1: Main system parameters
The products are a modular construction housed in a
very compact and sturdy extruded aluminium profile.
2.2. Special features
The outstanding features of the safety light curtain
systems of the GuardShield Safe 4 are:
Integrated laser alignment (ILAS)
M
ax. 256 beams per system
Typical markets are:
Automotive
Appara
tus
Semi conductor industry
Metal processing
Paper processing
Wood processing
Glass manufacturing
Textile industry.
5
GuardShield Safe 4 Operation Manual
3.2. Applications restrictions
GuardShield Safe 4 is not designed and approved for
any application in explosive EX or radioactive areas.
3.3. Application conditions
The safe application of the light curtain system
GuardShield Safe 4 needs certain precautions:
1. The control unit of the machine or system must
be able to be electrically stopped and the stop
time must be known.
2. The hazardous moving parts of the machine
must always be stoppable and must achieve a
safe position or complete standstill within the
specified stop time of the machine.
3. When installing GuardShield Safe 4, the only
way to access the hazard must be through the
sensing field of the GuardShield Safe 4.
Figure 3: Correct installation
Figure 4: Incorrect installation
For the professional installation and connection,
please consult the relevant laws and regulations.
The safety officer of the manufacturing facilities,
the local authorities (OSHA in USA, HSE in GB)
or the respective industry associations as well as
the intensively trained employees of ROCKWELL
AUTOMATION are available for any safety related
queries.
3.3.1. Corner mirrors
The protective field between transmitter and receiver
can be guided around a corner using a mirror to allow
safeguarding of two or three hazardous areas. Note
that using one mirror will help reduce max. operating
Figure 2: Typical Applications
6
range by approx. 15 %.
It is not recommended to use more than two mirrors
due to alignment difficulties that may occur.
Operation Manual GuardShield Safe 4
POWER
Transmitter
Power on
(orange)
POWER
Receiver
Power on
(orange)
Output active
(green)
Output inactive
(red)
OK
Normal operation
(green)
TEST
Test input
(red)
Optical
(IR light)
Optical
(IR light)
As accessories two types of mirrors are available,
with different mounting plates and sizes. Detailed
information is available from ROCKWELL
AUTOMATION.
4. Principles of operation
The transmitter sends coded infrared light pulses to
the receiver, which evaluates them. If an object e.g.
a finger (14 mm) or a hand (30 mm) penetrates the
protective field, the fully redundant solid state Output
Signal Switching Devices OSSD of the receiver switch
off to stop the machine. As soon as the protective field
is cleared, both outputs switch on again (automatic
restart).
4.1. Mode of operation
GuardShield Safe 4 operates in the guard only mode
with automatic restart. Other modes of operation e.g.
PSDI mode (break mode), muting, external relay
monitoring can be realized using external safety
devices.
4.2. Intelligent Laser Alignment System ILAS
The ILAS is a most convenient feature to make
alignment a pleasure. The ILAS can be activated at
any time during installation or operation. It provides
the possibility to check if the sensor is still perfectly
aligned. In addition it indicates any vibrations at the
mounting base.
4.3. LED indicators
The GuardShield Safe 4 PAC is a multiple beam
safety light curtain designed for perimeter or access
detection around hazardous machinery or equipment.
The Safe 4 PAC is offered in 2 or 3 beam configurations
with 360mm spacing between segments for a 2 beam
pair and 360mm spacing for 3 beam pairs. Both the 2
and 3 beam Safe 4 PACs have a 30 meter operating
range.
The clear front window of the Safe 4 PAC allows for
easy identification of the active sensing modules and
the Integrated Laser alignment system simplifies
the alignment of the Safe 4 PAC in long range and
complex applications.
The GuardShield Safe 4 PAC multi beam safety light
curtain may be used as an optical electronic fence;
detecting the presence of personnel as they pass
through the sensing field or for safe guarding access
to a hazardous area or machine process.
The protective field and the active elements
respectively, are clearly recognized as black surfaces
with the integrated optical lenses. The not monitored
areas (passive elements) are also clearly indicated as
yellow surfaces.
4.5. Muting
Muting of the GuardShield Safe 4 PAC is best
accomplished by connecting the Safe 4 PAC to an MSR
42 multi function safety module. The MSR 42 allows
two muting sensors to be connected for uni directional
muting. The muting sensors can be positioned on the
same side of the Safe 4 PAC in parallel for entry or
exit end muting of a machine process. The two muting
sensors may also be positioned in a crossed or X
configuration for bi directional muting.
Rockwell Automation offers a number of muting
solutions. Check with your local Rockwell Automation
office or Rockwell Automation authorized distributor for
muting application possibilities and muting application
notes.
Figure 5: LED Indicators
4.4. Perimeter systems
Perimeter systems are usually produced by means of
several single beam light barriers. But the flexibility
of the GuardShield Safe 4 system allows also the
production of vertical entry safeguarding according to
the standard EN 999. Such systems are composed of
active and passive elements in one compact profile.
The active length of each is 120 mm.
7
GuardShield Safe 4 Operation Manual
AT T EN T IO N : T he G uardShield safety light
cur tains m ust b e m ount ed at a sufficien t
distance from th e pinch point or po int o f
op erat ion hazar d to help ensure that th e mac hine
stops be fore a pe rson’s finger, hand, ar m(s),
or bo dy r eaches the hazar d.
5.1.1. IEC Safety distance to danger point
According to the standards, the GuardShield Safe 4
light curtain and the point of danger must be separated
by a defined safety distance. This minimum distance
safeguards that the danger point may only be reached
after the hazardous motion has stopped. The safety
distance (see also standards EN 294, EN 775, EN
811, EN 999) depends on
• Machine stop time
• Response time of the protective device (light
curtain + safety relays)
• Resolution of the protective device
• Approaching speed to the danger point
• Position of the AOPD
The approaching speed is dependent on safety
distance S as follows
S ≤ 500 mm, speed = 2 mm / ms
S > 500 mm, speed = 1.6 mm / ms
In cases of ‘vertical’ installation of the light curtains
within an industrial environment and a resolution of
Figure 6: Perimeter Systems
(2 and 3 beams), accord. to EN999 (1998)
5. Installation
5.1. Regulations and standards
The compliance with the fundamental health & safety
requirements as detailed in the EU Machinery Directive
EC/98/37 and control reliability according to OSHA 29
CFR 1910.212, ANSI B11.19 and ANSI B11.20 has to
be achieved with the correct implementation of safety
components. With the help of a hazard analysis as
laid out in EN 292 and EN 1050, a comprehensive
safety evaluation has to be made when designing and
planning machinery and machinery control equipment.
If Active Optoelectronic Protective Devices (AOPD)
are used, the required safety distances, sufficient
protective height and all application conditions must
be considered during the planning phase.
the light curtain system
mm), the safety distance
calculated according to the formula:
For 100 mm ≤ S ≤ 500 mm:
S = 2 mm / ms x T + 8 x (d - 14)
For S > 500 mm
S = 1.6 mm / ms x T + 8 x (d - 14)
S = Safety distance in mm
T = Total response time in ms
(machine stop time + Safe2+ / Safe4
response time + safety relay response time)
d = Resolution of GuardShield Safe 4 in mm
In the case of perimeter systems (chapter 4.5) or light
curtains with a resolution
is calculated for vertical mounted light curtains and
horizontal approach, according to the formula:
S = 1.6 mm / ms x T + 850 [mm]
More detailed information regarding safety distance
and safety height can be found in EN 999 or EN 294,
depending on mounting type of application.
5.1.2 North American Safety Distance Formulas
US Safety Distance Formula
d, (where 14 mm ≤ d ≤ 40
S to the point of danger is
d > 40 mm the safety distance
8
Loading...