SMARTSCAN INFORMATION

Transcription

1 SMARTSCAN INFORMATION SS-1K+ AUG05 LIGHT CURTAINS HANDBOOK Smartscan Ltd, Pywell Road, CORBY, NN17 5XJ, UK, Tel: +44 (0) , Fax: +44 (0) , ISSUE 1

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3 LIGHT CURTAINS CONTENTS Page INTRODUCTION 3 INTERFACE 5 SPECIFICATION 6 LIGHT CURTAINS 7 LIGHT CURTAINS 30mm DETECTION CAPABILITY 8 LIGHT CURTAINS 40mm DETECTION CAPABILITY 9 LIGHT CURTAINS FOR PERIMETER GUARDING 10 MULTIFUNCTION SAFETY UNITS 11 ACCESSORIES 37 SAFETY SYSTEM SOLUTIONS 49 INSTALLATION SHEET 51 APPENDIX 1 65 APPENDIX

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5 INTRODUCTION Plus Safety Light Curtains In the past safety light curtains have been very expensive, negating their use for many machine safeguarding applications. Smartscan 1000 Plus safety light curtains are offered at exceptionally low cost and as such it is now more cost effective to use light curtains rather than conventional protective screens or fences, thus opening many new areas of application for light curtains throughout industry. The 1000 Plus system incorporates many unique design features that have enabled Smartscan to severely reduce manufacturing costs. The result, a high quality range of safety light curtains at low cost. As endorsement to its reliability each 1000 Series Plus system comes complete with a full two years warranty. Connecting the 1000 Plus light curtain to a machine control system couldn t be easier. A 24V DC supply is required to the transmitter and receiver units. Connect the two electronic output switches to the machine stop circuit and the installation is complete. There is NO interconnection cable between the transmitter and receiver units and NO control unit to install. The 1000 Plus has 22 standard models in the range. Detection heights vary from 180mm up to 1240mm in 150mm increments Plus light curtains detect objects of 30mm and 40mm and therefore suitable for hand detection. Two, three and four beam models, for safeguarding around the perimeter of a machine are also available. The 1000 Plus has passed Type Examination from European Notified Body, AMTRI VERITAS to the Machinery Directive. Certification provides users with an assurance that the 1000 system meets all relevant legislative safety requirements.

6 4 INTRODUCTION Step forward safely to greater productivity A technically advanced light curtain, offering outstanding cost effectiveness, opening the gates to new opportunities in machine guarding Typical machine safeguarding applications include: Robots Packaging machines Special purpose equipment Process machinery Injection moulding machines Transfer lines Automated warehouses Textile machinery Electronic component assembly lines Bottling and filling machines 1000 Plus light curtains comply with European and International Safety Standards BS EN and BS IEC Type 2. They are normally used where the risk assessment for the safety related parts of a control system, as indicated in BS EN 954-1, determines a requirement up to and including Category 3 control equipment. EC Type Examined Safety integrity classification EN Category 3 Simple installation and alignment Up to 10m scanning range (model dependant) Two year manufacturers warranty Features Slim-line enclosures No range setting Continually self monitoring system Diagnostic indicators Dual channel, fail-safe electronic outputs (control reliable) Interface cables included Two part system Flexible mounting options

7 INTERFACE 5 (Output Signal Switching Devices) OSSD1 and OSSD2 (F6) Two independent electronic switches provide the fail-safe outputs for connection to the machine control system. Outputs ON = 24V DC, Outputs OFF = 0V DC. Maximum switching current for each output = 0.5A@24V. Cable colours for output switches Black = OSSD1, White = OSSD2. Power Supply A regulated power supply is required: +24V DC, up to 1.5A dependent on OSSD loads ±20%. Cable colours for power supply connections at both transmitter and receiver: Brown = +24V DC, Blue = 0V DC. Indicators F1 - Yellow flashing indicators on the (TX) transmitter column indicates the unit is powered-up and the electronic system is operational. (There is a yellow indicator associated with every block of 6 beams in the light curtain). F2 - Yellow flashing indicators on the (RX) receiver column indicates that communication is established between transmitter and receiver, and the light curtain is correctly aligned. Yellow steady indicators on the (RX) receiver column indicates that the light curtain is incorrectly aligned or the light curtain detection zone is blocked. F3 - Green LED indicator on the (RX) receiver unit illuminates when the electronic output switches, OSSD1 and OSSD2 are ON (only when the light curtain detection zone is clear of any obstruction). F4 - Red LED indicator on the (RX) receiver unit illuminates when the electronic output switches, OSSD1 and OSSD2 are OFF e.g. when the light curtain detection zone is blocked. If the Red LED indicator is flashing the system is in lockout. To recover from a lockout condition disconnect the transmitter and receiver from the power source and then re-apply.

8 6 SPECIFICATION 1000 Plus Light Curtains Number of beams 2 48 Object detection 30mm, 40mm plus 2, 3 & 4 beam perimeter systems Detection zone 180mm to 1240mm Range m (model dependent) Light type Infra-Red 880nm Response time 40ms Operating 0 C to +50 C temperature Light curtain IP65 (HxWxD) Hx28x41mm enclosure Status indicators TX - Yellow (flashing) TX OK RX - Red (steady) OSSDs OFF - Red (flashing) system lockout RX - Green OSSDs ON RX - Yellow (flashing) TX to RX communications established RX Yellow (steady) incorrectly aligned or detection zone is blocked Power supply 24V DC 1.5A ± 20% reg requirement Current consumption 200mA transmitter + 200mA receiver (OSSD LOAD ADDITIONAL) Light curtain 5m cables connected to both TX & RX units connection Finish Polyester powder coated (yellow) Classification BS EN Type 2 BS IEC Type 2 BS EN Category 3 Warranty Two Years OUTPUTS Safety Outputs OSSD1 & OSSD2 2 x electronic switches, each rated at 24V DC, 500mA - ON = 24V DC, OFF = 0V standing current (min 20mA) amtri veritas Type Examined Certificate Number: AV EC 1926 Certificate Number: CC/TCF/00012 Report Number: 288/ FM27828

9 LIGHT CURTAINS 7 The 1000 Plus light curtain represents a major step forward in light curtain design. The system continually selftests itself and de-energises its output if a fault is detected This eliminates the need for a test input. By utilising two safety outputs 1000 Plus Series light curtains have a far higher safety integrity than those with a single output. Furthermore, the outputs are monitored by the light curtain (short circuit proof) and therefore are termed control reliable and meet the safety requirements of BS EN Category 3. Mechanical features The light curtain enclosure is of aluminium construction finished in a yellow polyester powder coating. An adapter bracket set is provided enabling the light curtain to be mounted from the column ends using a transmitter and receiver mounting kit ( ). The enclosures are totally sealed making them suitable for use in wet environments. Each enclosure has integral M6 threaded slots down the sides and back so that it may be mounted from any face with no special fixtures.

10 8 LIGHT CURTAINS Each enclosure has integral M6 threaded slots down the sides and back so that it may be mounted from any face with no special fixtures. Light Curtains 30mm Detection Capability Range 0.5m to 5m Model number Number of beams Detection zone (K) mm Overall length (M) mm Weight (TX + RX) Kg Includes 5m transmitter cable & 5m receiver cable. Note: 1000 Plus guards over 1300mm long will not be available from stock. Please contact us direct on requests for guards above this length.

11 LIGHT CURTAINS 9 Light Curtains 40mm Detection Capability Range 4m to 10m Model number Number of beams Detection zone (K) mm Overall length (M) mm Weight (TX + RX) Kg Includes 5m transmitter cable & 5m receiver cable. Note: 1000 Plus guards over 1300mm long will not be available from stock. Please contact us direct on requests for guards above this length.

12 10 LIGHT CURTAINS Light Curtains Perimeter Guarding Range 0.5m to 5m Model number Beam pitch Overall length (M) mm Weight (TX + RX) Kg mm mm mm Includes 5m transmitter cable & 5m receiver cable. Light Curtains Perimeter Guarding Range 4m to 10m Model number Beam pitch Overall length (M) mm Weight (TX + RX) Kg mm mm mm Includes 5m transmitter cable & 5m receiver cable.

13 MULTIFUNCTION SAFETY UNITS 11 Smartscan 1000 Plus Series light curtains incorporate two fail-safe, electronic output switches. If there is a requirement for relay output switching a Multifunction Safety Unit (MFU) may be used. The MFU Type is effectively a safety relay module, and, just like any other proprietary safety relay it provides relay output switching contacts and a choice of control functions, for example auto/manual reset and external device monitoring. An, MFU Type has much more to offer. Not only does it provide inputs for the emergency stop function but it also has two further sets of inputs for connecting up to two light curtains. The monitored output switching contacts are rated at 250V AC, 2A with two additional electronic outputs for status indication etc. Other features include selectable auto/manual reset modes, external device monitoring (EDM) and LED indicators for all input and output channels. The unit is automatically self testing and with simultaneous monitoring between related channels it ensures the unit is suitable for Category 4 control systems as defined in BS EN

14 12 MULTIFUNCTION SAFETY UNITS MFU Type further enhances the Smartscan range of multifunction safety units. The unit incorporates a light curtain muting facility, designed specifically for those systems that require the light curtain detection zone to be inhibited, or muted, during specific periods of a machine s operating cycle. Muting allows access through the light curtain for the passage of material or for a person to load and unload parts through the light curtain during safe periods without interrupting the machines operating cycle. MFU Type provides a dual channel safety monitored input for automatically muting the light curtain during safe periods of machine operation. Mute signals are often derived from the machine control system or from external sensors or switches. It also provides dual inputs for a Series 1000 light curtain and a two channel emergency stop system. The monitored safety output relay switches are rated at 250V AC, 2A, for connection to a power-switching device or directly to a machines final control element. Two electronic outputs are provided one for guard status indication and the other to indicate a mute on condition. Both are for direct connection to a PLC or indicator lamps etc. Other features include external device monitoring (EDM) and LED indicators on all inputs and outputs. Monitoring between associated input channels ensures the unit is suitable for Category 3 control systems as defined in BS EN MFU Type is an output switching expansion module. The unit provides 8 N/O and 2 N/C switching contacts each rated at 250V AC 4A. The expansion module operates in conjunction with MFU s , , and to provide additional output switching contacts that may be required for a particular application. MFU Type has been designed specifically for entry/exit applications where the light curtain is positioned across a conveyor. The control module provides two safety monitored inputs for signals that automatically mute the associated light curtain during safe periods of the machine operation. Mute signals are usually derived

15 MULTIFUNCTION SAFETY UNITS 13 from external PE sensors, limit switches or, the machine control system. For additional integrity a 3 rd mute input channel (mute enable) is provided. This input is often connected to a conveyor run signal to enable a mute condition, ONLY when the associated conveyor is running. The also provides dual inputs for a Series 1000 light curtain and a guard override function. The override facility enables the light curtain s safety output relays to be negated for a short period. This facility is essential in the packaging industry, for light curtains that are positioned across conveyors that prevent access to personnel but allowing pallet loads to pass through. The monitored safety output relay switches are rated at 250V AC, 2A, for connection to a power-switching device or directly to a machines final control element. Electronic outputs are provided, one for guard status indication and the other for mute indication. The MFU also includes external device monitoring (EDM) and visual indicators on all inputs and outputs. Monitoring between associated input channels ensures the unit is suitable for Category 3 control systems as defined in BS EN

16 14 MULTIFUNCTION SAFETY UNITS Multifunction Safety Unit Type Status Indicators Function Colour Status Power Red LED ON when power ON Inputs Green LED ON when input ON EDM Amber ON when EDM active

17 MULTIFUNCTION SAFETY UNITS 15 Features - Type Dual safety inputs for connecting the light curtain Safety monitored output relays. Contacts rated at 250V AC, 4A Auxiliary electronic output for status indication etc. Reset function External Device Monitor (EDM) LED status indicators Din rail mounting - 70mm enclosure Built to BS EN Category 3 Specification - Type Response time Operating temperature Enclosure rating Enclosure Power supply requirements Current consumption 10ms max 0 to +50 C IP40 70mm DIN rail mounting (HxWxD) 90x70x60mm 24V DC ± 10% reg 100mA (NO LOAD) Status indicators LEDs, power on + lockout + output Classification BS EN Category 3 INPUTS Dual safety monitored inputs 24V DC = ON, 0V = OFF External device monitoring (EDM) Use voltage free switch contacts (N/O & N/C) Reset function (selectable) Use voltage free switch contacts OUTPUTS Safety output relays Auxiliary solid-state switch (non safety) 2 x fail safe change over contacts, each rated at 250V AC, 4A 1 electronic output switch, rated at 24V DC, 500mA Electrical connections - Type Terminals A1 and A2 Power supply input - Connect a suitably stabilised 24V DC power supply to terminals A1 = +24V DC and A2 = 0V DC. The current consumption of the MFU with no load applied on the output switching terminals is 100mA. Note: When in a tripped condition there will be no 24V DC supply to the transmitter head on terminal B1.

18 16 MULTIFUNCTION SAFETY UNITS Terminal A3 and A4 Automatic reset mode - Link terminal A3 to terminal A4 if automatic reset is required. In the automatic reset mode no connections are required at terminal B7 and terminal B8. To simplify set-up link A3 to A4. Remove link after set-up if latched mode is required. Terminals A5 and A6 External device monitor (EDM) - Auxiliary change over contacts, from an external power-switching device are connected across terminals A5 and A6. The monitoring circuit checks that the power switching devices both de-energise at the same time the MFU safety output switches de-energise. If one of the power switching devices fail to de-energise at this time the MFU will trip. Note: If the EDM circuit is not used it is necessary to link terminals A5 to A6 otherwise the system will default into a lockout condition. If connection is missing between A5 & A6 there will be no 24V DC supply to the transmitter head on terminal B1 Terminals A7 and A8 no connections Terminal A9 Auxiliary electronic switching output - The Auxiliary switching output should only be used for non-safety critical applications. For example connecting an indicator lamp or as feedback to a PLC to the safety outputs have de-energised. The auxiliary output, derived from safety input OSSD2, energises when output switches 1 and 2 energise. Auxiliary output ON = 24V DC and OFF = 0V DC. Terminal A10, A11 and A12 Safety output 1 switch contacts - Terminals A10, A11 and A12 are the output connections to safety relay 1 changeover switching contacts. Terminal A11 is the common output, with terminal A12 as the normally open switch and A10 as the normally closed switch. Normally, terminals A11 and A12 would be connected to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element. Terminals B1 24V DC supply- + 24V DC output for connecting to the light curtain Transmitter head (TX).

19 MULTIFUNCTION SAFETY UNITS 17 Terminals B2 0V DC supply - 0V DC output for connecting to the light curtain TX. Terminals B3 24V DC supply V DC output for connecting to the light curtain RX. Terminals B4 0V DC supply - 0V DC output for connecting to the light curtain RX. Terminal B5 and B6 light curtain inputs (OSSD1 and OSSD2) Connect the electronic output switches (OSSD1 and OSSD2) of a 1000 Plus Series light curtain to terminals B5 and B6 respectively. Terminals B7 and B8 Reset - If the MFU is required to be in the latch mode a suitable switch should be connected between terminal B7and terminal B8. If the safety output relays de-energise a depression of the switch is required to re-energise the output switches to an ON condition. The MFU s safety output switches will only re-energise when the reset switch is depressed and then released. If the MFU is required to operate in an automatic reset condition do not connect a switch to terminals B7 and B8. However, it is necessary to link terminal A3 to terminal A4 before an automatic reset condition can be established. Terminals B9 No connections Terminal B10, B11 and B12 Safety output 2 switch contacts - Terminals B10, B11 and B12 are the output connections to safety relay 2 changeover switching contacts. Terminal B11 is the common output, with terminal B12 as the normally open switch and B10 as the normally closed switch. Normally, terminals B11 and B12 would be connected to one channel of a machine s stop circuitry. For example, via an external power switching relay or, directly to a safe PLC input or to a machines final control element. Connect terminals A5 and A6 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or, directly to a safe PLC input or a machines final control element. Note: If a single channel safety circuit is used link terminals A12 and B11. Terminals A11 and B12 are then connected to the machine s safety circuit. Connecting in this way links safety output switch 1 and safety output switch 2 in a series configuration.

20 18 MULTIFUNCTION SAFETY UNITS Multifunction Safety Unit Type Status Indicators Function Colour Status Inputs Green LED ON when input ON Outputs Green LED ON when output ON Reset Amber LED ON, when reset input ON (Auto reset mode - LED on continuously) EDM Amber ON when EDM inputs are active Status Red + Red Steady ON = system ok Flashing ON /OFF = lockout

21 MULTIFUNCTION SAFETY UNITS 19 Features - Type Two dual safety inputs for connecting up to 2 light curtains Dual inputs for connecting the emergency stop circuit Safety monitored output relays. Contacts rated at 250V AC, 2A Auxiliary electronic output switches for status indication etc Reset function External Device Monitoring (EDM) LED indicators for all inputs and outputs DIN rail mounting 70mm enclosure Automatic self testing Simultaneous monitoring between related channels Built to BS EN Category 4 Specification - Type Response time 25ms max Operating temperature Enclosure rating Enclosure Power supply 0 to +50 C IP40 70mm DIN rail mounting (HxWxD) 90x70x60mm 24V DC ± 10% reg Current consumption 150mA (NO LOAD) Status indicators LEDs for all inputs and outputs Classification BS EN Category 4 INPUTS Dual inputs for light curtain 1 Dual inputs for light curtain 2 Dual inputs for emergencystop circuit External device monitoring (EDM) Reset function (selectable) OUTPUTS Safety output relays Auxiliary solid-state switches (non safety) 24V DC = ON, 0V = OFF - Disparity between related channels = 100ms max. Use voltage free switch contacts - Disparity between channels = 100ms max. Use voltage free switch contacts (N/C) 24V DC = ON, 0V = OFF 2 x N/O - fail safe contacts, each rated at 250V AC, 2A 2 electronic output switches, each rated at 24V DC, 500mA

22 20 MULTIFUNCTION SAFETY UNITS Electrical connections - Type Terminals A1 and A2 Power supply input - Connect a suitably stabilised 24V DC power supply to terminals A1 = +24V DC and A2 = 0V DC. The current consumption of the MFU with no load applied on the output switching terminals is 150mA. Terminals A3 and A4 External device monitor (EDM) - Normally closed switch contacts, in series from the external power switching devices are connected across terminals A3 and A4. The monitoring circuit checks that the power switching devices both deenergise at the same time the MFU safety output switches deenergise. If one or both of the power switching devices fail to deenergise at this time the MFU goes into a lockout condition, turning all output switches off. To reset from a lockout condition it is necessary to remove the 24V DC supply from the MFU and then re-apply. If the EDM circuit is not used it is necessary to link terminals A3 to A4 otherwise the system will go to a lockout condition at the next demand upon the safety system. Terminals A5 and A6 Safety output 1 switch contact - Connect terminals A5 and A6 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element. Terminals A7 and A8 Safety output 2 switch contact - Connect terminals A7 and A8 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element. If a single channel safety circuit is used link terminals A6 and A7. Terminals A5 and A8 are then connected to the machine s safety circuit. Connecting in this way links safety output switch 1 and safety output switch 2 in a series configuration. Terminal A9 No connection Terminal A10 Auxiliary electronic switching output 1 - The Auxiliary switching output should only be used for non-safety critical

23 MULTIFUNCTION SAFETY UNITS 21 application. For example connecting an indicator lamp or as feedback to a PLC to confirm the safety outputs have de-energised. Terminal A11 Auxiliary electronic switching output 2 - The Auxiliary switching output should only be used for non-safety critical applications. For example connecting an indicator lamp or as feedback to a PLC to confirm the safety outputs have de-energised. Auxiliary outputs 1 and 2 both energise when safety output switches 1 and 2 energise and both de-energise when the safety outputs de-energise. Auxiliary outputs ON = 24V DC and OFF = 0V DC. Terminal A12 Reset - If the MFU is required to be in the latch mode a suitable switch should be connected between terminal A12 and the 24V DC supply. If the safety output relays de-energise a depression of the switch is required to re-energise the output switches to an ON condition. The MFU s safety output switches will only re-energise when the reset switch is depressed and then released. If the MFU is required to operate in an automatic reset condition do not connect a switch to terminal A12. However, it is necessary to link terminal A12 to terminal A10 before an automatic reset condition can be established. Terminal B1 and B2 light curtain 1 inputs (OSSD1 and OSSD2) - Connect the electronic output switches (OSSD1 and OSSD2) of a 1000 Plus Series light curtain to terminals B1 and B2 respectively. Note: An internal circuit monitors disparity between the two input channels. If the inputs do not switch together (within 100ms of each other) the system will go into a lockout condition. Terminal B3 and B4 light curtain 2 inputs (OSSD1 and OSSD2) - Connect the electronic output switches (OSSD1 and OSSD2) of a 1000 Plus Series light curtain to terminals B3 and B4 respectively. Note: An internal circuit monitors disparity between the two input channels. If the inputs do not switch together (within 100ms of each other) the system will go into a lockout condition.

24 22 MULTIFUNCTION SAFETY UNITS Important, if either terminal B1/B2 or, B3/B4 are not used; for example, if only one light curtain is employed for a particular application, it is necessary to link the unused input terminals to the 24V DC supply. If not the MFU s output switches will not energise. Terminals B5/B6 and B7/B8 dual channel emergency stop circuit - Connect one channel of the machines emergency stop circuit between terminals B5 and B6 and the second channel between terminals B7 and B8. Note: An internal circuit monitors for short circuits and switching disparity between the two input channels. If the inputs do not switch together (within 100ms of each other) the system will go into a lockout condition. This configuration meets the requirements for control reliability and cannot be used in a single channel configuration. Important, if the emergency stop inputs are not used it is necessary to link terminals B5 to B6 and terminals B7 to B8. If not the safety output switches will not energise. Terminals B9 and B11 24V DC supply - Additional + 24V DC outputs for connecting to the light curtains etc. Terminals B10 and B12 0V DC supply - Additional 0V DC outputs for connecting to the light curtains etc.

25 MULTIFUNCTION SAFETY UNITS 23 Multifunction Safety Unit Type Status Indicators Function Colour Status Inputs Green LED ON when input ON Outputs Green LED ON when output ON Reset Amber LED ON, when reset input is ON EDM Amber ON when EDM inputs are active Status Red + Red Steady ON = system ok Flashing ON /OFF = lockout

26 24 MULTIFUNCTION SAFETY UNITS Features - Type Dual safety inputs for connecting the light curtain Dual inputs for muting the light curtain Dual inputs for connecting the emergency stop circuit Safety monitored output relays. Contacts rated at 250V AC, 2A Auxiliary electronic output for mute indication Reset function External Device Monitoring (EDM) LED indicators for all inputs and outputs DIN rail mounting 70mm enclosure Automatic self testing Monitoring between related channels Built to BS EN Category 3 Specification - Type Response time 25ms max Operating temperature 0 to +50 C Enclosure rating IP40 Enclosure 70mm DIN rail mounting (HxWxD) 90x70x60mm Power supply requirement 24V DC ± 10% reg Current consumption 150mA (NO LOAD) Status indicators LEDs for all inputs and outputs Classification BS EN Category 3 INPUTS 24V DC = ON, 0V = OFF - Disparity between Dual inputs for light curtain channels =500ms max. 24V DC = ON, 0V = OFF - Disparity between Dual inputs for mute sensors channels =10 secs. max. Dual inputs for emergency-stop Use voltage free switch contacts - Disparity circuit between channels =100 ms max. External device monitoring (EDM) Use voltage free switch contacts (N/C) Reset function (selectable) 24V DC = ON, 0V = OFF OUTPUTS Safety output relays Auxiliary solid-state switch (non safety) Auxiliary solid-state switch for mute indication 2 x N/O - fail safe contacts, each rated at 250V AC, 2A Electronic output switch, rated at 24V DC, 500mA Electronic output switch, rated at 24V DC, 500mA

27 MULTIFUNCTION SAFETY UNITS 25 Electrical connections MFU Terminals A1 and A2 Power supply input - Connect a suitably stabilised 24V DC power supply to terminals A1 = +24V DC and A2 = 0V DC. The current consumption of the MFU with no load applied on the output switching terminals is 150mA. Terminals A3 and A4 External device monitor (EDM) - Normally closed switch contacts, in series from the external power switching devices are connected across terminals A3 and A4. The monitoring circuit checks that the power switching devices both deenergise at the same time the MFU safety output switches deenergise. If one or both of the power switching devices fail to deenergise at this time the MFU goes into a lockout condition, turning all output switches off. To reset from a lockout condition it is necessary to remove the 24V DC supply from the MFU and then re-apply. If the EDM circuit is not used it is necessary to link terminals A3 to A4 otherwise the system will go to a lockout condition at the next demand upon the safety system. Terminals A5 and A6 Safety output 1 switch contact - Connect terminals A5 and A6 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element. Terminals A7 and A8 Safety output 2 switch contact - Connect terminals A7 and A8 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element. If a single channel safety circuit is used link terminals A6 and A7. Terminals A5 and A8 are then connected to the machine s safety circuit. Connecting in this way links safety output switch 1 and safety output switch 2 in a series configuration. Terminal A9 No connection

28 26 MULTIFUNCTION SAFETY UNITS Terminal A10 Auxiliary electronic switching output 1 - The Auxiliary switching output should only be used for non-safety critical application. For example connecting an indicator lamp or as feedback to a PLC to confirm the safety outputs have de-energised. The auxiliary output energises when safety output switches 1 and 2 energise and de-energises when the safety outputs de-energise. Auxiliary output ON = 24V DC and OFF = 0V DC. Terminal A11 Auxiliary electronic switch (mute out). The Auxiliary switching circuit energises when the light curtain is muted, e.g. when suitable signals have been applied to terminals B3 and B4. The output switch is normally used for connecting an indicator lamp or as feedback to a PLC to confirm safety light curtain inputs at terminals B1 and B2 are overridden e.g. in a muted condition. Terminal A12 Reset - A suitable switch should be connected between terminal A12 and the 24V DC supply. If the safety output relays de-energise a depression of the switch is required to reenergise the output switches to an ON condition. The MFU s safety output switches will only re-energise when the reset switch is depressed and then released. Terminal B1 and B2 light curtain inputs (OSSD1 and OSSD2) Connect the electronic output switches (OSSD1 and OSSD2) of a light curtain to terminals B1 and B2 respectively. Note: An internal circuit monitors disparity between the two input channels. If the inputs do not switch together (within 500ms of each other) the system will go into a lockout condition. Important: If terminal B1/B2 are not used it is necessary to link them to the 24V DC supply. If not the MFU s output switches will not energise. Terminal B3 and B4 mute input signals - Connect suitable mute initiating signals to terminals B3 and B4 respectively. The mute signals override the light curtains operation therefore, the inputs should only be active during safe periods of the machinery s operating cycle. Note: An internal circuit monitors disparity between the two mute input channels. If the inputs do not switch within 10 secs. of each other the system will go into a lockout condition.

29 MULTIFUNCTION SAFETY UNITS 27 Terminals B5/B6 and B7/B8 dual channel emergency stop circuit - Connect one channel of the machines emergency stop circuit between terminals B5 and B6 and the second channel between terminals B7 and B8. Note: An internal circuit monitors for short circuits and switching disparity between the two input channels. If the inputs do not switch together (within 100ms of each other) the system will go into a lockout condition. This configuration meets the requirements for control reliability and cannot be used in a single channel configuration. Important, if the emergency stop inputs are not used; it is necessary to link terminals B5 to B6 and terminals B7 to B8. If not the safety output switches will not energise. Terminals B9 and B11 24V DC supply - Additional + 24V DC outputs for connecting to the light curtains etc. Terminals B10 and B12 0V DC supply - Additional 0V DC outputs for connecting to the light curtains etc.

30 28 MULTIFUNCTION SAFETY UNITS Multifunction Safety Unit Type Status Indicators Function Colour Status K1 ON Green LED ON with power to K1 coil K2 ON Green LED ON with power to K2 coil

31 MULTIFUNCTION SAFETY UNITS 29 Features - Type Positive guided contacts (8 N/O + 2 N/C) Din rail mounting - 70mm enclosure LED status indication Feedback control loop connections Built to BS EN Category 4 Specification - Type Response time 10ms max Operating temperature -10 to +55 C Enclosure rating IP40 Enclosure 70mm DIN rail mounting (HxWxD) 90x70x60mm Power supply requirement 24V DC ± 10% reg Status indicators LEDs Relay Power on Classification BS EN Category 4 Contact switching capability 24V DC / 250V AC 0.01A - 4A Maximum total output current 26A The expansion module operates in conjunction with MFU s , , and to provide additional output switching contacts that may be required for a particular application.

32 30 MULTIFUNCTION SAFETY UNITS Electrical connections Type Terminal A1 Input connection from a safe output device to the relay coil of K1 (+24V DC) Terminal B1 - Power supply input to the relay coil of K1 (0V DC) Terminal A2 - Power supply input to the relay coil of K2 (+24V DC) Terminal B2 Input connection from a safe output device to the relay coil of K2 (0V DC) Terminals A3 to A10 and terminal B3 to B10 Total of 8 N/O safe output switching contacts each contact rated at 250V AC 4A. Terminals A11, B11, A12 and B12 2 N/C output switching contacts each contact rated at 250V AC 4A. One of the N/C contacts can be used as feedback connections to the External Device Monitor associated with MFU types and One N/C contact in conjunction with one of the N/O contacts can be used as feedback connections to the External Device Monitor associated with MFU type

33 MULTIFUNCTION SAFETY UNITS 31 Multifunction Safety Unit Type Status Indicators Function Colour Status Inputs Green LED ON when input ON Outputs Green LED ON when output ON Reset Amber LED ON, when reset input is ON Guard override Green LED ON, when override input is ON EDM Amber ON when EDM inputs are active Status Red + Red Steady ON = lockout Flashing ON /OFF = system ok

34 32 MULTIFUNCTION SAFETY UNITS Features - Type Dual safety inputs for connecting the light curtain Dual inputs for muting the light curtain 3 rd mute input (mute enable) for increased safety integrity Safety monitored output relays. Contacts rated at 250V AC, 2A Monitored electronic output for mute indication Reset control function External Device Monitoring (EDM) LED indicators for all inputs and outputs Guard override function Electronic output for guard status indication Simultaneous monitoring between related channels Built to BS EN Category 3 Specification - Type Response time 25ms max Operating temperature 0 to +50 C Enclosure rating IP40 Enclosure 70mm DIN rail mounting (HxWxD) 90x70x60mm Power supply requirement 24V DC ± 10% reg Current consumption 150mA (NO LOAD) Status indicators LEDs for all inputs and outputs Classification BS EN Category 3 INPUTS Dual inputs for light curtain 24V DC = ON, 0V = OFF - Disparity between channels =500ms max. Dual inputs for mute sensors 24V DC = ON, 0V = OFF - Disparity between channels =10 secs. max. 3 rd mute input (mute enable) 24V DC = ON, 0V = OFF External device monitoring (EDM) Use voltage free switch contacts (N/C) Reset function 24V DC = ON, 0V = OFF Override function 24V DC = ON, 0V = OFF (3 min time-out) OUTPUTS Safety output relays Auxiliary solid-state switch (non safety) Monitored solid-state switch for mute indication 2 x N/O - fail safe contacts, each rated at 250V AC, 2A Electronic output switch, rated at 24V DC, 500mA Electronic output switch, rated at 24V DC, 500mA

35 MULTIFUNCTION SAFETY UNITS 33 Electrical connections MFU Terminals A1 and A2 Power supply input - Connect a suitably stabilised 24V DC power supply to terminals A1 = +24V DC and A2 = 0V DC. The current consumption of the MFU with no load applied on the output switching terminals is 150mA. Terminals A3 and A4 External device monitor (EDM) - Normally closed switch contacts, in series from the external power switching devices are connected across terminals A3 and A4. The monitoring circuit checks that the power switching devices both deenergise at the same time the MFU safety output switches de-energise. If one or both of the power switching devices fail to de-energise at this time the MFU goes into a lockout condition, turning all output switches off. To reset from a lockout condition it is necessary to remove the 24V DC supply from the MFU and then re-apply. If the EDM circuit is not used it is necessary to link terminals A3 to A4 otherwise the system will go to a lockout condition at the next demand upon the safety system. Terminals A5 and A6 Safety output 1 switch contact - Connect terminals A5 and A6 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element refer to drawing (E) above Terminals A7 and A8 Safety output 2 switch contact - Connect terminals A7 and A8 to one channel of a machine s stop circuitry. For example, via an external power-switching relay or directly to a safe PLC input or a machines final control element - refer to drawing (E) above.

36 34 MULTIFUNCTION SAFETY UNITS If a single channel safety circuit is used link terminals A6 and A7. Terminals A5 and A8 are then connected to the machine s safety circuit. Connecting in this way links safety output switch 1 and safety output switch 2 in a series configuration. Terminal A9 No connection Terminal A10 Auxiliary electronic switching output 1 - The Auxiliary switching output should only be used for non-safety critical application. For example connecting an indicator lamp or as feedback to a PLC to confirm the safety outputs have de-energised. The auxiliary output is on when OSSD 1 and 2 energise. They are off when OSSD 1 and 2 are de-energised. Auxiliary output ON = 24V DC and OFF = 0V DC. Terminal A11 Monitored electronic switch (mute out). A monitored switching circuit energises when the light curtain is in a muted condition, e.g. when suitable signals have been applied to terminals B3 and B4. This output is for connection of a 24V DC 2.2W filament lamp. The lamp will illuminate when the light curtain is in a muted condition. Warning: The system must have a 24V, 2.2 watt filament lamp connected between A11 and 0V for the system to work. Terminal A12 Reset - A suitable switch should be connected between terminal A12 and the 24V DC supply. If the safety output relays de-energise then a depression of the switch is required to reenergise the output switches to an ON condition. The MFU s safety output switches will only re-energise when the reset switch is depressed and then released. Terminal B1 and B2 light curtain inputs (OSSD1 and OSSD2) - Connect the electronic output switches (OSSD1 and OSSD2) of a light curtain to terminals B1 and B2 respectively. Note: An internal circuit monitors disparity between the two input channels. If the inputs do not switch within 500ms of each other then the system will go into a lockout condition.

37 MULTIFUNCTION SAFETY UNITS 35 Terminal B3 and B4 mute input signals - Connect suitable mute initiating signals to terminals B3 and B4 respectively. The mute signals override the light curtains operation therefore, the inputs should only be active during safe periods of the machinery s operating cycle. Note: An internal circuit monitors disparity between switching of the two mute input channels. If the inputs do not respond within 2 seconds. of each other the system will trip. To satisfy the latest Health and Safety requirements the safety system will trip if the light curtain remains in a muted condition for more than 15 minutes. Terminals B5 3 rd mute input (mute enable) For additional safety integrity a third mute input signal is provided. For entry/exit applications the input is normally connected to a conveyor run signal thus, initiating a mute condition only when the appropriate conveyor is running. Link terminal B5 to 24V dc if the third mute input is not required. Terminal B6 no connection Terminal B7 Guard override Should the guard trip during a period when a pallet is transferring through the light curtain detection zone it is necessary to remove the load from the zone before the light curtain can be reset. Install the guard override function by connecting a N/O key or, push button switch between terminal B7 and +24V dc. The override function can only be operated if a pallet load is obstructing the detection zone and the light curtain is in a tripped condition. Operate the override function as follows: Activate and release the override switch. This will automatically mute the light curtain for a maximum period of three minutes or, until the light curtain detection zone has been cleared of the obstruction. If the latter then, as the pallet load passes out from the light curtain the override function is cancelled and the guard becomes fully active once again, without interrupting the machine operating cycle.

38 36 MULTIFUNCTION SAFETY UNITS Terminals B9 and B11 24V DC supply - Additional + 24V DC outputs for connecting to the light curtains etc. Terminals B10 and B12 0V DC supply - Additional 0V DC outputs for connecting to the light curtains etc.

39 ACCESSORIES 37 Mounting Kit Model number Description Mounting bracket kit 4 x 'L' shaped stainless steel mounting brackets and a set of M6 x 8mm screws. For fixing centres 36mm + (m)mm For (m) see product tables on page 8, 9 & 10

40 38 ACCESSORIES 1000 Series Reset Station The 1000 Series reset station provides the user with a guard reset function and guard status indication. Mounted in a robust enclosure with a bright LED lamp and 6mm screw size mounting brackets top and bottom. Each unit comes with an integrated 10m connection cable for interface via a 1000 Series multi function unit (MFU), , or Model number Description Series push button reset station with trip indication

41 ACCESSORIES 39 Power Supplies Model number If a suitable stabilised 24V DC 2.5A power supply is not available the following unit is recommended. A 24V DC 1A power supply option is also available. Description Power supply Input V AC Output 24V DC, 2.5A Power supply Input V AC Output 24V DC, 1.1A Features High reliability High efficiency, low working temp Built in EMI filter, low ripple noise Compact size, lightweight Short circuit, over load, over voltage protection Approvals: UL, TUV, CB and CE Specification Type Switch mode Input Voltage V AC Input frequency 47-63HZ Inrush current Cold start, 24A, 115V & 50A, 230V Output voltage/current rating 24V DC, 2.5A Operating temperature 0 C to 50 C Storage temperature -10 C to +70 C Connection 5P/9.5mm pitch terminal block Enclosure 160x98x38mm Din rail mounting Weight 0.5 Kg Specification Type Switch mode Input Voltage V AC Input frequency 50-60HZ Inrush current Cold start, 15A, 115V & 30A, 230V Output voltage/current rating 24V DC, 1.1A Operating temperature 0 C to 50 C Storage temperature -10 C to +70 C Connection 5P/9.5mm pitch terminal block Enclosure 99x97x35mm Din rail mounting Weight 0.37 Kg

42 40 ACCESSORIES Mirror Units Two or three sides of a machine can be safeguarded with a single light curtain by using mirrors to deflect the light curtain s infra-red beams. (see appendix 2 for installation guidance) The Smartscan mirror system provides a sturdy floor mounting kit togethr with an aluminium column for mounting the mirror. The mirror assembly simply slots onto the column and can be adjusted to the height required for the application. The special mounting stand enables the mirror unit to be rotated through 360 degrees while also allowing full adjustment in all axes. Note: Mirrors cause a reduction in optical efficiency, reducing the effective range of the light curtain. Refer to appendix 2 for guidance.

43 ACCESSORIES 41 Range of the light curtain Maximum range through 1 mirror Maximum range through 2 mirrors 0.5m - 5m 4m 3m 4m -10m 8m 6.5m Model number Description mm x 110mm wide mirror unit mm x 110mm wide mirror unit mm x 110mm wide mirror unit mm x 110mm wide mirror unit Note: Mirror length must be a minimum of 100mm longer than the overall length of the light curtain to be installed. Column & Floor Stand Model number Description m aluminium universal mounting column m aluminium universal mounting column m aluminium universal mounting column m aluminium universal mounting column m aluminium universal mounting column Floor stand Note: A universal mounting column and floor stand is required for each mirror unit.

44 42 ACCESSORIES Mute signalling photocell Type The polarised retro-reflective photocell can be used in conjunction with MFU to provide the mute initiating signals to terminals B3 and B4 of the MFU. A safety light curtain with mute control function is often used in the packaging industry. In conjunction with a 1000 Series light curtain and an MFU two photocells are positioned to scan across a conveyor, to detect loaded pallets prior to the load interrupting the light curtain. The photocell must be positioned to detect the load during the entire time the load is passing through the light curtain. Type photocell has a maximum sensing range of 3 metres. Each photocell comes complete with mounting bracket and retroreflective mirror. Model number Description Polarised retro reflective photocell kit (each kit contains 1x photocell, 1x reflector mirror, 1x mounting bracket) Sensing Distance 10m Transmitter Diode Infrared Sensing Adjustment None Protection Rating IP65 Operating Voltage V dc, V ac - 50/60Hz Output Relay Current Consumption 2VA max Response Time 15ms Enclosure Intensive ABS Cable 1.5m length Operating Temp -20 C to +60 C Humidity 35% to 85% Weight 285g

45 ACCESSORIES 43 Mute Signalling Photocell Type The through-beam infra-red photocell can be used in conjunction with MFU to provide the mute initiating signals to terminals B3 and B4 of the MFU. A safety light curtain with mute control function is often used in the packaging industry. In conjunction with a 1000 Series light curtain and an MFU two photocells are positioned to scan across a conveyor, to detect loaded pallets prior to the load interrupting the light curtain. The photocells are positioned to scan across a conveyor, to detect loaded pallets prior to the load interrupting the light curtain. Type photocells have a maximum sensing range of 10 metres. Each transmitter and receiver comes complete with a 1.5m cable. Model Description number Through-beam photocell kit (each sensor kit contains 1x Transmitter unit, 1x Receiver unit, Mounting brackets) Sensing Distance 10m Transmitter Diode Infrared Sensing Adjustment None Protection Rating IP65 Operating Voltage V dc, V ac - 50/60Hz Output Relay Current Consumption 2VA max Response Time 15ms Enclosure Intensive ABS Cable 1.5m length Operating Temp -20 C to +60 C Humidity 35% to 85% Weight 285g

46 44 ACCESSORIES Remote Mounting Stackable Beacons A range of Stackable Beacons are available. They are typically used where the machine application requires visual indication of control functions from a single location. The translucent plastic lenses provide all round light visibility and can be programmed to provide either flashing or a steady output. The bright LED s are supplied in a variety of colours as listed below. Smartscan Remote Mounting Stackable Beacons Model number Description High intensity LED stackable beacon kit - Red High intensity LED stackable beacon kit - Orange High intensity LED stackable beacon kit - Green High intensity LED stackable beacon kit - Blue Monitored mute beacon module Mounting Stands Designed to accommodate our range of safety light curtains. The Adjustable Stand (50mm x 50mm) offers the user a flexible mounting option. The stand has adjustable brackets that allow the safety light curtain to be mounted at different positions to suit a specific application. Brackets for mounting mute signalling photocells on the stand are also available. The Channel Stand allows the user to mount the safety light curtain inside a protective housing. This provides protection on three sides to give a more robust installation. Channel stands would typically be used where the safety light curtain is at risk of damage from fork lift truck operations, or in the case of end-of-line applications damage from falling pallet loads.

47 ACCESSORIES 45 Adjustable Mounting Stands Straight stands Model number Description Pair of adjustable straight stands (with complete bracket set) Height 2m

48 46 ACCESSORIES L stands (exit systems) Model number Description Pair of adjustable L style stands (with external mute sensor bracket sets) Height 2m

49 ACCESSORIES 47 T stands (entry / exit systems) Model number Description Pair of adjustable T style stands (with external mute sensor bracket set) Height 2m

50 48 ACCESSORIES Channel Mounting Stands Straight stands Model number Description Height Pair of channel floor stands (straight) 1.5m Pair of channel floor stands (straight) 2m

51 SAFETY SYSTEMS SOLUTIONS 49 Safety System Solutions Smartscan recognise the difficult balance that customers have to make between meeting Health & Safety legislation requirements and managing their demanding production needs. Smartscan design and manufacture systems to meet the particular needs of their customer s safety applications - from single machines to full production lines. We provide our customers with a total service, from initial safety advice through to regular maintenance of their safety systems. Expert Advice Safety System Design Safety System Installation Risk Assessment Product Specification System Maintenance

52 50 INSTALLATION SHEET Installation Sheet Number CD205/ Unpacking Remove all packaging material and retain it Locate and keep the delivery note Inspect all items for transit damage Match goods supplied to those specified on the delivery note Keep the Installation Sheet in a safe place Each 1000 Plus system supplied would normally include: Light curtain with 5m of cable attached to transmitter and receiver columns Test piece Installation sheet Service questionnaire form Storage requirements Humidity - <95% Temperature range between 20 C and +70 C

53 INSTALLATION SHEET 51 Operating Requirements Humidity <95% Temperature range between 0 C and 50 C Vibration: Frequency <55Hz Max. Movement <0.35mm Do not use equipment in explosive atmospheres, (contact the manufacturer for further advice) Fig. B also describes important parameters associated with the light curtain. Those parameters are shown as M, K, R and N. M Overall length of light curtain enclosures K Detection zone width R Minimum and maximum scanning ranges of the light curtain N Object Detection Capability. (The minimum size of object guaranteed to be detected when placed in the light curtain energy field.)

54 52 INSTALLATION SHEET Typical Mounting Arrangement for a Smartscan 1000 Plus The 1000 Plus Series system does not use cable connectors. Both the transmitter and receiver units come complete with 5m cables attached. Transmitter = 2 way cable, Receiver = 4 way cable. The 1000 Plus Series has a unique mounting arrangement. Threaded slots running from top to bottom of the transmitter and receiver columns enable M6 screws to be affixed at any position along the length of the slot. The M6 threaded slots run the entire length of the aluminium extrusion, between the two end caps. There is a slot at each side of the extrusion and two slots at the rear as shown in Fig. C. Note: As an additional option a Mounting Bracket Kit ( ) is available.

55 INSTALLATION SHEET 53 Detection zone width (K) - Must be of a suitable height for each application to prevent personnel access to the danger area either over, under or around the light curtains detection zone. Detection capability (N) - A test piece of appropriate size is provided to test that the light curtain object detection capability is within the parameter specified for the particular model number. Range (R) - Ensure the light curtain is capable of satisfying the range requirement for the application.

56 54 INSTALLATION SHEET When installing a Smartscan 1000 Plus Series light curtain your attention is drawn to the following: (Fig. E) 1. Consider reflective surfaces that may give rise to optically short circuiting the direct path of the light curtains as shown in Fig. E. To ensure the light curtain is mounted far enough away from reflective surfaces use the formulae provided to calculate the minimum dimension between the light curtain and reflective surface. X = minimum distance between reflective surface and light curtain. 2. To prevent intermittent tripping of the light curtain ensure extraneous infra red energy between 800 and 1000 nanometers is not directed towards the Perspex window of the receiver unit (RX). Extraneous sources would include infra red sensors, infra-red remote controls or scanning systems. 3. Ensure the mounting position of the light curtain in respect to the nearest danger point meets the requirements of European Standard BS EN 999. See Appendix Ensure the light curtain transmitter and receiver units are mounted accurately in line with each other and are both perpendicular and parallel to each other within the parameters shown for each axis. 5. If utilising mirrors to deflect the light curtain ensure the mirror length is 100mm longer than the light curtain detection zone width and, mounted centrally to the zone. To ensure reliable operation the light curtain deflection angle from the mirror must not be less than 40 degrees or greater than 100 degrees.

57 INSTALLATION SHEET 55 Fig. F shows examples of the identification labels that are affixed to the end cap at the bottom of the transmitter and receiver columns.

58 56 INSTALLATION SHEET Fig. G defines the features (F) associated with the Smartscan 1000 system. LED Status Indicators F1 - Yellow flashing indicators on the (TX) transmitter column indicates the unit is powered-up and the electronic system is operational. F2 - Yellow flashing indicators on the (RX) receiver column indicates that communication is established between transmitter and receiver, and the light curtain is correctly aligned. Yellow steady indicators on the (RX) receiver column indicates that the light curtain is incorrectly aligned or the light curtain detection zone is blocked. F3 - Green LED indicator at the receiver unit illuminates when the electronic output switches, OSSD1 and OSSD2 are ON (only when the light curtain detection zone is clear of any obstruction). F4 - Red LED indicator at the RX unit illuminates when the electronic output switches, OSSD1 and OSSD2 are OFF eg a trip condition or, when the light curtain detection zone is blocked. If the Red LED indicator is flashing the system is in lockout. To recover from a lockout condition disconnect the transmitter and receiver from the power source and then reapply. F6 - Output Signal Switching Devices OSSD1 and OSSD2 provide the fail-safe signals for switching a safe control relay or electrical contactor. Both output signals are termed, control reliable ; the transistor output switches are automatically turned OFF for a very brief period of time to enable the electronic safety system to automatically self check thus ensuring the switches are able to turn OFF permanently if required to do so. This function increases the

59 INSTALLATION SHEET 57 safety integrity of the Smartscan 1000 Plus system to a very high level. The switching period is so short (500 µs max.) that it has no effect on the output signal to the machine safety circuits, thus the machine will continue to operate during the automatic test periods. Note: The standing current for each OSSD should be no less the 20mA and no greater than 500 ma

60 58 INSTALLATION SHEET Fig. H shows the 1000 Plus light curtain model list, showing part codes, detection zone width (K) and weight in Kg of transmitter and receiver columns. Note: Perimeter guards have a 6 beam unit at the beam locations.

61 INSTALLATION SHEET 59 Input and Output Connections at the Transmitter and Receiver Units A 24V DC regulated power supply should be used for connection to the transmitter and receiver units. The transmitter and receiver units operate entirely independently from each other, e.g. there are no electrical connections between the transmitter and receiver units therefore separate 24V DC power supplies may be used if required. In order to protect the 1000 Series electronic system please remember to install fuses of suitable rating between incoming 24V DC supply and 24V input connections at both the transmitter and receiver units. Recommended fuse ratings, transmitter 0.5A and receiver 1.5A. In applications where there may be high levels of EMC interference or where the cables from the Smartscan receiver unit have been extended it is recommended that the clip-on Ferrite EMI suppressor provided is clamped to the receiver cable. For details refer to the installation sheet supplied with each suppressor. OSSD1 and OSSD2 - Each output switch has a maximum current rating of 0.5A. To prevent possible damage never exceed the maximum current rating for the switching devices. Note: Inductive load suppressors should be used when driving large power relays. Ensure both transmitter and receiver units are connected to GROUND. Insert an M6 bolt into one of the threaded slots in the extrusion to ensure a good ground connection.

62 60 INSTALLATION SHEET Glossary of words and terminology used in the Installation Sheet in a number of International languages:

63 INSTALLATION SHEET 61 Testing the light curtain with the test piece The test procedure should be carried out frequently as indicated by the risk assessment for the particular installation. Smartscan Ltd recommends the test should be carried out daily. For light curtains with ODC (N) 30mm and 40mm - refer tofig.l Power-up the light curtain and activate the output switching circuits to an ON condition. Insert a test piece of appropriate size into the light curtain detection zone, at the bottom, 150mm from the transmitter unit. At this point the output switches will turn OFF. Sweep the test piece up through the detection zone parallel to the transmitter. Now sweep the test piece down through the detection zone equal distance between the transmitter and receiver. Now sweep the test piece up through the detection zone 150mm and parallel to the receiver unit. At no time during these tests should the output switches turn ON. Now thrust the test piece anywhere in the light curtain detection zone and ensure the machinery stops without apparent delay. For light curtain models with an ODC above 40mm undertake the same tests as described. During these tests the output switches should only turn OFF as the test piece totally obscures each beam in the light curtain. Ensure that while the test piece is obscuring each beam the output switches are OFF.

64 62 INSTALLATION SHEET Routine Maintenance No routine maintenance is required beyond periodic cleaning of the transmitter and receiver windows. Dirt build up on the windows may lead to intermittent tripping or a totally blocked condition of the light curtain. Clear adhesive tape may be applied to the windows of curtains in dirty or abrasive conditions. Renew the clear adhesive tape periodically. Clean the windows with a clean damp cloth using a mild detergent. Never use abrasive, corrosive cleaners or spray detergents. Fig. M shows an operations chart for the 1000 Plus system. Before installation read and understand the Installation Sheet provided paying particular attention to the information provided in Fig. E Refer to Fig. L for test and maintenance procedures Every 24 hours carry out tests as indicated in Fig. L Every 6 months check the entire installation paying particular attention to Fig. E If the equipment fails to operate as intended check the electrical connections as shown in Fig. J

65 INSTALLATION SHEET 63 Fig. N outlines the procedure for returning a Smartscan product. If a fault occurs that cannot be resolved or the equipment is damaged return the system to the nearest Smartscan distributor or Smartscan Ltd. Indicate the nature of the fault and the symptoms displayed on the form provided. Note: Please ensure that returned guards are matching serial number pairs.

66 64 INSTALLATION SHEET Fig. P shows a copy of the declaration of conformity.

67 APPENDIX 1 65 Positioning the light curtain The following points should be considered before final selection of a light curtain. The position of the light curtain in relation to the danger point, particularly the separation distance (S) The stopping performance of the machine together with the response time of the safety system (t1 + t2) To assist with the selection of a Smartscan light curtain for a specific application refer to the following information which has been taken from European Standard BS EN 999. Detection capability - the dimension representing the minimum diameter of an opaque cylinder which, when placed into the light curtain, at any angle to the detection plane, is guaranteed to actuate the light curtain. Separation distance (S) - The distance along the direction of approach, between the outermost position at which an appropriate opaque object is detected and the nearest hazardous part. Abbreviations: S = separation distance (mm) H = height of the light curtain above the reference plane (mm) e.g. floor t1 = response time of light curtain and control unit (secs) t2 = stop time of machine (secs) The detection zone of the selected light curtains must be of a length to prevent access to the hazard from either over or underneath the light curtain. If necessary install additional mechanical guarding to prevent access into the hazardous area.

68 66 APPENDIX 1 Normal Approach Detection Capability (mm) To calculate separation distance (S) Use a formula below Use a formula below when (t1+ t2) is when greater than (t1+ t2) is less than secs secs (t1+t2) (t1+t2) (t1+t2) (t1+t2) (t1+t2) (t1+t2) or 3 beam light curtains Example for normal approach Using a light curtain with a 30mm detection capability Where the response time of the safety system (t1) = secs Where the stopping time of the machine (t2) = 0.05 secs Therefore (t1+t2) = secs S = 2000 x S = 278mm

69 APPENDIX 1 67 Normal Approach Total response time of machine and safety Separation distance (S) in mm system (t1 + t2) Detection capability of the light curtain ms secs (30) mm (40) mm 2, 3 & 4 beam systems

70 68 APPENDIX 1 Parallel Approach To calculate separation distance (S) S = 1600(t1+ t2) + ( (0.4 x H)) The detection capability of a parallel approach light curtain determines the lowest permissible mounting height between the curtain and reference plane (H) e.g. floor. Refer to the guidance below Detection capability (mm) Lowest allowable height of the light curtain above the reference plane (H) e.g. floor (H) = Any height above the reference plane providing safety can be maintained (H) = Any height above the reference plane providing safety can be maintained Example for parallel approach The light curtain to be mounted 750mm from the floor (H) Using a light curtain with a 40mm detection capability Where the response time of the safety system (t1) = secs] Where the stop time of the machine (t2) = 0.08 secs Therefore (t1 + t2) = secs S = 1600 x ( (0.4 x 750)) S = S = 1068mm

71 APPENDIX 1 69 Parallel Approach Total response time of machine and safety systems (t1 + t2) Separation distance where (H) = 750mm ms secs (S) in mm Note: The chart shows light curtain Separation Distance (S) in relation to the systems response time (t1 + t2). In the chart 750mm has been chosen as a value for (H).

72 70 APPENDIX 1 Angled Approach To calculate separation distance (S) If B >30 degrees calculate S as for Normal approach If B <30 degrees calculate S as for Parallel approach More detailed information on the application of safety light curtains is provided in the Health & Safety Executive booklet HSG180

73 APPENDIX 2 71 Mirrors Reflector mirrors can be provided enabling two or three sides of a machine to be safeguarded with, what is effectively a single light curtain. When mirrors are employed it is essential that the mounting of the transmitter unit, receiver unit and mirrors themselves are sufficiently rigid. Alignment becomes increasingly critical as the range and number of mirrors increase. Mirrors cause a reduction in optical efficiency, reducing the effective range. A guide to the practicality of using mirrors is given below. Range of the light curtain Maximum range through 1 mirror Maximum range through 2 mirrors 0.5m - 5m 4m 3m 4m -10m 8m 6.5m Total Light Path 1 Mirror 2 Mirror 2m# Easy Easy 4m* Easy Medium 6m* Medium Hard 8m* Hard Not Feasible # Based upon a , * Based upon a Note: Perimeter curtains will be easy to align, curtains over 900mm may be more difficult to align. Check with Smartcan technical department prior to ordering for a particular application. support@smartscan.com, Tel: +44 (0) , Fax : +44 (0) Note: The angle of the light curtain striking the reflective surface must be within defined limits.

74 72 APPENDIX 2 Alignment though one mirror 1. Secure the transmitter, receiver and mirror units in the position in which they are intended to be used. 2. Ensure all units are perfectly upright in all planes by using a sprit level. 3. If the units are floor mounted on stands ensure the floor is even. Shim the floor mounts if necessary to ensure the units are all upright. 4. With one eye looking over the top of the receiver unit in line with the centre of the extrusion look towards the reflective surface of the mirror, in a similar manner to looking through a gun sight. 5. A second person must adjust the mirror to the left and right until the Perspex window of the transmitter unit can be seen reflected in the mirror. 6. If the light curtain is scanning over a long range it may be difficult to see the reflection of the transmitter units Perspex window in the mirror. If so, cut a piece of white paper to the size of the Perspex window and mount directly in front of the window. Now repeat step If the reflection of the white paper is difficult to see in the mirror then employ a third person to hold a flashlight in front of the transmitter unit with the light beam pointing directly in line with the Perspex window towards the mirror. Now repeat step Use shims to ensure the mirror is accurately aligned to enable the infra red beams in the lightcurtain to reach the receiver. Alternatively, fabricate mirror mountings to include some form of adjustment to enable movement both left and right and also forward end backwards from the central axis of the mirror.

75 APPENDIX 2 73 Alignment though two mirrors 9. Follow instruction A second person must adjust the position of the first mirror to the left and to the right until the entire length of the second mirror is reflected in the first mirror. If difficulties are experienced in seeing the reflection on the second mirror in the first mirror then use a piece of white paper cut to size and position in front of the second mirror. 11. If the reflection of the white paper is difficult to see in the first mirror then employ a third person to hold a flashlight in front of the second mirror with the light beam pointing directly in line with its mirror housing towards the first mirror. Secure the first mirror. 12. Again follow instructions 1 to The second person must adjust the position of the second mirror to the left and to the right until the entire length of the transmitter unit is reflected through both the first mirror and the second mirror. If difficulties are experienced in seeing the reflection of the transmitter unit through both the first then the second mirrors then use a piece of white paper cut to size and position in front of the transmitter unit. 14. If the reflection of the white paper is still difficult to see through the first and second mirrors then employ a third person to hold a flashlight in front of the transmitter unit with the light beam pointing directly towards the second mirror. Secure the second mirror. 15. Ensure the mirrors are directly aligned thus enabling the infra red beams of the transmitter to reach the receiver. Alternatively, fabricate mirror mountings to include some form