XPSLCM1150
Safety light curtains mute
module
User’s Manual
08/2007
W917063480211A03
2
08/2007
Table of Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Chapter 1 Description of XPSLCM1150 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
At a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Description of XPSLCM1150 mute module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Description of Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjusting the safe mounting distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Technical ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Terminal assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation wiring example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
XPSLCM1150 visible indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operating states and corresponding outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cable lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setting XPSLCM1150 configuration switches. . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 2 Application examples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
At a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Application information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Two sensor muting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Three sensor muting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Four sensor muting system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Description of the bypass-allowed feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Chapter 3 Diagnostic display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
At a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
System diagnostic codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Mute operation diagnostic codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 4 Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
08/2007 3
4 08/2007
Safety Information
§
Important Information
NOTICE Read these instructions carefully, and look at the equipment to become familiar with
the device before trying to install, operate, or maintain it. The following special
messages may appear throughout this documentation or on the equipment to warn
of potential hazards or to call attention to information that clarifies or simplifies a
procedure.
The addition of this symbol to a Danger or Warning safety label indicates
that an electrical hazard exists, which will result in personal injury if the
instructions are not followed.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
DANGER
DANGER indicates an imminently hazardous situation, which, if not avoided, will
result in death or serious injury.
WARNING
WARNING indicates a potentially hazardous situation, which, if not avoided, can result
in death, serious injury, or equipment damage.
CAUTION
CAUTION indicates a potentially hazardous situation, which, if not avoided, can result
in injury or equipment damage.
08/2007 5
Safety Information
PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by
qualified personnel. No responsibility is assumed by Schneider Electric for any
consequences arising out of the use of this material.
© 2007 Schneider Electric. All Rights Reserved.
6
08/2007
About the Book
At a Glance
Document Scope The XPSLCM1150 Mute Module is an accessory device used to provide a safety-
rated muting function in conjunction with safety light curtains. Muting is defined as
«bypassing the protective function on safety related control system such as a safety
light curtain, during a pre-determined operation of a machine.»
Validity Note The data and illustrations found in this book are not binding. We reserve the right to
modify our products in line with our policy of continuous product development. The
information in this document is subject to change without notice and should not be
construed as a commitment by Schneider Electric.
08/2007 7
About the Book
Product Related
Warnings
WARNING
IMPROPER SET UP OR INSTALLATION.
Read all responsibilties and requirements listed below before installing the
XPSLCM1150 module.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
WARNING
UNINTENDED OPERATION.
Muting can disable the safety functions of a machine. The proper installation,
checkout and operation of a machine and muting system in accordance with all
applicable laws and standards, is critical to the safe operation of the machine.
Failure to comply with these instructions may result in severe injury to personnel..
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
WARNING
REDUCED PROTECTION LEVEL
When the XPSLCM1150 module is used with a Type 2 rated light curtain or another
Type 2 device, the overall system protection is reduced to Category 2.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Whether a specific machine application and XPSLCM1150 installation complies with
safety regulations depends on several factors, including the proper application,
installation, maintenance and operation of the XPSLCM1150 and its associated
sensors. These items are the responsibility of the purchaser, installer and employer.
The employer is responsible for the selection and training of personnel to properly
install, operate and maintain the machine and its safeguarding systems.
This product is designed to comply with:
IEC61496-1
ANSI B11.19 - 1990
EN954-1
8
08/2007
About the Book
The XPSLCM1150 should only be installed, verified and maintained by a qualified
person, as «a person or persons who, by possession of a recognized degree or
certificate of professional training, or who, by extensive knowledge, training or
experience, has successfully demonstrated the ability to solve problems relating to
the subject matter and work.».
Use of a muting function requires special precautions by the safety system machine
controller, installer, operator and employer. The following is only a partial list of
requirements when utilizing muting and is not intended to be a complete guide to
muting standards. The employer must contact the local safety authority for specific
requirements regarding the machine, machine controller and safety related control
system. Schneider provides the following information for user reference only and
makes no claim regarding the accuracy, completeness or effectiveness for a specific
application from any organization:
Muting of the light curtain is only permitted during the nonhazardous portion of
the machine cycle.
If the machine tool has reversing capability where a muting hazard is possible the
control shall include an automatic means through which muting is only permitted
in the forward direction.
Selection of the muting feature shall be by a key-operated switch under
supervisory control by the employer.
One or more visual indicator(s) shall be provided which are illuminated when the
light curtain is in a muted condition.
Any fault condition of the mute indicator(s) shall not allow the light curtain to enter
a mute condition.
The mute indicator(s) should be readily visible from any normal machine operator
position and from the position at which any adjustment of the muting is normally
carried out.
There shall be at least two, independent muting signal sources to be used with
the XPSLCM1150. A single, simple cam-operated limit switch is inadequate as a
muting signal source since its failure can remain undetected.
The proper selection, installation and orientation of the muting sensors are the
responsibility of the employer and installer.
The muting position (of the mute signal source) shall be secured against
unauthorized adjustment by provision of special tools, key entry, electronics
passwords and the positioning and mounting of associated limit switches.
The guarded machine must be able to stop anywhere in its cycle. Do not use an
XPSLCM1150 on a press with a full-revolution clutch.
The guarded machine must have a consistent stopping time and adequate
control mechanisms.
Severe smoke, particulate matter and corrosives may degrade the efficiency of
the optical safety devices. Do not use optical safety devices in this type of severe
environment.
All applicable governmental, state, local and employers rules, codes and
regulations must be satisfied. This is the employers responsibility.
08/2007 9
About the Book
All safety-related machine control elements must be designed so that a fault in
the control logic or failure of the control circuit does not lead to a failure or danger.
Additional guarding may be required for access to dangerous areas not covered
by the safety device system.
Perform the test procedure at installation and after maintenance, adjustment,
repair or modification to the machine controls, tooling, dies or machine, or the
XPSLCM1150 and safety device system.
Follow all procedures in this manual for proper operation of the XPSLCM1150
Mute Module.
The enforcement of these requirements is beyond the control of the manufacturer.
The employer has the sole responsibility to follow the preceding requirements and
any other procedures, conditions and requirements specific to his machinery.
User Comments We welcome your comments about this document. You can reach us by e-mail at
techpub@schneider-electric.com
10
08/2007
Description of XPSLCM1150
At a glance
Overview This chapter describes the XPSLCM1150.
1
What's in this
Chapter?
This chapter contains the following topics:
Topic Page
Description of XPSLCM1150 mute module 12
Description of Controls 14
Adjusting the safe mounting distance 19
Technical ratings 20
Terminal assignments 22
Installation wiring example 23
XPSLCM1150 visible indicators 28
Operating states and corresponding outputs 30
Cable lengths 33
Setting XPSLCM1150 configuration switches 34
Dimensions 36
08/2007 11
Description of XPSLCM1150 mute module
Front panel XPSLCM1150 Front panel
Features
The XPSLCM1150 Mute Module is a Category 4 safety device that interfaces
between a machine and certain protective safety devices to temporarily suspend
those devices during the non-hazardous portion of the machine cycle. It conforms
with EN 954-1 and has been certified to IEC 61496-1.
Fast 1 ms response time.
Works with either 1 or 2 safety devices (safety light curtain, safety controller, etc.)
Two-channel mute sensor inputs for 2, 3 or 4 PNP-type electro-optic sensors, or
limit switches or other sensing devices.
LED indications for individual input and output status.
Two-digit diagnostic display.
External mute indication for operator awareness.
12 08/2007
Applications
Automatic conveyer, stacker and palletizing machines.
Mechanical and hydraulic presses with automatic or manual feed with the muting
function is only used in the non-hazardous portion of the press cycle.
When the mute mode is disabled, the XPSLCM1150 outputs are the same as those
of the connected safety devices. Any entry into the guarded area will result in a stop
signal being sent to the guarded machine.
The XPSLCM1150 provides two "mute safety channels", each accepts a single
safety device, and either two, three or four mute sensors to activate the mute mode.
The mute mode is active when the correct sequence of mute sensor input signals is
achieved.
Each safety device output must be capable of supplying two 24 V (PNP) output
signals when the sensing field is clear. Mute sensors must have PNP type outputs,
sensor pairs are made-up of both "dark operate" and "light operate" sensors.
An indicator lamp for each safety channel is required to illuminate anytime the
XPSLCM1150 is in the mute state. These lamps must be visible to personnel in the
immediate area. The XPSLCM1150 monitors the lamp circuit to ensure the indicator
is operational.
08/2007 13
Description of Controls
IMPROPER INSTALLATION
Muting can disable the safety functions of a machine. The proper installation,
checkout and operation of a machine and muting system; in accordance with all
applicable laws and standards, is critical to the safe operation of the machine.
Failure to comply with these instructions may result in severe injury to personnel.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
WARNING
Power
requirements
The XPSLCM1150 requires a dedicated power supply of 24 V +/- 10 %, providing
a minimum of 2 amperes that meets the requirements of IEC61496-1 and
IEC60204-1, part number ABL8RPS24030 or equivalent.
System Common Return
For proper operation, the power supply common, (0 V ), must be connected to
each of the components in the system, including start/enable switches, EDM/MPCE
monitor, all OSSD and Auxiliary loads.
Chassis Ground or Protective Earth (PE) Connection
The chassis ground terminal of the XPSLCM1150 must be connected to the earth
ground of the installation site to ensure protection from electrical interference and
high voltage transients.
14 08/2007
XPSLCM1150
input devices
Sensor Inputs
The XPSLCM1150 module accommodates up to two independent channels
identified as Channel 1 & Channel 2. Each channel is comprised of one safety input
device and either two, three, or four mute input sensors.
Safety Input Devices (OSSD Inputs)
The XPSLCM1150 supports safety devices such as safety light curtains, safety
controllers or other safety-rated devices that provide two 24 V inputs into the
XPSLCM1150 whenever their protected area is clear.
Note: If using an input from a relay-type safety device, the two OSSD signals must
switch to the On and Off state within 300 msec of each other to be recognized as
proper OSSD inputs.
Mute Sensor Inputs
Muting is controlled by two or more separate input sources. These devices can be
optical, inductive or mechanical. Sensors S1A, S1C, S2A & S2C must have «DarkOn» PNP type outputs, nominal 24 V when Ok to mute. Sensors S1B, S1D, S2B
& S2D must have «Light-On» PNP type outputs, nominal 0 volts (no current flow)
when Ok to mute.
WARNING
IMPROPER SET UP OR INSTALLATION
You must have at least two independent mute sensors to activate the mute circuit.
A single device with multiple outputs such as single limit switch, is inadequate as a
mute sensor since its failure can remain undetected. Failure to comply with this
requirement may cause the muting circuit to activate at the incorrect part of the
machine cycle. Serious injury to personnel could result.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Mute Enable / Disable
A single selector switch is used to enable the XPSLCM1150 to detect the mute input
sensors, or disable the XPSLCM1150 from entering the mute state. When in the
disable position all muting errors are cleared from the diagnostic display.
08/2007 15
Start Switch
A push-button switch is required to reset the XPSLCM1150 from a Start/Interlock
condition, a fault interlock, or allow the Bypass feature to be used. The input is DIP
switch selectable for N/O or N/C operation.
WARNING
IMPROPER INSTALLATION OF THE START BUTTON
The Start switch shall be located outside of the safeguarded area such that it
cannot be reached from within the safeguarded area. The location must allow
complete visibility of the guarded area. The operator must ensure that the
safeguarding zone is clear before press & release of Start.This prevents the
machine or muting function from starting while personnel may be in the hazardous
area and avoids possible serious injury to personnel.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
16 08/2007
XPSLCM1150
outputs
WARNING
IMPROPER OUTPUT OPERATION
Muting is only allowed during the non-hazardous portion of the machine cycle! A
muting application must be designed so that no single component failure can
prevent the stop command or allow subsequent cycles until the failure is corrected.
(USA standard OSHA 1910.217(c)(3)(iii) (d), ANSI B11.19-1990 section 4.2.3.3.7)
Failure to comply with this requirement may cause the muting circuit to activate at
the incorrect part of the machine cycle, serious injury to personnel could be
resulted.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Output Signal Switching Devices (OSSD’s)
The XPSLCM1150 uses two solid-state outputs to send a stop signal to the guarded
machine. When the XPSLCM1150 is in the normal Run mode with the safety
device(s) clear, or in the Mute mode regardless of the safety device(s) status, the
OSSD outputs are turned on, sourcing 24 V @ a maximum of 625 mA.
Solid-state outputs achieve their safety ratings by periodically switching the output
state and verifying that the device did indeed switch. This operation is performed
periodically and is essentially transparent to the machine control circuit.
WARNING
IMPROPER OUTPUT SET UP
You Must Use both OSSD safety outputs from the XPSLCM1150! Each output
must be wired such that it is capable of stopping the guarded machine. Failure to
use both XPSLCM1150 safety outputs may prevent the machine from stopping,
resulting in possible severe injury to personnel.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Auxiliary Outputs
The XPSLCM1150 provides non-safety auxiliary outputs in both PNP and NPN
configurations. The PNP output source 24 V @ 500 mA, the NPN output sinks
up to 100 mA.
The auxiliary outputs are user selected to either follow the OSSD outputs, or activate
when a fault condition is detected.
08/2007 17
Mute Lamp Outputs 1 & 2
A visible mute lamp is required for each channel of the XPSLCM1150 to indicate the
mute function is active. Mute Lamp outputs are NPN current sinking inputs. Each
input is monitored to ensure 40-300 mA is flowing through the circuit when Mute is
activated. If the required current is not detected, then the XPSLCM1150 will not
enter the Muting state and will display diagnostic codes. If a current is detected when
the mute function is NOT activated, the XPSLCM1150 will enter the Lockout state.
WARNING
IMPROPER MUTE INDICATION
An indication that the protected area is muted must be provided and readily
observable to the machine operator. The mute lamp is an important warning device
to the machine operator, indicating that muting is active.
Failure to follow these instructions can result in death, serious injury, or
equipment damage.
Mute Indicator Auxiliary Outputs
Mute Auxiliary and Mute Armed functions are available as non-safety-rated outputs.
Each is configured as NPN sinking at a maximum of 100 mA. Mute Aux will indicate
whenever the XPSLCM1150 is in the Muting state. Mute Armed will indicate the
XPSLCM1150 is Mute Enabled.
EDM/MPCE Monitor
The XPSLCM1150 OSSD outputs are designed to connect directly to the machine
primary control element, or EDM/MPCE. EDM/MPCE monitoring is the capability to
directly monitor machine control devices and ensure their operation coincides with
the commands of the XPSLCM1150.
18 08/2007
Adjusting the safe mounting distance
Using the
XPSLCM1150
without
mechanical
relays
Using the
XPSLCM1150
with safety
mechanical
relays
The XPSLCM1150, when used without mechanical relays, will add 1 millisecond
(0.001 sec) to the overall response time of the safety control system. This will
increase the safe mounting distance of the safety sensing device. See the
installation manual of the safety sensing device for further information on calculating
the proper safeguarding distance.
The XPSLCM1150 itself adds 1 millisecond (0.001 sec) to the response time of the
safety control system. Additionally, you must also add the response time of the
mechanical relays to determine the total impact on the safety control system. This
will increase the safe mounting distance of the safety device.
The XPSLCM1150 should only be used with safety rated mechanical relays
employing force guided contacts. Contact the relay supplier for the safety rating
suitability and response time.
Refer to the installation manual of the safety sensing device for further information
on the safe mounting distance.
08/2007 19
Technical ratings
Specifications
Safety Category Type 4 per IEC 61496-1.
Response Time Less than 1 msec.
Input Power 24 V +/- 10%, 150 W max. (a) 24 V +/- 10%, 6 W (250mA)
min
Operating Temperature 0 °C to 55 °C.
Humidity Less than 95% Non Condensing
Storage Temperature -25 °C to 75 °C
Vibration In accordance with IEC 60068-2-6, 0.35mm displacement, 10 to
55 Hz.
Shock In accordance with IEC 60068-2-29, 10g, 16 ms pulses, 1000/
axis.
Enclosure IP-20
Outputs
Safety Outputs (OSSD) Two independent 625 mA (max.) current sources (PNP), 24 V
.
Auxiliary Outputs Auxiliary NPN output: 100 mA (max.) current sink, 24 V max.
Auxiliary PNP output: 500 mA (max.) current source, 24 V .
Mute-Lamp Two (NPN) Outputs 40-300 mA, 24 V Max. (b)
Mute Auxiliary NPN Output 100 mA (max.), 24 V Max
Mute-Armed NPN Output 100 mA (max.), 24 V Max
EDM/MPCE Monitor 24 V , 50 mA (sourced by XPS)
Inputs
Safety Devices(OSSD
Inputs)
Mute Sensor PNP 24 V (20 mA consumption)
Mute-Enable Selector Key-Operated Switch, Maintained Contacts
Start / Restart Either N/O or N/C Momentary Contact (10 mA consumption)
PNP 24V @ 50 mA Machine Run, 0 volt Machine Stop
(a) Power to the XPSLCM1150 must be provided from a dedicated power supply
that meets the requirements of IEC 60204-1 and IEC 61496-1, Schneider part
number ABL8RPS24100 (150 W) or equivalent maxi loads on outputs.(not included
NPN outputs, mute lamps, sensors and light curtains).
20 08/2007
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