Shadow. Tech Support Hotline EST. Safety Light Curtain Rev. F April

Transcription

1 Shadow V Safety Light Curtain Rev. F April 2010 Tech Support Hotline EST Wintriss Controls Group, LLC 100 Discovery Way Unit 110 Acton MA USA Phone (800) Fax (978) PRINTED IN USA DA

2 DANGER Requirements You Must Meet When Installing and Using Shadow Safety Light Curtains FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID- STROKE OR MID-CYCLE DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped at any point in its stroke or cycle. Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle. Failure to comply with these instructions will result in death or serious injury. DANGER IMPROPER INSTALLATION, USE OR MAINTENANCE Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-supplied replacement parts. Wire, install and maintain Shadow safety light curtain in accordance with OSHA lockout/tagout regulation Ensure that Shadow safety light curtain is installed, tested and repaired by qualified personnel. Ensure that all metal stamping presses on which Shadows are used meet the requirements and inspection procedures of OSHA regulation and ANSI standard B , which govern the use of presence-sensing devices on metal stamping presses. Ensure that all other machinery, or other devices on which Shadows are used, meet the general machine guarding requirements in OSHA standard and any other regulations and standards that apply. Ensure that guarding is installed to prevent access to the machine over, under or around the light curtains. Test the operation of your Shadow safety light curtain daily using the checkout sequence shown on the Shadow safety light curtain units and also listed in this manual. If your Shadow safety light curtain is installed so the warning and test procedure labels are not clearly visible, call the factory for extra warning labels to affix to your machinery in a visible area. Perform the checkout sequence after any maintenance is done on the Shadow safety light curtain. Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, or any others responsible for the proper operation of the machinery have read and understood all instructions for use of the Shadow light curtain. Failure to comply with these instructions will result in death or serious injury. WARNING MACHINERY NOT CONFIGURED OR WORKING PROPERLY Ensure that the machinery and devices on which Shadow safety light curtains are used meet the general machine guarding requirements of OSHA standard and any other regulations and standards that apply. Inspect all stopping mechanisms of the machinery regularly to be sure they work properly. DO NOT operate a machine equipped with Shadow safety light curtains if the machine or any of its stopping mechanisms is not in proper working order. Failure to comply with these instructions could result in death or serious injury. WARNING STOPPING MECHANISM FAILURE Install and maintain stopping mechanisms of machinery or other devices according to the applicable regulations or standards. Regularly inspect all stopping mechanisms of the machinery to ensure proper functioning. Failure to comply with these instructions could result in death or serious injury. WARNING OTHER EQUIPMENT CONTINUING TO OPERATE Equipment that operates with the machinery connected to Shadow safety light curtain may continue to operate after the machinery has received a stop signal. Ensure that all operators and other affected personnel know which equipment is connected to Shadow safety light curtain and which is not. Failure to comply with these instructions could result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD Turn off and disconnect power from Shadow safety light curtain and from the machinery it is connected to before making any wiring connections. This includes power to the machine control and motor. Failure to comply with these instructions could result in death or serious injury.

3 Changes for Revision F of the Shadow V User Manual ( ) This revision of the Shadow V Safety Light Curtain User Manual covers all Shadow V models. The changes include: Updates to the ANSI standards provided in Appendix A, ANSI B replacing B , B replacing B

4 Thank you for purchasing a Wintriss Product. We appreciate your business and want to do whatever we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are backed by an ironclad guarantee, international standards approvals, and unbeatable support. Whenever you need assistance or service, we back all our products with excellent spare parts inventories, training programs, and prompt repair service. We would like to share with you a list of service options probably the largest number of service options offered in the industry. Technical Assistance We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at TECH (8324) should you have any questions about your equipment. Our technical staff is ready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our experienced technical staff can resolve your inquiry right over the phone. Return Authorization Please call our 800 number for a return authorization (RMA) number to return a product for repair. Returned goods must arrive freight prepaid. In order to process your return quickly, we ask that you provide us with the following pertinent information when you call: purchase order number, shipping address, contact name and telephone number, and product type. The assigned RMA number should appear on all packages returned to Wintriss Controls Group to ensure prompt service. At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you are returning. We ask that you either fax us a PO for that amount or enclose the PO with the returned item. This will enable us to ship the item back to you as soon as the repair has been completed. If the item cannot be repaired or there are additional charges, you will be contacted for approval. Please be sure to carefully pack all returned items and ship to our Acton, MA location. Expedited Repair Program Rush service providing 48 hour turnaround is available for most products upon request. An Expedite Fee will be applied to our standard repair rate. Board Exchange Program If your needs are urgent, you can take advantage of out Board Exchange (EX) program. Call our 800 number between 8 a.m. to 5 p.m. EST and we will send a replacement to you overnight. A fee does apply to this service. Contact Wintriss Technical Support at for details. Service Center Our Service Center for product service is located at our headquarters in Acton, MA. If your equipment requires repair, please contact us at to obtain a return authorization number. Nationwide field service is also available. Contact the Wintriss Technical Support group at Product Training We also offer both product training and maintenance/troubleshooting courses at our Acton, MA and Chicago-area facilities. On-site training is available from the factory or through your local Wintriss representative. Restocking Charge Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge is $50, not to exceed $250 per item. Whatever the product, we are committed to satisfying you with innovative engineering, quality construction, reliable performance, and ongoing, helpful support. Call us whenever you need assistance.

5 Table of Contents Chapter 1 Shadow V Safety Light Curtain...1 Safety Compliance...2 Shadows Provide Excellent Protection...2 How Shadow Works...3 Electricity to Light to Electricity...3 Sequenced Light Pulses...4 Stop Signal Sent to Shadow Control Relays...5 Shadow and Control Reliability...5 Indicator Lights on Shadows...6 Receiver indicators...6 Transmitter indicator...6 Object Sensitivity...7 Size and Scanning Distance...7 Shadow Is Easy to Maintain...7 Weld Shields for Extra Protection...7 Chapter 2 Installation and Checkout...11 Installation Overview...12 Overview of Steps Necessary to Install Shadow...12 Correct Light Curtain and Safeguarding Installation...12 Installation Procedure...14 Calculating the Safety Distance...15 Height Considerations...23 Designing and Mounting Brackets...23 Wiring and Loosely Mounting Your Shadow Light Curtains...35 Remote Testing of PLC Input Modules...47 Aligning and Tightening Down Your Shadow Light Curtains...48 Diagnostic Steps to Perform Before Shadow Operation...50 Final Checkout Sequence...52 Chapter 3 Floating and Blanking Windows...55 Blanking Windows...56 Blanking Windows Affect Safety Distance...56 Adding to Safety Distance for Fixed Blanking...57 Installing Master Blanking Window...58 Floating Window...61 Adding to Safety Distance for Floating Window...62 How to Enable the Floating Window Feature...62 Chapter 4 Troubleshooting...63 Checks and Repairs You Can Make...63 Checking and Cleaning Windows...65 Shadow V Safety Light Curtain User Manual Table of Contents page i

6 Shadow V Safety Light Curtain User Manual Checking and Correcting Shadow Alignment...65 Alignment problem or bad phototransistor...65 Checking and Correcting Crosstalk...66 Checking and Replacing Fuses...66 Checking and Replacing Indicator Lamps...68 Checking and Replacing Control Relays...69 If Relay Has Failed Completely...70 Appendix A Extracts from OSHA Regulations and ANSI Standards...73 Section 1 OSHA regulation Section 2 Extracts from ANSI Standards for Presence-sensing Devices...77 Appendix B Daily Tests...93 Daily Tests in English...93 Tests Quotidiens du Rideau de Lumiere...94 Daily Tests in French...94 Index...95 Wintriss Manuals...97 List of Figures Figure 1-1. Shadow Light Curtain...4 Figure 1-2. Weld Shield on a Weld Shield Ready Shadow...8 Figure 2-1. Prevent Reaching Over, Under or Around a Light Curtain...13 Figure 2-2. Closing Gaps with Supplementary Mechanical Guards...13 Figure 2-3. Measuring Distance Between Pinch Point...16 Figure 2-4. Plan View Illustrating Pass-through Protection...22 Figure 2-5. Brackets for Shadow...25 Figure 2-6. Shadow Mounting Dimensions...26 Figure 2-7. Transmitter and Receiver Properly Aligned...28 Figure 2-8. Wrong Transmitter and Receiver NOT Aligned...28 Figure 2-9. Simplified View of How Shadow Light Curtains Align...29 Figure Aligning Brackets Using Mounting Holes...30 Figure Shadow Mirror Dimensions...32 Figure Using Shadow Light Curtains with Mirrors, Example...33 Figure One Way to Avoid Crosstalk - Reversing Transmitters (TX) and Receivers (RX)...34 Figure Removing Screws from Shadow Cover...36 Figure Wiring Connector Location on Shadow Transmitter...37 Figure Wiring Connector for Shadow Transmitter...38 Figure Inserting Wires...38 Figure Schematic Showing Shadow Relays Wired to Emergency Stop Circuit...40 Figure Wiring Connector for Shadow Receiver...41 Figure Connecting Shadow V to WPC II Wintriss Clutch/Brake Control...43 Figure Connecting Shadow V to WPC 1000 Clutch/Brake Control...44 Figure Connecting Shadow V to WPC I Wintriss Press Control...45 Figure 3-1. Connecting Master Blanking Window...59 Figure 3-2. Coil Stock Unwinding Using Floating Window...61 Figure 4-1. Location of Fuse and Indicator Lamp on Shadow Transmitter...67 Figure 4-2. Location of Fuses, Indicator Lamps and Relays on Receiver...68 Page ii Table of Contents

7 Shadow V Safety Light Curtain User Manual How to Use the Manual This is the installation and reference manual for the Shadow Safety Light Curtain. It has information about how to install Shadow, as well as pertinent information about OSHA and ANSI requirements. Chapter 1, Shadow Safety Light Curtain, introduces you to Shadow, tells how it works specifically about control reliability, and explains how to use this product. Chapter 2, Installation and Checkout, gives the instructions for installing Shadow. This chapter also includes installation of the mirrors, as well as installation information when installing for different applications. At the end of the chapter is a diagnostic and checkout section. Be sure to check out your Shadows prior to operating the machinery. Chapter 3, Floating and Blanking Windows, tells what you need to know about using blanking and floating windows, including installation and safety distance. Chapter 4, Troubleshooting, provides information to help diagnose and correct problems you may encounter when using a Shadow Light Curtain. Appendix A, OSHA Regulations and ANSI Standards, gives excerpts from documents related presence-sensing safety devices. Appendix B, Daily Tests, contains instructions for the daily tests in English and French. Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: DANGER A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. WARNING A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury. CAUTION A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in property damage. NOTICE A NOTICE symbol indicates important information that must be remembered and aids in job performance. Table of Contents Page iii

8 Shadow V Safety Light Curtain User Manual Warranty Wintriss Controls warrants that Wintriss electronic controls are free from defects in material and workmanship under normal use and service for a period of one year (two years for Shadow light curtains) from date of shipment. All software products (LETS and SBR), electro-mechanical assemblies, and sensors are warranted to be free from defects in material and workmanship under normal use and service for a period of 90 days from date of shipment. Wintriss s obligations under this warranty are limited to repairing or replacing, at its discretion and at its factory or facility, any products which shall, within the applicable period after shipment, be returned to Wintriss Controls freight prepaid, and which are, after examination, disclosed to the satisfaction of Wintriss to be defective. This warranty shall not apply to any equipment which has been subjected to improper installation, misuse, misapplication, negligence, accident, or unauthorized modification. The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by Wintriss Controls. No other warranty is expressed or implied. Wintriss accepts no liability for damages, including any anticipated or lost profits, incidental damages, consequential damages, costs, time charges, or other losses incurred in connection with the purchase, installation, repair or operation of our products, or any part thereof. Please note: It is solely the user s responsibility to properly install and maintain Wintriss controls and equipment. Wintriss Controls manufactures its products to meet stringent specifications and cannot assume responsibility for consequences arising from their misuse. U.S. patent numbers 4,266,124 and 3,805,061 apply. Wintriss Controls Group. LLC SHADOW V SAFETY LIGHT CURTAIN 100 Discovery Way USER MANUAL Unit Acton, MA Wintriss Controls Group, LLC Telephone: (800) 586-TECH (8324) (978) Fax: (978) Internet: Page iv Table of Contents

9 Chapter 1 Shadow V Safety Light Curtain DANGER FULL REVOLUTION MECHANICAL POWER PRESSES CANNOT BE STOPPED IN MID- STROKE DO NOT use Shadow safety light curtains on full-revolution clutched machinery. Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle. Failure to comply with these instructions will result in death or serious injury. WARNING IMPROPER INSTALLATION Install and use Shadow safety light curtains according to applicable safety standards. Install presses used with Shadow safety light curtains according to the requirements and inspection procedures of OSHA regulation and ANSI standard B Install other machinery or devices according to OSHA regulation for general machine guarding and any other regulations that apply. Failure to comply with these instructions could result in death or serious injury. NOTICE USE EXCERPTS FROM SAFETY STANDARDS FOR REFERENCE ONLY Refer to the latest versions of the documents from which Wintriss has provided excerpts for your convenience. An excerpt from OSHA regulation appears in the appendix of this manual. Excerpts from the American National Standards Institute (ANSI) standards for safety devices are also included in the appendix. ANSI is a federation of trade and professional organizations which sets standards for the industry based on a national consensus of manufacturers, scientists, technical and professional groups. Shadow Safety Light Curtains protect personnel working around dangerous machinery. They signal the press to stop if a person s hand (or any other part of the body) gets too close to the hazardous area. Unlike mechanical guards which physically block access to the hazardous area, Shadow protects personnel by emitting a field of invisible infrared light in front of the hazard. When this light beam is obstructed, Shadow immediately sends a stop signal to the press. Shadow V Safety Light Curtain User Manual Shadow V Safety Light Curtain Chapter 1 page 1

10 Shadow V Safety Light Curtain User Manual Safety Compliance Shadow Vs comply with OSHA CFR General Machine Guarding and Mechanical Power Presses, ANSI B Mechanical Power Presses, ANSI B11.19 Performance Criteria for Safeguarding, ANSI B11.20 Manufacturing Systems/Cells, and ANSI/RIA Industrial Robots and Robot Systems. Shadows Provide Excellent Protection DANGER INCORRECT INSTALLATION Ensure that presses equipped with Shadow light curtains meet the requirements and inspection procedures of OSHA regulation and ANSI standard B Ensure that other machinery or devices meet OSHA regulation for general machine guarding and any other regulations that apply. Failure to comply with these instructions will result in death or serious injury. NOTICE EXCERPTS FROM OSHA REGULATIONS AND ANSI STANDARDS Excerpts from OSHA regulation and from the American National Standards Institute (ANSI) standards for safety devices are also included in Appendix A. ANSI is a federation of trade and professional organizations which sets standards for the industry based upon a national consensus of manufacturers, scientists, technical and professional groups. Shadow actually provides much better protection than physical guards. Once properly installed, it does not have to be adjusted. You do not have to worry about personnel forgetting to close gates or replace barriers. The invisible light screen does not get in the way of operation; yet automatically signals hazardous motion to stop. In addition, no maintenance is required on Shadow. Shadow has dual components. As a result, it can shut down the press even if a component fails. If a failure does occur, Shadow s self-checking circuitry automatically detects the failure and immediately sends a stop signal to the press. These features make Shadow more reliable and more convenient to use than other types of press guards. Page 2 Chapter 1 Shadow V Safety Light Curtain

11 Shadow V Safety Light Curtain User Manual How Shadow Works WARNING IMPROPER INSTALLATION Connect the Shadow safety light curtain stop relays to the machine s stop circuit. If you do not use the stop relays, you will not have the maximum protection afforded by these light curtains. DO NOT attempt to connect Shadow safety light curtains to any control until you have carefully read the installation instructions. Failure to comply with these instructions could result in death or serious injury. WARNING UNPROTECTED MACHINERY MAY CONTINUE TO OPERATE Ensure that all operators know which device(s) your Shadow safety light curtain protects and which it does not. The press Shadow is wired to will stop when the light curtain is interrupted and sends a stop signal to the press. However, the associated feeds and conveyors, to which Shadow is not wired, will continue to operate after the press stops. Failure to comply with these instructions could result in death or serious injury. You cannot see the light field emitted by Shadow. But this invisible curtain of light automatically prevents access to hazardous areas while the press is operating. Electricity to Light to Electricity Shadow consists of a transmitter and receiver pair which is not a matched set. In other words, a transmitter will work with any same-sized receiver. You mount each unit on the press on each side of the hazardous area as shown. Shadow can be described as an optoelectronic presence-sensing device. Presence-sensing means the light curtain can detect an object that penetrates its field and react to it (for instance, signal the press to stop when an intrusion occurs). Optoelectronic means Shadow works using light and electric current. An electric current is used to create the light beam in the transmitter. When the light strikes a phototransistor in the receiver, this action creates an electric current which signals the control circuitry that the light has been detected. Transmitter LEDs emit light towards receiver Transmitter LEDs emit light towards the receiver. The Shadow transmitter contains LEDs (light emitting diodes) which give off a harmless, invisible, infrared light pulse when an electrical pulse is passed through them. The Shadow receiver contains phototransistors that detect each light pulse and produce an electrical signal whenever the light pulse hits them. An invisible light barrier is formed by infrared light beams sent from the transmitter to the receiver. Shadow sends a stop command to the press when the light beam is penetrated. Shadow V Safety Light Curtain Chapter 1 page 3

12 Shadow V Safety Light Curtain User Manual transmitter receiver amber power indicator light beams red light green light (light field unobstructed) Figure 1-1. Shadow Light Curtain Sequenced Light Pulses The transmitter sends out light pulses from the LEDs one at a time in succession from top to bottom as the light curtain is operating. The light pulses (very short bursts of light) are emitted in a conical beam as shown in Figure 1-1 (above). The phototransistors in the receiver detect the light pulses instantly. They produce an electrical signal (turn on) when the light strikes them. Each phototransistor detects only the one pulse of light designated for it. It is only enabled (powered up) at the instant that the beam is expected. Shadow s electronics must see the phototransistor turn on, then off as the beam hits it and disappears. Each phototransistor must turn on then off in sequence, or Shadow will send a stop command to the press. Because the receiver only accepts infrared light pulses of a certain duration in proper sequence, Shadow is not affected by other light sources. As a result, all other continuous light sources and even pulsed light sources are tuned out. Shadow is not affected by shiny or reflective objects nearby, or by smoke, dirt, and oil found in a typical industrial environment. In addition, changes in area lighting, flashing strobe lights, or the incidence of crosstalk will not adversely affect operation (Refer to Chapter 2 and Chapter 4 for more on crosstalk ). And even if the Shadow receiver were flooded with infrared light of the same intensity, the receiver would not be fooled because it only accepts light pulses of the right frequency in the proper sequence. Instead it would send a stop command to the press. Because of this, you would need to alternate sets when Shadows are stacked on top of each other or are in close proximity. As an example, you might have a transmitter on top of a receiver on the left side, and alternately a mating receiver on top of a transmitter on the right. Page 4 Chapter 1 Shadow V Safety Light Curtain

13 Shadow V Safety Light Curtain User Manual A very fast pulse The pulsed sequence of Shadow is so fast that, where we mark time in units no smaller than a second, the effect is a continuous light field across the guarded area. You would have to move the point of your finger across an LED in the transmitter in less than 5/1000 th of a second (5 ms or milliseconds) to evade the light pulses coming from that LED. Therefore in our world of seconds and minutes, the light curtain is really always there even though only one light beam is actually produced at a time. The actual light pulse lasts for only 1/100,000 th of a second (10 microseconds). Consequently it does not take long to create a whole series of pulses one after the other. Stop Signal Sent to Shadow Control Relays We explained how the light field is created. Here is what happens when you put your hand into the field. As soon as you block one of the beams, the phototransistor reacts to the loss of light. No light means no electrical signal out from the phototransistor. This tells the control circuitry that there is an obstruction. Control relays The control circuitry operates two captive-contact relays in the Shadow receiver. Their contacts are connected in series to the press control s emergency stop circuit. These relays are normally open held closed 1. This means that the relays are always energized (contacts held closed 1 ) when the light field is not broken. When an obstruction enters the field, Shadow s control circuitry instantly de-energizes the relays 1, which initiates a stop. The response time of Shadow, from loss of light to relay contacts open, is 30 milliseconds, (50 ms for 36 and 48 models). Shadow and Control Reliability WARNING IMPROPER INSTALLATION Install Shadow safety light curtains in compliance with applicable safety regulations from the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI). See excerpts in the appendices. Refer to the latest revision of all applicable documents. Ensure that your installation meets the control reliability requirements of the applicable regulations. Ensure that both Shadow control relays are used in any Shadow installation, including connection directly to the press control s stop circuit, to a PLC, or to other type of machine control. Wiring is explained in Chapter 2. Read carefully and understand the installation instructions before attempting to install and wire Shadows to any control Ensure that installation is performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. 1 Optionally available with one normally open-held closed and one normally closed-held open. When energized and with no obstruction, the relay outputs change state. Shadow V Safety Light Curtain Chapter 1 page 5

14 Shadow V Safety Light Curtain User Manual WARNING UNPROTECTED MACHINERY MAY CONTINUE TO OPERATE Ensure that all operators know which device(s) your Shadow safety light curtain protects and which it does not. The press Shadow is wired to will stop when the light curtain is interrupted and sends a stop signal to the press. However, the associated feeds and conveyors, to which Shadow is not wired, will continue to operate after the press stops. Failure to comply with these instructions could result in death or serious injury. Shadow is control reliable. Control reliability is a term used and defined by the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI). These agencies have issued regulations for the use of presence-sensing devices like Shadow. Both agencies require control reliability. Sometimes ANSI uses the term control component failure rather than control reliability. See Appendix A for more information on these regulations. Control reliability means that all critical components in the light curtain are duplicated so that if one fails, the other will still allow normal operation to stop the press. It also means that if a component failure does occur, the light curtain will immediately detect the failure and send a stop signal to the press. The light curtain will not allow operation until the repairs are made. Control reliability is why Shadow makes an excellent machine guard. A key example is the Shadow control relays. Shadow has dual, captive-contact relays which operate simultaneously. Even if one of Shadow s control relay contacts fails closed (contact welds shut or open), the second relay will still de-energize to send the stop signal to the press. Shadow will also detect the failed relay. It will not allow press operation until the relay is replaced. The chance of both relay contacts failing simultaneously is very small. Indicator Lights on Shadows Shadow has three clearly visible indicator lights that tell you the Shadow condition. Receiver indicators The Shadow receiver has a green indicator and red indicator on its cover. The green indicator (bottom light) means the light curtain is unobstructed, and the press will be allowed to operate (control relay contacts held closed or in the unobstructed/energized state). The red indicator means the light curtain is obstructed and the press will not be allowed to operate (control relay contacts held in the obstructed/de-energized state) 2. Or it means the output relays are de-energized, which may also be due to an internal failure. Transmitter indicator The Shadow transmitter has one amber indicator which illuminates when power to the transmitter is on. 2 With optional 1 normally open-held closed and 1 normally closed-held open outputs, the outputs change state to the unpowered state. Page 6 Chapter 1 Shadow V Safety Light Curtain

15 Shadow V Safety Light Curtain User Manual Object Sensitivity Object sensitivity is the minimum diameter object that Shadow can detect. Object sensitivity for Shadow is 11/4 (3.2 cm). This means that it will detect an object of this diameter anywhere in the sensing field. Shadow light beams are on ¾ (1.9 cm) centers. An object smaller than 11/4 diameter could pass through the light field if it traveled in a path directly between the light beams. See Figure 1-1 (found earlier in this chapter). Size and Scanning Distance Shadow is available in 12 (30.5 cm), 18 (45.7 cm), 24 (60.9 cm), 36 (91.5 cm), and 48 (121.9 cm) heights. Scanning range is up to 25 ft. (7.6 m) up to 50 ft. (15.3 m) optional. Shadow 12 units have 16 light beams (or channels). The 18 units have 24 channels; the channels the channels; and the channels. See the tables at the end of this chapter for more Shadow specifications. Shadow Is Easy to Maintain No adjustments or periodic maintenance is required. It continues working silently. You should, however, clean the windows every once in a while if your operation is particularly dusty, dirty, or smoky. A heavy build-up of dirt or oil could block a light beam and cause an inadvertent press shutdown. Weld Shields for Extra Protection The operation of Shadow is not affected by smoke, dirt, or oil found in a typical industrial environment. In a more severe environment, you may need to install clear plastic shields that provide protection from weld splatter and other hazards. Weld shields are clear plastic covers that fit on the face of the transmitter and/or receiver, as shown in the next figure. They come in kits ready for installation and can be easily replaced if they become so damaged or scratched that the light curtain no longer indicates green during normal operation. Shadow V Safety Light Curtain Chapter 1 page 7

16 Shadow V Safety Light Curtain User Manual Weld Shield on each transmitter & receiver hard-coated acrylic: 1.69" wide, 0.125" thick shown being inserted Weld Shield Guides at every 12" on "Weld Shield Ready" Shadows (with easy slide-thru tracks) Weld Shield Guides Figure 1-2. Weld Shield on a Weld Shield Ready Shadow (with guides installed) Page 8 Chapter 1 Shadow V Safety Light Curtain

17 Shadow V Safety Light Curtain User Manual Table 1-1. Shadow V Specifications WARNING INDICATOR OUTPUTS NOT SUITABLE FOR SAFETY USE DO NOT use the indicator outputs listed in the specifications table for personnel protection. They cannot be used to stop the machinery. Use the safety outputs for personnel protection. Failure to comply with these instructions could result in death or serious injury. Curtain heights Scanning range (horizontal sensing field) Beam spacing Object sensitivity Size Transmitter and receiver units Weight Housing 12 (30.5 cm), 18 (45.7 cm), 24 (60.9 cm), 36 (91.5 cm), and 48 (121.9 cm) Standard: up to 25 ft (7.6 m) Optional: up to 50 ft (15.3 m) ¾ (1.9 cm) centers Minimum 11/4 (3.2 cm) Depth: 5.75 (14.6 cm) Width: 6.0 (15.2 cm) Height: Add 2.5 (6.4 cm) to curtain height Approximately 8, 11, 13, 19, and 23 lbs (3.6, 5, 5.9, 8.6, 10.4 kg, respectively) 18 gauge welded steel, NEMA 4 hose down, IP65 Operating Temperature - 4 F to 122 F (-20 to 50 C) Input Power Transmitter/receiver power Remote Interrupt Output Stop circuit VAC, Hz, 220 VAC available as option 7 watts transmitter; 12 watts receiver One set per system with no wiring between optic heads Closure to ground. Max ON voltage 2mA 2 captive contact stop relays 115 VAC or DC resistive Std: 2 NO contacts Opt: 1 NO and 1 NC Response time 30 msec max: 12 to msec max: 36 to 48 Light source Infrared light emitting diodes (LEDs) Approximately 850 nanometer wavelength Optics Angle of Divergence and Acceptance: less than ± 2 Indicators Transmitter: Amber power light Receiver: Red curtain obstructed light ; Green curtain unobstructed light Flashing red floating on Warranty Interchangeability 2 years Transmitter and receiver are not matched sets. Shadow V Safety Light Curtain Chapter 1 page 9

18 Shadow V Safety Light Curtain User Manual Table 1-2. Shadow V Options Option Mirrors Muting Blanking window Floating window Function Provides 2 or 3-sided protection; each mirror reduces effective scanning distance by 10%. To bypass the light curtain during the non-hazardous portion of the stroke (upstroke). Instructions for installation and use of the muting package are supplied with the muting package. External blanking windows required. Optional 1 beam floating. Page 10 Chapter 1 Shadow V Safety Light Curtain

19 Chapter 2 Installation and Checkout DANGER IMPROPER INSTALLATION, USE OR MAINTENANCE Follow all procedures in this manual. This is required for proper operation of the light curtain. Ensure that the light curtain is installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the machine without being detected. Use the correct height light curtain, combined with ancillary physical guards. Install and maintain your machine guarding system according to OSHA standard and any other regulations and standards that apply. Wire and install Shadow safety light curtains in accordance with the requirements of OSHA lockout/tagout regulation Ensure that Shadow safety light curtains are installed, tested and repaired by qualified personnel. Perform only the tests and repairs listed in this manual. Test the operation of your Shadow safety light curtains daily using the checkout sequence shown on the Shadow safety light curtain units and also listed in this manual. If your Shadow safety light curtains are installed so the warning and test procedure labels are not clearly visible, call the factory for extra warning labels to attach to your machinery in a highly visible area. Perform the checkout sequence after any maintenance is done on the Shadow safety light curtains. Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, or any others responsible for the proper operation of the machinery have read and understood all instructions for use of the Shadow safety light curtains. Failure to comply with these instructions will result in death or serious injury. Installing Shadow is a straightforward procedure. You must proceed carefully, however, since the Shadow is a safety device which protects press operators and other personnel. Before you start to install your Shadow Light Curtains, read the instructions carefully. Then proceed deliberately to be sure Shadow Light Curtains are installed correctly and working properly. A brief general overview of the installation procedure is listed first in this chapter. After reading the overview, follow the more detailed installation instructions that come next. Shadow V Safety Light Curtain User Manual Installation and Checkout Chapter 2 page 11

20 Shadow V Safety Light Curtain User Manual Installation Overview Read this overview before beginning the installation procedures that follow. It will familiarize you with the steps required to install a Shadow. Overview of Steps Necessary to Install Shadow Calculating the safety distance All press safeguarding devices, including Shadow, must be located at the correct safety distance from the pinch point or hazardous area. This distance allows enough time for Shadow to react, and the press to stop before an intrusion, like the operator s hand, reaches the pinch point. The pinch point is the area of the press where moving parts can cause injury. The safety distance can be calculated precisely using the formula explained in the section Calculating Safety Distance. Preparing the Mounting Location for Shadow A mounting location is selected. Rigid mounting brackets are fabricated and attached to your press. Brackets are used to bring the Shadow Light Curtains out to the proper safety distance and to allow for proper alignment. The light curtain must be installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the machine without being detected. This is accomplished with the proper height light curtain, combined with ancillary physical guards. Wiring, Aligning and Mounting Shadow The Shadow Light Curtains are mounted to the brackets, wired into your press s control circuitry, then aligned. Ensuring That the Shadow Is Working Properly A checkout sequence is performed after installation to ensure that the Shadow units are working properly. Correct Light Curtain and Safeguarding Installation Install your light curtain so that no one can reach the hazardous area by reaching over, under, around or behind the light curtain. See the illustration below. Select the correct size light curtain and add supplemental auxiliary guarding, if necessary, to prevent access to the hazardous area. Page 12 Chapter 2 Installation and Checkout

21 Shadow V Safety Light Curtain User Manual Figure 2-1. Prevent Reaching Over, Under or Around a Light Curtain Examine the press for any place a person could reach into the hazardous area. See Table 0-10 in OSHA Section (reproduced in Table 2-1) for how far one can reach through an opening of a certain size. Be careful not to leave unguarded gaps large enough for someone to reach a hand through. For example, where the light curtain is raised high enough to clear a chute, add supplementary mechanical guards to close any gaps, as shown in the figure below. mechanical guards chute Figure 2-2. Closing Gaps with Supplementary Mechanical Guards Installation and Checkout Chapter 2 page 13

22 Shadow V Safety Light Curtain User Manual Installation Procedure DANGER FAILURE TO PERFORM SAFETY SYSTEM TESTS Perform the final checkout sequence below when you have completed installation of your light curtain, before operating the equipment it is connected to. Operate your machinery only after your safety system meets all the requirements of the checkout sequence. Perform the final checkout sequence whenever repair, maintenance or modification is performed on your light curtain or the machinery it is connected to. Perform the daily test safety system checkout sequence on page 93 (in French, en Français, page 94) every day before operating any machinery connected to Shadow safety light curtains. Failure to comply with these instructions will result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD Turn off and disconnect power from the Shadow safety light curtain and from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Remove all fuses and tag out per OSHA Control of Hazardous Energy (Lockout/Tagout). Ensure that installation is performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. The installation procedure is divided into these steps: Calculating the Safety Distance, page 15 Designing and Mounting Brackets, page 23 Wiring and Loosely Mounting Your Shadow Light Curtains, page 35 Aligning and Tightening Down Your Shadow Light Curtains, page 48 Diagnostic Steps to Perform Before Shadow Operation, page 50 It is a good idea to read over the complete installation procedure before starting. This will give you an idea of the materials and techniques required for making and positioning mounting brackets and aligning your Shadow Light Curtains. Page 14 Chapter 2 Installation and Checkout

23 Shadow V Safety Light Curtain User Manual Calculating the Safety Distance DANGER INCORRECT SAFETY DISTANCE Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area. Mount your light curtain heads at least 7.5 (191 mm) from the hazardous area, regardless of the calculated safety distance. Failure to comply with these instructions will result in death or serious injury. DANGER INCREASED SAFETY DISTANCE DUE TO BLANKING OR FLOATING WINDOWS Modify the safety distance between the light curtain and the hazardous area according to the instructions in this chapter and in Chapter 3, Floating and Blanking Windows. Failure to comply with these instructions will result in death or serious injury. DANGER INCORRECT SAFETY DISTANCE DUE TO LONGER RESPONSE TIME Determine which model Shadow safety light curtains you have. Use the correct response time for your model light curtain in your safety distance calculations. Safety depends on your installing your light curtain at the correct safety distance from the hazardous area. 12 to ms response time 36 to ms response time Failure to comply with these instructions will result in death or serious injury. DANGER STOPPING TIME TOO LONG Use a brake monitor where a Shadow light curtain is used to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA (3) (5). A brake monitor continually checks that the machine s stopping time does not exceed a predetermined limit. Failure to comply with these instructions will result in death or serious injury. Shadow Light Curtains must be mounted away from the pinch point (or hazardous area) of the press at a specific distance. This distance is based on the stopping time of your press. This distance is called the safety distance. It must be calculated using a precise formula. This ensures that Shadow can send the stop signal to the press, and the press will stop, before the operator s hand reaches the hazardous area. The next illustration shows how you would measure the distance between the pinch point (or hazardous area) of your press and the light curtain. Installation and Checkout Chapter 2 page 15

24 Shadow V Safety Light Curtain User Manual pinch point transmitter One of the invisible light beams Distance between light curtain and pinch point receiver Figure 2-3. Measuring Distance Between Pinch Point and Light Curtain in a Metal Stamping Application This distance must be greater than the calculated safety distance or Shadow may not be able to stop the press before an operator s hand reaches the hazardous area. OSHA and ANSI Requirements All press safeguarding devices, including Shadow, must be located at the correct safety distance from the pinch point or hazardous area. OSHA regulations govern the mounting of infrared light curtains when used with mechanical power presses (OSHA ). The OSHA formula should be used as a guide in other applications since at present there is not a well-known formula for safety distance which governs general machine guarding. ANSI B11.19 also deals with general machine guarding. For complete information on OSHA regulation and ANSI standard B , see Appendix A. Both the ANSI and OSHA formulas are explained next. Page 16 Chapter 2 Installation and Checkout

25 Shadow V Safety Light Curtain User Manual The OSHA Safety Distance Formula DANGER INCORRECT SAFETY DISTANCE Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area. Mount your light curtain heads at least 7.5 (191 mm) from the hazardous area, regardless of the calculated safety distance. Be sure your value for Ts includes the response times of all devices that react to stop the press. If your measurement of stop time does not include response time of the press control, light curtain, and any other devices that react to stop the press, the safety distance will be too short. Failure to comply with these instructions will result in death or serious injury. DANGER STOPPING TIME TOO LONG Use a brake monitor where a Shadow light curtain is used to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA (3) (5). A brake monitor continually checks that the machine s stopping time does not exceed a predetermined limit. Failure to comply with these instructions will result in death or serious injury. The OSHA safety distance formula as specified in OSHA regulation is explained below. As noted earlier, Wintriss recommends you use the American National Standards Institute formula for calculating safety distance because it contains more factors that allow you to calculate the safety distance more precisely. The ANSI formula is explained in the next section. Here is the OSHA safety distance formula as specified in OSHA : Ds = 63 inches/second x Ts 63 inches-per-second is the OSHA-recommended hand-speed constant. D s is OSHA safety distance in inches D s = 63 x Ts T s is the stopping time of the press in seconds, measured at approximately 90 of crankshaft rotation (or at maximum velocity). T s must include: all components that are involved in stopping the press; response time of the press control that activates the brake and response time of the light curtain (30 ms for Shadow 12, 18, and 24 ; 50 ms for 36 and 48 models); plus response time of other devices if also involved in stopping the press. Since some increase in stop time can invariably be anticipated due to clutch/brake system deterioration, a percentage factor must also be added to the actual measured stop time of your press when determining your safety distance. A percentage factor of 20 percent is recommended for machines with new brakes or brakes in good condition; a percentage factor of 10 percent is recommended for presses with older Installation and Checkout Chapter 2 page 17

26 Shadow V Safety Light Curtain User Manual brakes. This is because the stopping time for older brakes will be longer due to wear. Therefore, you add less time for older brakes. Example: Calculating the safety distance using the OSHA formula The OSHA formula for finding safety distance is: Ds = 63 inches/sec. x Ts We will use a stop time of seconds for this example. This includes reaction time of all devices noted above in signaling the press to stop except the response time of the light curtain. Next we will add in Shadow response time seconds (30 msec). Then: Ts = sec sec. (Shadow response time) Ts = Now, we will calculate safety distance: Ds = 63 in/sec x Ts Ds = 63 x Ds = 13.9 in. Shadow must be mounted more than 13.9 inches from the hazardous area, using the OSHA formula. Page 18 Chapter 2 Installation and Checkout

27 Shadow V Safety Light Curtain User Manual The ANSI Safety Distance Formula DANGER INCORRECT SAFETY DISTANCE Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area. Mount your light curtain heads at least 7.5 (191 mm) from the hazardous area, regardless of the calculated safety distance. Be sure your value for Ts includes the response times of all devices that react to stop the press. If your measurement of stop time does not include response time of the press control, light curtain, and any other devices that react to stop the press, the safety distance will be too short. Failure to comply with these instructions will result in death or serious injury. DANGER STOPPING TIME TOO LONG Use a brake monitor where a Shadow light curtain is used to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA (3) (5). A brake monitor continually checks that the machine s stopping time does not exceed a predetermined limit. Failure to comply with these instructions will result in death or serious injury. This is the ANSI B11.1 safety distance formula that Wintriss recommends: Ds = 63 x (Ts + Tc + Tr + Tbm) + Dpf D s is the ANSI safety distance in inches. K (which shows an actual value of 63 in the previous equation) is the OSHA-recommended hand-speed constant. The hand-speed constant (equaling 63 inches-per-second) indicates how far you could theoretically move your hand and arm in one second. It is very similar to OSHA s formula, except that it takes more details (such as response times, brake monitoring setting, and depth penetration factor) into account. Ts, Tc, and Tr are the worst case response times of the press Ts, the control Tc, and the light curtain Tr. Response time for the Shadow is 30 ms (50 ms for 36 and 48 models).ts is the worst case stopping time of a press in seconds. Tc is the response time of the press control. This is the time it takes for the control to activate the machine s brake. Tr is the response time of the light curtain. Response time for the Shadow is 30 milliseconds (50 ms for 36 and 48 models). Tbm is the additional stopping time of the press allowed by the brake monitor. The brake monitor you use with your press control stops the press when the stop time set on it is exceeded. This means excessive brake wear has occurred. It is time for repair. The brake gradually wears until the limit is reached. Installation and Checkout Chapter 2 page 19