Shadow VI. Tech Support Hotline EST. Safety Light Curtain Rev. E July

Transcription

1 Shadow VI Safety Light Curtain Rev. E July 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. DANGER 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 will result in death or serious injury. DANGER 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 will result in death or serious injury. DANGER 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 will 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 E of the Shadow VI User Manual ( ) This revision of the Shadow VI Safety Light Curtain User Manual covers Shadow VI models with response times of 30 to 40 ms, maximum. The changes include: The Remote Interrupt button has been removed from the Shadow VI Control board (see page 44), and, as a result, all references to the button have been removed from the manual. AC power is now grounded to the set screw terminal on the Shadow VI enclosure rather than to pin #3 on TB 1 (see page 51). The procedure for replacing Shadow VI safety relays has been updated. Instead of replacing individual relays in the event of a relay failure, you now must replace the Shadow VI Control board. See page 91. References to and excerpts from ANSI standards B11.1 and B11.19 have been updated to their current versions, B and B See Appendix A.

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 Introduction to Shadow VI Safety Light Curtain...1 OSHA and ANSI Compliance...2 About Shadow VI...2 How Shadow Works...4 Shadow and Control Reliability...6 Description of Shadow VI indicators...7 At the Optic Heads...7 At the Control...8 Inside the Control...8 Object Sensitivity...8 Size and Scanning Distance...8 Shadows Are Easy to Maintain...9 Shadow VI Features and Options...10 Weld Shield Kit...11 Chapter 2 Installation and Checkout...15 Installation overview...16 Calculating the safety distance...16 Mounting location for your Shadow transmitter and receiver...16 Wiring, aligning, mounting, and making proper settings...16 Ensuring that the Shadow light curtains are working properly...16 Installation Procedure...17 Calculating the Safety Distance...18 OSHA and ANSI Requirements...19 The OSHA Safety Distance Formula...20 The ANSI Safety Distance Formula...21 Perimeter Guarding...24 Blanking Windows Affect Safety Distance...24 Pass-through Protection...25 Height Considerations...26 Designing and Mounting Brackets...26 Universal Mounts...26 Mounting Location Requirements...27 How to Design and Mount Brackets or Floor Stands...28 Alignment Considerations...33 Maximum Openings for Side Guards...35 Using Mirrors with Shadows...36 Using Weld Shields...39 Mounting Shadow Light Curtains Upside Down...39 Avoiding Cross Talk When Mounting 2 Sets of Shadows...39 Loosely Mounting Shadow VI Transmitter and Receiver...40 Mounting the Control...42 Shadow VI User Manual Table of Contents page i

6 Shadow VI User Manual Connecting RF (Radio Frequency) Ground...42 Wiring the Transmitter and Receiver to the Control...45 Terminating Shields of the Head Cables...46 Connecting the Head Cables to the Control...47 If You Have a Second Set of Shadow Optic Heads...49 Connecting AC Wiring to the Control...50 Connecting Stop Circuits to the Control A. Wiring Shadow to the WPC (One or Two Control Boxes) B. Wiring Shadow to a PLC...56 Optional Wiring...57 Indicator Outputs...57 MPCE Monitor Inputs...58 Making Settings Inside the Control...59 S1 settings...60 S4 Settings...60 J12 Setting...61 Plug in Connector and Replace Cover...61 Aligning and Tightening Down Shadow VI Components...61 Alignment Procedure...62 Diagnostic Steps to Perform Before Using Shadow...63 No Power to Unit...63 The Light Curtain Is in a "Reset Required" Condition...63 If the Transmitter Has No Power or Is Not Functioning...63 Check Power and Indicator Lights...63 Check Lens Window...64 Bring Shadow Heads Close Together...64 Green Light On...64 No Green Light...65 If You Have Two Sets of Shadow Heads...65 Green Light On But Still Cannot Start Press...65 Final Checkout Sequence...66 Chapter 3 Fixed and Floating Blanking...69 Blanking Windows Affect Safety Distance...70 Adding to Safety Distance for Fixed Blanking...71 Adding to Safety Distance for Floating Window...71 Installing Blanking Windows...72 Installing the Master...72 Installing Slave Windows...75 Floating Window...77 Adding to Safety Distance for Floating Window...78 How to Enable the Floating Window...78 Chapter 4 Troubleshooting Shadow VI...79 How to use this chapter...79 Description of Shadow VI Indicators...80 page ii Table of Contents

7 Shadow VI User Manual At the Optic Heads...80 At the Control...80 Inside the Control...81 External MPCE Monitoring: Checking DS5 and DS Shadow VI Optic Head Connector...86 Checking and Cleaning Lens Window(s)...87 Checking Alignment...87 Alignment Problem or Bad Phototransistor...87 Checking and Replacing Fuses...88 Checking and Replacing Control Relays...89 If the Relay Has Failed Completely...89 Checking Relays with a Voltmeter...90 Replacing Safety Relays...91 Checking and Correcting Cross Talk...92 Appendix A Extracts from OSHA Regulations and ANSI Standards...93 Extracts from OSHA Regulation Extracts from ANSI Standards for Presence-sensing Devices...97 Daily Tests in English Tests Quotidiens du Rideau de Lumiere Daily Tests in French Appendix B Shadow VI Panel Mount Standard Enclosure Versus Optional Panel Mount Preparation for Mounting Shadow Using Your Enclosure About Shadow VI Panel Mount Labels Appendix C Installation of Shadow VI-WPC Control Board Mounting Dimensions and Required Clearance About Shadow VI-WPC Control Board Labels Wiring Shadow VI optic heads to the board Connecting AC wiring to WPC Connecting Stop Circuits to WPC Making settings on the control board Floating window setting J12 Setting Reset button Appendix D Replacement Parts Index Wintriss Manuals Table of Contents page iii

8 Shadow VI User Manual List of Figures Figure 1-1. Illustration of Shadow Transmitter and Receiver...3 Figure 1-2. Illustration of Shadow Control...4 Figure 1-3. Showing Light Beams with Shadow Light Curtain...5 Figure 2-1. Distance Between Pinch Point and Light Curtain...19 Figure 2-2. Plan View Illustrating "Pass Through" Protection...25 Figure 2-3. Brackets for Shadow Light Curtains...29 Figure 2-4. Shadow VI Optic Heads Mounting Dimensions...31 Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts)...32 Figure 2-6. Transmitter and Receiver Properly Aligned...34 Figure 2-7. Using Laser Alignment Tool to Properly Align Shadow...34 Figure 2-8. Aligning Brackets Using Mounting Holes So Shadow Light Beams Line Up Later When Mounted...35 Figure 2-9. Shadow VI Mirror Dimensions...37 Figure Representation of Shadow with Mirrors for Three-sided Guarding...38 Figure One Way to Avoid Cross Talk - Reversing Transmitters (TX) and Receivers (RX)...40 Figure Mounting an Optic Head with Shock Mounts...41 Figure Shadow VI Control Enclosure Mounting Dimensions...43 Figure Location of Components, Shadow VI Control...44 Figure Terminating Drain Wires to Set Screw Terminal...46 Figure Terminal Block TB1 Connections...50 Figure Setting Voltage Selector Switch S Figure Connecting to Protective Earth Ground Set Screw Terminal...51 Figure Relays Wired to Emergency Stop Circuit, Typical...54 Figure Wiring "Upper" TB4 Connector in Control...55 Figure Example of MPCE Usage...58 Figure Setting MPCE Jumpers...59 Figure Factory Settings for Switch Blocks S1 and S Figure Jumper Position for "1 SET" and "2 SET"...61 Figure 3-1. Connecting Master Blanking Window...73 Figure 3-2. Close-up Installing Blanking Window...74 Figure 3-3. Coil Stock Unwinding Using Floating Window...77 Figure 4-1. Optic Head Connector Pinout Orientation and Chart...86 Figure B-1. Daily Tests Label (left) and Operator instructions Label (right) Figure B-2. Shadow VI Panel Mount Control Dimensions Figure C-1. Shadow VI - WPC Labels Figure C-2. Mounting Dimensions and Required Space for Control Board Figure C-3. Important Components - Shadow VI-WPC Control board Figure C-4. TB1 Power Terminal Figure C-5. Setting Voltage Selector Switch S Figure C-6. Floating Window Switch S Figure C-7. Jumper Position for "1 SET" and "2 SETS" Figure C-8. Reset Button page iv Table of Contents

9 Shadow VI User Manual List of Tables Table 1-1. Shadow VI Specifications...12 Table 1-2. Shadow options and functions...14 Table 2-1. Light Curtain Dimensions: inches (cm)...30 Table 2-2. OSHA Table Table 2-3. Connecting Light Curtain Receiver Head to TB2 in Controller...48 Table 2-4. Connecting Light Curtain Receiver Head to TB3 in Controller...49 Table 4-1. Shadow troubleshooting guide for 1 or 2 sets...82 Table 4-2. Shadow Troubleshooting Guide for 2 Sets...85 Table C-1. Connecting Light Curtain Receiver Head to TB2 in Controller Table C-2. Connecting Light Curtain Transmitter Head to TB3 in Controller Table C-3. Shadow-WPC Board TB1 to WPC Table C-4. Shadow-WPC Board TB4 to WPC Table D-1. Replacement Parts List Wiring Diagrams at End of Manual Figure 1. Dual Light Curtain Wiring Diagram Figure 2. Simple Connection to N/O Machine ESTOP Circuit Figure 3. Connection for Simple N/O ESTOP and Auxiliary Circuit Figure 4. Wiring Diagram Showing External N/O and N/C Relays with Captive Contacts Figure 5. External Indication Wiring Diagram Figure 6. Wintriss Clutch/Brake Control Shadow VI Wiring Figure 7. Wintriss Clutch/Brake Control Dual Shadow Wiring Figure 8. Wintriss Clutch/Brake Control Integrated Shadow VI Wiring Figure 9. Older Model Wintriss Clutch/Brake Control Shadow VI Wiring Figure 10. WPC 1000 Shadow VI and Cam Output Wiring Table of Contents page v

10 Shadow VI 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, use and troubleshoot 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, ANSI Standards and Daily Tests gives excepts from documents related to presence-sensing safety devices, and instructions for tests that should be run every day. Appendix B, Shadow VI Panel Mount explains how to install Shadow VI as a panel mount. Mounting and "cutout" dimensions are provided. Appendix C, Installation of Shadow VI-WPC Control Board explains how to install, wire, and operate the optional Shadow VI-WPC control board assembly in conjunction with your Wintriss Clutch/Brake Control (WPC). This control board replaces the standard Shadow VI control box. Appendix D, Replacement Parts lists the replacement parts available for the Shadow VI from the factory. page vi Table of Contents

11 Shadow VI User Manual 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 vii

12 Shadow VI 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 VI 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 viii Table of Contents

13 Chapter 1 Introduction to Shadow VI Safety Light Curtain Shadow VI is a compact, state-of-the-art, 3-box light curtain which contains transmitter and receiver optic heads plus a separate control. Shadow protects personnel working around dangerous machinery. The system signals the press to stop if a person's hand (or any other part of the body) gets too close to the hazardous area. However, the invisible light screen does not interfere with normal operation. Unlike mechanical guards which physically block access to the hazardous area, Shadow safeguards personnel via this field of invisible infrared light. 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 Appendix A. 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 VI User Manual Introduction to Shadow VI Chapter 1 page 1 Safety Light Curtain

14 Shadow VI User Manual OSHA and ANSI Compliance Shadow complies 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". These regulations require that a single component failure cannot jeopardize operator safety. Critical components are duplicated and continually cross-checked during operation to guarantee that a single component failure can never create an unsafe condition. Selfchecking circuitry detects the presence of any faults and signals the press to stop. About Shadow VI 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 safety light curtains provide excellent protection. Once properly installed, Shadow VI does not require additional adjustment, and no maintenance is required. You do not have to worry about personnel forgetting to close gates or replace barriers. The optic heads are constructed of rugged, heavy-gauge extruded aluminum (0.12-inch wall thickness). These compact heads (2" x 2.85" cross-section) come in sizes ranging from 6 inches to 5 feet in height. The transmitter and receiver (see Figure 1-1) are optionally available in explosion-proof enclosures. Shadow also includes a control enclosure (Figure 1-2) to which any-sized receiver and transmitter can be wired. No special settings are required. The control contains a power supply, relay circuitry, and switch block assemblies where you can easily enable or disable Shadow's options. For added security, the control comes standard with an enclosure keylock and a reset keyswitch. Simply turn the reset keyswitch to the right when resetting is required. page 2 Chapter 1 Introduction to Shadow VI Safety Light Curtain

15 Shadow VI User Manual The cables join the control with the transmitter and receiver and are interchangeable between each optic head. These cables have connectors that plug into the optic head end and screw terminations that connect at the control end. They come in various lengths. Transmitter universal mounting brackets end caps mating connector for blanking window cable LED: Amber (power on) LEDs: Re d (curtain obstructed) Orange (floating window enabled) Green (curtain unobstructed) Receiver "quick-connect" cable connectors Figure 1-1. Illustration of Shadow Transmitter and Receiver Introduction to Shadow VI Chapter 1 page 3 Safety Light Curtain

16 Shadow VI User Manual LED Indicators for curtain clear, floating window enabled, curtain blocked and reset required CURTAIN CLEAR FLOATING WINDOW STOP SIGNAL RESET REQUIRED cover latches enclosure keylock OPERATE RESET reset keyswitch (key pointed toward "operate" during normal operation) LIGHT CURTAIN Figure 1-2. Illustration of Shadow Control 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 actual light curtain emitted by Shadow. However, the invisible curtain of light automatically prevents access to hazardous areas while the press is operating. page 4 Chapter 1 Introduction to Shadow VI Safety Light Curtain

17 Shadow VI User Manual transmitter light beams receiver Figure 1-3. Showing Light Beams with Shadow Light Curtain Shadow's transmitter and receiver are not "matched sets". In other words, a Shadow VI transmitter will work with any same-sized Shadow VI receiver. You mount the units on the machinery on either side of the hazardous area. Shadow can be described as an optoelectronic presence-sensing device. Presence-sensing means the light curtain detects an object that penetrates its field and reacts to it by signaling a press to stop when an intrusion occurs. Optoelectronic means Shadow works using light and electric current. The transmitter's LEDs (light emitting diodes) emit a harmless, invisible, infrared light pulse when an electrical pulse passes through them. These LEDs transmit light towards the receiver. The receiver's phototransistors 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. Reacting to the loss of light, Shadow sends a stop command to the press when there is an obstruction, such as when you put your hand into the light field. As the light curtain is operating, each transmitter LED pulses in succession from top to bottom, in the form of a conical beam. The phototransistors in the receiver detect these light pulses instantly and produce an electrical signal (turn on) when the light strikes them. Each phototransistor detects the one pulse of light designated to it. It is only enabled at the instant that the beam is anticipated. 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 machinery. Introduction to Shadow VI Chapter 1 page 5 Safety Light Curtain

18 Shadow VI User Manual Because the receiver only accepts infrared light pulses of a certain duration in proper sequence, Shadow cannot be affected or fooled by other light sources. All other continuous light sources and even pulsed light sources are "tuned out." Therefore, the light curtain is not affected by normal lighting near the light curtain. Also, changes in area lighting or even flashing strobe lights will not affect operation. This pulsed sequence 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 5/1000th 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 1/100,000th of a second (10 microseconds). Consequently it does not take long to create a whole series of pulses one after the other. 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. 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 in the same way by the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI). page 6 Chapter 1 Introduction to Shadow VI Safety Light Curtain

19 Shadow VI User Manual NOTICE The Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI) have issued regulations for the use of presence-sensing devices such as Shadows. Both of them require control reliability. See Appendix A for more information. Control reliability means "the device shall be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent the initiation of a successive stroke until the failure is corrected." Control reliability is another reason why Shadow is an excellent machine guard. All critical components in Shadow are duplicated so that if one fails, the other will still allow normal operation to stop the machinery. If a component failure does occur, Shadow will immediately detect the failure and send a stop signal to the machinery. The light curtain will not allow operation until the repairs are made. Another example of control reliability are Shadow's control relays. The control contains captive-contact relays (2 stop and 1 status relay). The N/O outputs are connected in series to the press's emergency stop circuit and are always energized (contacts held closed) when the light field is not broken. When an obstruction enters the field, Shadow's control circuitry instantly de-energizes the relays, which results in opening the contacts and breaking the stop circuit of the press. Shadow's response time from loss of light to relay contacts open is 30 to 40 milliseconds (depending on the size of the optic heads). Even if one of Shadow's control relay contacts fails closed (contact welds shut), the second relay will still de-energize and a stop signal will be sent to the machinery. Shadow will also detect the failed relay. It will not allow further press operation until the relay is replaced. It is highly unlikely that the relay contacts will fail simultaneously. Description of Shadow VI indicators Shadow includes several indicators. Figure 1-1 shows the indicators on the transmitter and receiver, and Figure 1-2 illustrates the control. These indicators communicate Shadow's operating status. Use them to troubleshoot your light curtain (see Chapter 4 troubleshooting guides). If any contradiction exists between the indicator lights at the receiver and those at the control, make sure you compare your findings with the information in these troubleshooting guides to solve the problem immediately. At the Optic Heads The transmitter has an amber-colored power indicator which remains illuminated when Shadow has power. There are three indicators on the front of the receiver. The red indicator means that the light curtain has been interrupted. The orange indicator flashes when the floating window option is turned "on" at the control (see Chapter 2). The green indicator means the light curtain is unobstructed. Introduction to Shadow VI Chapter 1 page 7 Safety Light Curtain

20 Shadow VI User Manual At the Control Four indicators appear on the front cover of the control and are clearly labeled. The green "curtain clear" indicator means that the light curtain is unobstructed and the machinery will be allowed to operate (the control relay contacts are held closed or in the unobstructed/ energized state). The "floating window" indicator lights up amber when this blanking feature is enabled inside the control (see Chapter 2). The "stop signal" indicator goes red when the light curtain is obstructed, the control relay contacts are open (or in the deenergized state) and the press is disabled, if there is misalignment, or when Shadow has detected an internal malfunction. The yellow "reset required" signifies that a reset required or condition exists. This could occur during power-up if power up reset settings are enabled at the control (see Chapter 2), or if Shadow detects an internal malfunction with any of the components (transmitter, receiver, or control). Inside the Control There are four indicators inside the control (refer to Figure 2-14 in Chapter 2 for location of components). DS1 and DS2 are red indicators that are located just above the TB2 receiver connectors at the lower right-hand corner of the board. They light up red if you are using only 1 set of optic heads and there is an obstruction, misalignment, or internal problem. If you have 2 sets, DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and TB3) is interrupted, the optic heads are misaligned, or an internal problem exists. DS2 corresponds with Set 2, which are wired to the lower connectors. Refer to the troubleshooting guides in Chapter 4 for more details. DS3 and DS4, located in the upper right-hand corner of the control near the power supply, light up green all the time to indicate that power is going to the receiver and transmitter respectively. Chapter 4 provides troubleshooting guides which reference the indicators at the control and the optic heads. They suggest how to solve a problem with the light curtains when certain conditions exist. Object Sensitivity Object sensitivity is the minimum diameter object that Shadow can detect. Object sensitivity for Shadow is 11/4" (3.2 cm), which means that it will detect any object of this diameter or larger anywhere in the sensing field. Shadow light beams are on 3/4" (1.9 cm) centers. An object smaller than 11/4" diameter could pass undetected through the light field if it traveled in a path directly between the light beams. Size and Scanning Distance Shadow is available in a wide array of standard sizes from 6" to 60". Shadow's standard scanning distance is 25 feet (7.6 meters), and optionally 50 feet (15.3 meters). The "standard range" units cannot be modified for "extended range" capability. page 8 Chapter 1 Introduction to Shadow VI Safety Light Curtain

21 Shadow VI User Manual Shadows Are Easy to Maintain No adjustment or maintenance is required. It continues working silently. You only need to replace fuses or relays as needed (described in Chapter 4). You should, however, clean the lens window(s) periodically if the working environment is particularly dusty, dirty, oily or smoky. A heavy build-up of dirt or oil could jeopardize Shadow's efficiency by blocking a light beam and cause an inadvertent press shutdown. You should also periodically verify proper alignment. Alignment is discussed in Chapters 2 and 4. Introduction to Shadow VI Chapter 1 page 9 Safety Light Curtain

22 Shadow VI User Manual Shadow VI Features and Options Shadow is designed for uncompromising safety and durability under real world conditions. The light curtain includes various features and options. Some of these are described next. The floating window feature provides a means for the random bypass of only one beam of the light curtain. It is useful in those applications where material must travel through or within the sensing field in a random pattern. The floating window may only be used when material or parts take up a space no greater than 11/8" (2.9 cm) within the sensing field. Larger material would block more than one light beam at a time which would generate a stop command. This built-in feature is enabled by turning a switch "on" at the control. The amber indicators at the receiver and on the front cover of the control flash when floating window is "on". A floating window automatically alters the object sensitivity from 11/4" to 2". If you plan to use this feature even occasionally, the safety distance for mounting must be increased. Refer to "Calculating Safety Distance" in Chapter 2 of this manual. Shadow has optional fixed blanking capability. External blanking windows (purchased separately) allow you to disable up to 5 contiguous beams in an area where a fixture penetrates the light field and permits stationery objects to protrude into Shadow's sensing field. For example, in a situation where a conveyor or work table extends into this field, moving the fixture may not be feasible. Therefore, you install a blanking window on the Shadow receiver where the fixture penetrates the field. This disables the light beam that would normally detect the fixture. However, if the light field is penetrated in any area above or below the fixture (or "blanked" light beam), the light curtain will send a stop signal to the machinery. Floating window can be used in conjunction with fixed blanking. An example could be an application where part of the tool physically protrudes into the light field and an air blow-off is randomly ejecting parts. Floating window is covered in Chapters 2 and 3, and fixed blanking is discussed in Chapter 3. Safety distance is also affected by fixed blanking window if the fixed obstruction does not extend all the way from the transmitter to the receiver. See Chapter 2 for a comprehensive discussion of safety distance. Shadow has passed stringent environmental stress tests for shock, vibration, impact, exposure to temperature extremes, dust, humidity, and electrical abnormalities. Shadow comes with a built-in status relay which can be set to perform different functions (setup is covered in Chapter 2). When wired to the main motor, the relay opens at power-up if reset on power up has been enabled at the control (see "Making settings" in Chapter 2). The status relay can be set to "mimic" stop outputs which can activate an alarm or beacon whenever Shadow is in a "stop signal" (red) condition. Shadow can also be used in perimeter guarding applications when there is a walk-in hazard inside the guarded area. In this case, a "stop signal" condition is generated when any of the light curtain beams has been obstructed. Shadow will not reset to "curtain clear" (green) automatically even when the obstruction has been removed. You must reset the system to resume operation. Activating this feature is discussed in Chapter 2. Both Shadow optic heads include universal mounts. These mounts are used to properly align the Shadow heads during installation. They can be rotated ±30 to make installation and page 10 Chapter 1 Introduction to Shadow VI Safety Light Curtain

23 Shadow VI User Manual alignment easier. By rotating the brackets 90 with respect to the head, they provide additional flexibility when mounting. Installing the universal mounts is covered in Chapter 2. Weld Shield Kit Shadow's operation is not affected by smoke, dirt, or oil found in a typical industrial environment. If necessary, however, you can at any time install replaceable shields to 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. 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. (See the Troubleshooting Guide in Chapter 4 of this manual). Refer to Chapter 2 of this manual for more information about using weld shields. Introduction to Shadow VI Chapter 1 page 11 Safety Light Curtain

24 Shadow VI User Manual WARNING Table 1-1. Shadow VI Specifications 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. Scanning heights 9 models: 6, 12, 18, 24, 30, 36, 42, 48 and 60 inches (15.2, 30.5, 45.7, 61.0, 76.2, 91.4, 106.7, 121.9, and cm) Scanning range Standard: up to 25 ft (7.6 m) Extended: up to 50 ft (15.3 m) Transmitter and receiver not matched sets Beam spacing 3 /4" (1.9 cm) centers Object sensitivity 1 1 /4" (3.2 cm) Response time 30 msec max. for 6" to 24" 35 msec max. for 30" to 48" 40 msec max. for 60" Size Optic heads Control enclosure See Figures 2-4, 2-5, and Table 2-1 in Chapter 2. 7" x 9" x 3.5" (17.8 x 22.9 x 8.9 cm). See Figure 2-13 in Chapter 2. Weight 6" optic heads Control Construction Heads Control Cables Environmental Heads Control Cables Vibration 1.4 lbs (.64 kg) ; add 0.9 lbs (.4 kg) for every additional 6 inches in height 9 lbs. (4 kg) Extruded aluminum; 0.12" (3 mm) wall min 18-gauge welded steel with enclosure keylock. 5, 15, 25, 50, and 100 ft. with connector at the optic head. NEMA 4, IP65; Optional explosion-proof enclosures. NEMA 2 / IP52; Optional NEMA 4/IP65; Optional with 4 connectors for 2 sets of optic heads; Optional explosionproof enclosure. NEMA 4 connector; Oil-resistant PVC cable standard; Optional SJOOW cable with 1 or 2 connectors. 10g, 0.03" displacement; freq Hz sine, per UL491 (applies to all three axes). page 12 Chapter 1 Introduction to Shadow VI Safety Light Curtain

25 Shadow VI User Manual Shock testing 50g, 11ms pulse per MIL-STD-810 C, Method 516, Procedure I (applies to all three axes). Operating Temperature Inputs Power Heads MPCE Remote Reset Light Source - 4 F to 122 F (-20 to 50 C) VAC (DC available) Hz; 30 VA max. Two sets (any height) can be connected to same control. Monitor input: For external dry contacts rated at VDC; 25 msec. response time max. Closure to ground ON voltage 2mA Infrared light emitting diodes (LEDs). Approximately 850 nanometer wavelength Optics Angle of Divergence and Acceptance: less than ± 3.5. Outputs Stop Circuit/status Indicator Outputs* Indicators Transmitter Receiver Control 2 "captive contact" stop relays and one status relay, plus 4 solid state indicator outputs. 120 VAC or DC resistive max; N/O and N/C contacts with all 3 relays. 4 open collector, NPN, opto-isolated outputs can switch 70 V 2 ma maximum (see warning below). Amber (power). Red "obstructed"; Amber "floating enabled"; Green "clear unobstructed". Red "obstructed"; Amber "floating enabled"; Green "clear unobstructed"; Yellow "Reset required". Introduction to Shadow VI Chapter 1 page 13 Safety Light Curtain

26 Shadow VI User Manual Table 1-2. Shadow options and functions OPTION Mirrors Blanking Windows Floating Window Weld shield kits Laser Alignment Tool Interchangeability FUNCTION Provide 2 or 3-sided protection; each mirror reduces effective scanning distance by 10%. Electronics for blanking standard; external blanking windows must be purchased separately; maximum number of blanked beams is 5. Allows objects smaller than 11/8" to move through light field without interrupting operation. One beam floating capability built-in; enabled at control. Specify the model size of your Shadow. See Chapter 2 for more information. For optimum alignment; uses 3V Lithium battery. Transmitter and receiver are not matched sets; Shadow VI transmitter can be used with Shadow VI receiver of same. page 14 Chapter 1 Introduction to Shadow VI Safety Light Curtain

27 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 VI light curtain is a safety device which protects press operators and other personnel. Check that you received everything. With Shadow, you should have received optic heads (transmitter and receiver), a control (the "third box"), and two interchangeable quick connect cables, one for each optic head (required cable lengths specified at time of order). If you are missing any of these, contact Wintriss Tech Support immediately before proceeding with the installation. Before you start the installation, read the instructions thoroughly. Then proceed carefully to be ensure proper installation and operation. 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. The actual instructions must be followed for proper installation of Shadow VI. Shadow VI User Manual Installation and Checkout Chapter 2 page 15

28 Shadow VI User Manual Installation overview Read this overview before beginning the installation procedures that follow. It will familiarize you with the steps required to complete the installation. Calculating the safety distance The proper distance that the Shadow heads must be mounted away from the pinch point (or hazardous area) is calculated. This is called the safety distance. 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 the safety distance". Mounting location for your Shadow transmitter and receiver A mounting location is selected. Rigid mounting brackets are fabricated and attached to your press. Brackets are used to bring the Shadow heads out to the proper safety distance and to allow proper alignment. Wiring, aligning, mounting, and making proper settings The Shadow light curtain optic heads are mounted to the brackets using shock mounts, then aligned, and wired to the control, which is then wired into your press's control circuitry. Proper settings are made at the Shadow s control to enable its features and options. The standard control enclosure is rated NEMA 2/IP52. You must use conduit of the same rating and make proper connections to ensure proper protection with the enclosure. If you have an optional NEMA 4/IP65 enclosure, suitably rated conduit hubs must be used on all unused holes in the control enclosure to maintain proper NEMA 4/IP65 rating. Ensuring that the Shadow light curtains are working properly Perform the checkout sequence after installation to ensure that Shadow VI is working properly. page 16 Chapter 2 Installation and Checkout

29 Shadow VI 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 114) 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 Designing and mounting brackets Loosely mounting Shadow VI heads Mounting the control Wiring the transmitter and receiver to the control Connecting AC wiring to the control Connecting stop circuits to the control Making settings inside the control Aligning and tightening down Shadow VI components Diagnostic steps to perform before Shadow operation Final checkout sequence It is a good idea to read over the complete installation procedure before starting. This will guide you about the materials and techniques required for making and positioning mounting brackets and aligning Shadow VI heads. Installation and Checkout Chapter 2 page 17

30 Shadow VI 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 INCORRECT SAFETY DISTANCE DUE TO BLANKING OR FLOATING WINDOWS Read Chapter 3 Fixed and Floating Blanking before calculating the safety distance. This chapter tells how to modify the safety distance when you use windows. Modify the safety distance calculated with the instructions below, as required. 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 (c) (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. page 18 Chapter 2 Installation and Checkout

31 Shadow VI User Manual 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 VI can send the stop signal to the press, and the press will stop, before the operator's hand reaches the hazardous area. This next illustration shows how you would measure the distance between the pinch point (or hazardous area) of your press and the light curtain. pinch point transmitter One of light curtain's invisible light beams Distance between light curtain and pinch point receiver Figure 2-1. Distance Between Pinch Point and Light Curtain 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 machine safeguarding devices, including Shadow VI, 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 has been used as a guide in other applications since there has not been a well-known formula for safety distance which governs general machine guarding. When calculating safety distance, Wintriss, on the other hand, recommends that you use the formula from ANSI B This formula represents a new consensus on the proper installation of light curtains. ANSI B11.1 has been developed specifically for guarding of mechanical power presses. However, it should be used as a guide in other applications as Installation and Checkout Chapter 2 page 19

32 Shadow VI User Manual well. For complete information on OSHA regulation and ANSI standard B , see the Appendix, found at the end of this manual. Both the ANSI and OSHA formulas are explained below. If you need assistance in calculating the safety distance, call Wintriss Tech Support. 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 (c) (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. Ds is OSHA safety distance in inches Ds = 63 x Ts T s is the stopping time of the press (or other machine) 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 6" through 24" models; 35 ms for 30" through 48" models; 40 ms for the 60" model); plus response time of other devices if also involved in stopping the press. page 20 Chapter 2 Installation and Checkout

33 Shadow VI User Manual 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 presses with new brakes or brakes in good condition; a percentage factor of 10 percent is recommended for presses with older brakes. This is because the stopping time for older brakes will be longer due to wear. Therefore, you add less time for older brakes. An example of 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.190 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 VI response time and the braking percentage factor. Let's say our brakes are new. Then we will add 20% additional time to the stop time measurement (.20 x.190 =.038). We also add response time of the 60 Shadow VI (.040 seconds). Then: Ts =.190 sec sec sec. (braking factor) (Shadow VI response time) Ts =.268 Now, we will calculate safety distance: Ds = 63 in/sec x Ts Ds = 63 x.268 Ds = in. Shadow VI heads must be mounted more than inches from the hazardous area using the OSHA formula. 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. Installation and Checkout Chapter 2 page 21

34 Shadow VI User Manual 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 (c) (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 is the OSHA-recommended hand-speed constant. This constant is 63 inches-per-second. The hand-speed constant 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 (or other machine) Ts, the control Tc, and the light curtain Tr. Ts is the stopping time of a press (or other machine) in seconds. It is measured at approximately 90 of crankshaft rotation (or at maximum closing velocity). Tc is the response time of the press control or other machine control. This is the time it takes for the control to activate the press's brake. Tr is the response time of the light curtain. Response time for the Shadow VI is 30 to 40 ms (30 ms for 6" to 24 models, 35 for 30 to 48 models and 40 ms for the 60 model). Tbm is the additional stopping time of the press (or other machine) allowed by the brake monitor. The brake monitor you use with your press control (or other control) stops the press when the preset stop time is exceeded. This means excessive brake wear has occurred. It is time for repair. The brake gradually wears until the limit is reached. T bm allows you to account for brake wear. You add the extra time allowed by the brake monitor to Tc and Ts. In other words: Tbm = brake monitor setting (Tc + Ts) Now the gradual increase in stopping time as the brake wear is accounted for up to the limit. What if you did not account for brake wear? The safety distance would be right at the time you measured stop time. But as the brake gradually wore, safety distance would be too short for proper operator protection. See instructions for your brake monitor to determine the proper brake monitor setting. Generally, the setting is 120% of the measured stopping time (Tc + Ts) when your brakes are new. It is 110% of stopping time (Ts + Tc) for older brakes. page 22 Chapter 2 Installation and Checkout

35 Shadow VI User Manual (The stopping time for older brakes will be longer due to wear. Therefore, you add less time for older brakes. This way, the brake monitor setting comes out approximately the same whether the brakes are new or old). Dpf is the depth penetration factor, and equals 3.3" (8.4 cm). This is a measure of how far an object, like an operator's hand, can move through the light curtain before the light curtain reacts. Dpf is related to the object sensitivity. Object sensitivity is the smallest diameter object that Shadow VI will detect anywhere in its field. Object sensitivity (S) for Shadow VI is 1.25" (3.2 cm), with beam centers of 3/4" (1.9 cm). An object smaller than 11/4" diameter could pass through the light field if it traveled in a path directly between the light beams. European standards discuss object sensitivity as it relates to the type of detection provided. For example, object sensitivity of less than 0.6 (1.5 cm) provides finger detection. Object sensitivities greater than 0.6 and up to 1.3 (~3.3 cm) offer hand detection. Object sensitivities within the hand detection range are equally effective. For Shadow VI with one beam blanked, refer to the section "Blanking windows affect safety distance" further on in this chapter. An example of calculating the safety distance using ANSI formula Here is an example of how to use the formula to calculate safety distance (Ds): First take a look again at the formula we must use: Ds = K x (Ts + Tc + Tr + Tbm) + Dpf Let's use these numbers for our variables in the formula: K (hand speed constant) = 63 inches per second (set by OSHA) T s + T c = sec. We include Ts and Tc together because many stop time measuring devices measure stopping time of the press control as well as the stopping time of the clutch/brake mechanism. T r =.040 sec. (response time of Shadow VI) T bm = sec. (brake monitor setting) sec =.038 sec. D pf = 3.3 Now let's put our numbers into the formula: Ds = K x (Ts + Tc + Tr + Tbm) + Dpf Ds = 63 x ( ) Ds = (63 x.268) Ds = Ds = 20.18" The distance the light curtain must be mounted from the pinch point in our example is 20.18". When using the formula, be sure to do all calculations in this order: (1) Add Ts + Tc + Tr + Tbm first. (2) Multiply the result by 63. (3) Add this result to Dpf. This is Ds. If you do not follow this order, your safety distance calculation will be incorrect. Installation and Checkout Chapter 2 page 23

36 Shadow VI User Manual Perimeter Guarding DANGER CONTROL INSIDE THE GUARDED AREA FOR PERIMETER GUARDING Install the light curtain control outside the guarded area for perimeter guarding applications. Failure to comply with these instructions will result in death or serious injury. For perimeter safeguarding, there is another consideration: walking speed combined with the hand speed. This is because personnel might be walking while simultaneously reaching into a safeguarded area. Although there is no commonly accepted walking speed constant like the hand constant, you might use ergonomic tables or possibly even 100 inches per second, which is a conservative European speed constant. For perimeter guarding, the formula would be: D s = (100) x (T s + T c + T r + T bm ) + D pf Blanking Windows Affect Safety Distance If you use a blanking window or floating blanking window, safety distance is affected, because you are changing the sensitivity of the light curtain. Remember, the minimum size that Shadow VI can sense is an object 1.25" (3.17 cm) in diameter. Anything smaller might fit between two light beams. This diameter (1.25") is called the object sensitivity of the light curtain. A blanking window or floating blanking window blocks one light beam, creating an additional 3/4" (1.9 cm) passageway through the light field where no object will be detected. Now the object sensitivity equals 2" (5.08 cm) wide (11/4"+ 3/4") and the Dpf = 5.9" (15 cm). The ANSI safety distance formula states that if object sensitivity increases, the safety distance must also increase. This means that use of blanking windows will require moving the light curtain farther back from the hazardous area. The rule of thumb for increasing safety distance is this: Add 2.6" (6.6 cm) to the calculated safety distance for every blanking window used up to 2 beams maximum. However, if the area blanked is entirely blocked by a fixture such that operator intrusion into this area is impossible, then you do not have to change the safety distance. For instance, you might have a work table that juts out into the light field but takes up the whole space between the transmitter and receiver which is unprotected by the light curtain. You can blank more than one beam of the light curtain by adding slave windows to the master blanking window. Always remove blanking windows when they are no longer required. page 24 Chapter 2 Installation and Checkout

37 Shadow VI User Manual Pass-through Protection DANGER OPERATOR CAN BE BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA Ensure that the operator cannot position him- or herself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee-to-waist height to prevent the operator or a passerby from being trapped between the light curtain and the hazard. Failure to comply with these instructions will result in death or serious injury. Another important impact on safety distance is pass-through protection. To illustrate, consider that you have determined your safety distance to be 12 inches from the hazardous point of operation pinch point. There is a danger that a person could become trapped between the light curtain and the pinch point. A recommendation would be to install a second set of light curtains at waist height mounted horizontally between the vertical light curtain and the hazard. See the illustration below. With Shadow VI, two sets of optic heads can be wired to the same control box. Press pinch point horizontal set vertical set safety distance Figure 2-2. Plan View Illustrating Pass Through Protection The size of the horizontal light curtain should be the minimum length necessary to detect the thinnest operator standing between the vertical light curtain and pinch point. For example, a 6" light curtain located in the center of a 12" safety distance at waist height may be reasonable. Installation and Checkout Chapter 2 page 25

38 Shadow VI User Manual Height Considerations DANGER IMPROPER INSTALLATION 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. Failure to comply with these instructions will result in death or serious injury. DANGER OPERATOR CAN BE BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA Ensure that the operator cannot position him- or herself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee-to-waist height to prevent the operator or a passerby from being trapped between the light curtain and the hazard. Failure to comply with these instructions will result in death or serious injury. Once you have determined the correct safety distance, you must select the proper curtain height. Shadow VI comes in sizes ranging from 6" to 60". Shadow 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 press without being detected. This is accomplished with the proper height light curtain, combined with ancillary physical guards. Designing and Mounting Brackets Once you have calculated the correct safety distance, you can mount your Shadow transmitter and receiver at this distance from the nearest pinch point (or other hazardous area of the press). This set of steps lists all the information and dimensions you need to know to do a good job in designing and mounting brackets. It covers: 1. What requirements you must meet when choosing your mounting location. 2. How to design and mount the brackets so that the Shadow heads can be easily aligned. 3. Maximum openings for side guards used with Shadow light curtains for three-sided guarding. 4. Mounting Shadow light curtains with mirrors. 5. Mounting Shadow light curtains upside down. A careful reading of this material will ensure that you will not have trouble mounting and aligning your Shadow light curtains. After you read this material, design and mount your brackets. Universal Mounts The Shadow VI transmitter and receiver come with universal mounts. These universal mounts are located at the top and bottom of each head and are held into place by mounting page 26 Chapter 2 Installation and Checkout

39 Shadow VI User Manual screws. They can be rotated ±30 to facilitate installation and alignment. If you need to pivot a bracket more than 30, remove the screws, move the bracket 90, and reattach the bracket to the head. Mounting Location Requirements DANGER IMPROPER INSTALLATION 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. Failure to comply with these instructions will result in death or serious injury. DANGER OPERATOR CAN BE BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA Ensure that the operator cannot position him- or herself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee-to-waist height to prevent the operator or a passerby from being trapped between the light curtain and the hazard. Failure to comply with these instructions will result in death or serious injury. There are two ways to mount the Shadow universal mounts. You can either mount them parallel to the light beam. Or mount them perpendicular to the light beam, as might be done on a gap frame press. When choosing the mounting location, you must make sure the location meets these requirements: 1. Shadow VI heads must always be installed so that it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the press without being detected. 2. The units must be protected from pathways used by forklifts, die carts, and other material-handling equipment. 3. The mounting location must allow unobstructed access to the point-of-operation. 4. Shadow light curtains must be located at an adequate safety distance from the point of operation (pinch point) to allow time for the press to stop once the light curtain has been interrupted. This is explained in the section "Calculating the safety distance" earlier in this chapter. 5. Every route to the press's pinch point or hazardous area must be guarded. Shadow VI transmitter and receiver by themselves provide guarding on one side of the press. Mirrors used with Shadow VI can provide 3-sided protection by "bending" the light curtain around the hazardous point-of-operation. When Shadow mirrors are not used in conjunction with the light curtain, however, other guarding means (such as mechanical side-guards) must be substituted for them, in accordance with OSHA/ANSI guidelines. Installation and Checkout Chapter 2 page 27

40 Shadow VI User Manual How to Design and Mount Brackets or Floor Stands You mount the light curtains to floor stands or to brackets on your machinery using the Shadow flanges on the top and bottom of each unit. Wintriss does not supply brackets or stands with Shadows. You must supply your own. This section lists the factors you must consider when designing and mounting brackets or stands. If you need more specific information about designing and mounting brackets for your particular machinery, do not hesitate to call our technical services department. If you cannot make your own brackets, we can also give you information on where you can buy various types of brackets. Brackets must meet these four conditions: 1. They must provide a rigid mounting surface for the Shadow heads. With stands, they must be rigidly attached to the floor. 2. They must bring the Shadow heads out far enough away from the point of operation to exceed the calculated safety distance. 3. They must allow the light curtain to be easily aligned. 4. They must allow you to use shock mounts to mount the optic heads. Four shock mounts are shipped for each head. It does not matter what type of brackets you design as long as they meet these four conditions. The illustrations (Figure 2-3) on the following page show several types of brackets you can make. It gives you an idea of just some of the types used. See Figure 2-4 and Figure 2-5 for layout and hole dimensions of the light curtain. Brackets have to be configured to fit the shape of your particular press. For instance, on some machinery like straight side presses you can mount angle iron (L-shaped) brackets directly to a sidewall of the press (see Figure 2-8). On other machinery, like gap frame presses or bending rolls, you may have to mount the Shadow light curtains from the bed or platform of the press. On gap frame presses, do not attach the top Shadow VI bracket to the press frame and the bottom bracket to the bolster. The upper portion of the press will deflect (pull away) from the bolster during the work portion of the stroke. When mounting brackets on the bolster of presses, choose your location carefully. Make sure the brackets do not prevent dies from being removed from the press. Brackets used must be made of strong, thick steel so mounting is rigid. These are only a few of the designs you can make or use. They are shown only to give you an idea of what brackets are. Many different designs are possible as long as all mounting requirements are met. page 28 Chapter 2 Installation and Checkout

41 Shadow VI User Manual L-shaped brackets with side supports for rigidity Box type brackets Wedge-shaped bracket good for mounting units to bed or wall of machinery Long angle iron type of bracket. Here one unit mounts right on one large bracket. Figure 2-3. Brackets for Shadow Light Curtains Installation and Checkout Chapter 2 page 29

42 Shadow VI User Manual Table 2-1. Light Curtain Dimensions: inches (cm) * see Figure 2-4 Size A B C 6 (15) 7.75 (19.7) 9.5 (24.1) 11 (27.9) 12 (30) (34.9) 15.5 (39.4) 17 (43.2) 18 (45) (50.2) 21.5 (54.6) 23 (58.4) 24 (61) (65.4) 27.5 (69.9) 29 (73.7) 30 (76) (80.6) 33.5 (85.1) 35 (88.9) 36 (91) (95.9) 39.5 (100.3) 41 (104.1) 42 (106) (111.1) 45.5 (115.6) 47 (119.4) 48 (122) (126.4) 51.5 (130.8) 53 (134.6) 60 (152) (156.8) 63.5 (161.3) 65 (165.1) page 30 Chapter 2 Installation and Checkout

43 Shadow VI User Manual (6.5) 2.1 (5.3) 2. 5 (6.4) (min. req'd blk. wind. cable allowance) (4.1).75 (1.9).5 (1.3) 2.75 (7) 2.1 (5.3) (3)(.7).12 (.3) location of 1st beam 1. 5 (3.8) (5.9) blanking window.75 (1.9) see Table 2-1 A B C 3 (7.6) (min. req'd heads cable allowance) 1.5 (3.8) ** Use 1/4-20 bolts for mounting Figure 2-4. Shadow VI Optic Heads Mounting Dimensions Installation and Checkout Chapter 2 page 31

44 Shadow VI User Manual (82,6) 1.5 (38,1) (64,8) 1.5 (38,1) 1.05 (26,7) 2.10 (53,3) 2.75 (69,9) Dimensions: inches (mm) Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts) page 32 Chapter 2 Installation and Checkout

45 Shadow VI User Manual Shadow optic heads must be attached at both ends so that vibration does not cause the units to go out of alignment. It is all right to mount Shadow VI brackets to your press at one end only (to the bolster of a press, for instance). However, the bracket must be designed so that the shock mounts supplied with your heads can be placed between the head and the bracket. You can mount your Shadows directly to a vertical wall or column of your press if the location meets all mounting requirements, including safety distance. Installing Brackets with Alignment in Mind The bracket design must allow adjustment of the Shadow VI heads once they are mounted. Shadow light curtains may have to be moved slightly up or down or rocked slightly to one side or the other to align them once they are mounted (you will see why when we discuss alignment). As we mentioned earlier the Shadow universal mounts allow subtle adjustments of the heads. These mounts can be rotated ±30 to facilitate installation and alignment. If you need to pivot a bracket more than 30, remove the mounting screws, move the bracket 90, and reattach the bracket to the head. Alignment Considerations Although Shadow is easy to align and tolerant of vibration and shock, optic life is improved by alignment optimization. Optimum alignment can easily be accomplished using the optional Laser Alignment Tool (see "Using the Laser Alignment Tool" later in this section), which slides along the groove on either optic head. As long as the phototransistor's field is anywhere within the funnel-shaped path of the light beam, Shadow will align. The optic heads don't have to be perfectly aimed (see Figure 2-6). What alignment means The alignment procedure is explained in the section "Aligning and tightening down Shadow VI components". For Shadows to operate properly, each infrared LED emitted horizontally from the Shadow transmitter must be detected by each PT in the receiver. The PTs as well as the LEDs are located on the front of each unit. You cannot see them but their location can be determined using the alignment indicator guides on the Shadow receiver. To find the mating beam on the transmitter, use the same measurement from the base of the receiver to the lowest indicator guide. Each LED must match up with its opposite phototransistor when the Shadow light curtains are mounted as shown in the next illustration. Therefore, Shadow optic heads must be mounted in the same plane. You should always try to mount the brackets as precisely as possible. Then, the alignment procedure in the section "Aligning and tightening down Shadow VI components" will be easy. Also note that the optic heads don't have to be mounted vertically (although this is certainly a common approach). They can be mounted at any angle as long as they are in the same plane. Installation and Checkout Chapter 2 page 33

46 Shadow VI User Manual If PT is in funnel-shaped light path, Shadow is in alignment, even if optic heads are not perfectly aligned. funnelshaped light path phototransistor (PT) transmitter receiver light beams plane of alignment Figure 2-6. Transmitter and Receiver Properly Aligned transmitter receiver Laser Alignment Tool laser's alignment path Laser Alignment Tool is used to achieve optimum alignment. Installing it at the very top and very bottom of optic head will not block any beams. Figure 2-7. Using Laser Alignment Tool to Properly Align Shadow page 34 Chapter 2 Installation and Checkout

47 Shadow VI User Manual Aligning brackets When mounting your brackets you can draw a leveling line using the center of the bracket holes as the end points (see the next illustration). When you mount the Shadow VI flanges onto the bracket holes, the Shadow light curtains will be aligned (or at least very close). Use a plumb or leveling line and square to properly align the brackets. Use the bed of your press (if applicable) or the floor as a leveling reference point. Make sure that the brackets are placed in the same plane. levelling lines through center of bracket holes top mounting holes bracket Figure 2-8. Aligning Brackets Using Mounting Holes So Shadow Light Beams Line Up Later When Mounted Maximum Openings for Side Guards When mechanical side guards are used in addition to the Shadow light curtains for three sided-guarding, you must ensure that the openings between or around the guards meet OSHA requirements. You must also make sure that the openings in the guard material itself (wire, extruded mesh, rods, etc.) or openings between the guards and working surface meet OSHA requirements. OSHA requirements for the maximum openings allowed in guards or between the guards and the top and bottom of the working surface are listed in OSHA Table See Table 2 2. Installation and Checkout Chapter 2 page 35

48 Shadow VI User Manual Table 2-2. OSHA Table 0-10 Distance of opening from pinch point Maximum Dimension of Opening 1/2" to 1 1/2" 1/4" 1 1/2" to 2 1/2" 3/8" 2 1/2" to 3 1/2" 1/2" 3 1/2" to 5 1/2" 5/8" 5 1/2" to 6 1/2" 3/4" 6 1/2 to 7 1/2" 7/8" 7 1/2" to 12 1/2" 1 1/4" 12 1/2" to 15 1/2" 1 1/2" 15 1/2" to 17 1/2" 1 7/8" 17 1/2" to 31 1/2" 2 1/8" Using Mirrors with Shadows NOTICE MIRRORS DECREASE SCANNING DISTANCE AND ANGLE OF DIVERGENCE Allow for a reduction in scanning range of 10% for each mirror you use. For example, if your extended range unit normally scans 50 and you use two mirrors, it will now scan 40 (50 minus 10 ). Allow for a reduction in angle of divergence if you use mirrors. This greatly reduces the light curtain s tolerance of vibration and makes alignment more critical. You can use mirrors with Shadow VI for two- or three-sided guarding. Wintriss offers frontreflective mirrors that provide optimal light transmission or reflection. Mirrors can be optionally purchased from Wintriss. Dimensions for mirrors are shown in Figure 2-9. Wintriss does not recommend the use of other mirrors or other reflective surfaces as they may severely reduce vibration tolerance or scanning distance. The Shadow transmitter and receiver are aimed at the mirrors. The light beam is reflected from the transmitter to the receiver by way of the mirrors. This method could be used on any type of machinery where three-sided guarding is needed. When using mirrors, your setup will look similar to the drawing in Figure You do not have to arrange the Shadow light curtains and mirrors in a rectangle as shown, however. You can adjust the mirrors to reflect light from the Shadow VI transmitter at other angles besides right angles. Shadow VI aligns in the same way using mirrors as without them. Even though the transmitter and receiver will not be pointed at each other, the units and the mirrors page 36 Chapter 2 Installation and Checkout

49 Shadow VI User Manual must be mounted in line with each other so each phototransistor in the receiver can detect the light beam coming from its opposite light emitter. The Laser Alignment Tool (illustrated in Figure 2-6 and Figure 2-7) is a useful tool when installing mirrors. 50 MAX Top view See table A B C D 2.25 (5.72) 1 (2.54).75 (1.91) 2 (5.08) 3.25 (8.26) 3.75 (9.53) 4.62 (11.73).19 (.48) 1.75 (4.45) 3.89 (9.88) 1 (2.54) Model A B C D Figure 2-9. Shadow VI Mirror Dimensions Installation and Checkout Chapter 2 page 37

50 Shadow VI User Manual receiver corner mirror light beams transmitter corner mirror Figure Representation of Shadow with Mirrors for Three-sided Guarding Use of Laser Alignment Tool Is Useful During Mirror Installation page 38 Chapter 2 Installation and Checkout

51 Shadow VI User Manual Using Weld Shields The operation of Shadow VI 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. 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. (see the Troubleshooting Guide in Chapter 4 of this manual). If you want to install a weld shield, you must order a separate kit (weld shield #42873xx, where xx is the height of the optic head in inches) for each optic head. Detailed instructions for installation are included in each kit, along with the necessary screw and clip(s). Each optic head has a screw hole for mounting a shield. Mounting Shadow Light Curtains Upside Down There is nothing inherent in the design of Shadow VI heads that prevents them from being mounted upside down. If you are mounting Shadow VI this way for any reason, both heads must be inverted. Shadow heads can also be mounted at any angle as long as they are in the same plane. Vertical mounting is the easiest. Avoiding Cross Talk When Mounting 2 Sets of Shadows Because the receiver only accepts infrared light pulses of a certain duration in proper sequence, Shadow cannot be affected or fooled by other light sources. All other continuous light sources and even pulsed light sources are "tuned out", and Shadow continues to work. Also, changes in area lighting or even flashing strobe lights will not affect operation. 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 proper sequence. Instead it would send a stop command to the press. In some cases, however, using two sets of Shadows in close proximity of each other may cause "cross talk". Cross talk occurs when the LEDs from the first set's transmitter are detected by the phototransistors from the second set's receiver. If your application requires that you mount a set of Shadows horizontally next to a vertical set to detect an operator between the vertical set and the pinch point, you may need to alternate these sets to avoid any incidence of cross talk between sets. To do this, you may need to mount the horizontal transmitter next to the vertical receiver and vice versa. Another scenario where cross talk may occur involves machines that are close together. Use caution if the guarded machines are too close together, such that the light from one transmitter may be detected by the other press's receiver. To avoid any incidence of cross talking, you can select from several solutions. One is to insert a barrier of some type, such as a blind, between the two sets of Shadow heads. Make sure that the barrier runs all the way from the transmitter to the receiver. A second approach is to reverse the position of the transmitter and receiver on the second press. Another option is a combination of the above. The next illustration shows reversing the position of the optic heads on the second press. Installation and Checkout Chapter 2 page 39

52 Shadow VI User Manual Press #1 Press #2 RX TX TX RX Figure One Way to Avoid Cross Talk - Reversing Transmitters (TX) and Receivers (RX) Loosely Mounting Shadow VI Transmitter and Receiver CAUTION FAULTY SHOCK MOUNT INSTALLATION Install the shock mounts between the mounting surface and the universal mounting brackets that hold the optic heads in order to protect the heads from damage. Failure to comply with these instructions could result in property damage. Leave the Shadow VI heads loose on their mounting brackets so that you can properly determine wiring length and conduit required. You will align and tighten the heads later. Shock mounts are provided to help protect the optic heads of your Shadow VI from damage due to shock or vibration. Follow the steps below to loosely mount the optic heads (transmitter and receiver). 1. Locate four mounting holes for each head, in either your brackets or on a solid surface as described above. The shock mount studs have 1/4-20 threads. For installation into a solid surface, use a No. 7 drill and 1/4-20 tap. For through-installation onto a metal bracket, drill clearance holes. 2. Before mounting the optic heads, install four shock mounts for each head. Thread a shock mount into each of the four tapped holes in the mounting surface (Figure 2-12, next page), or use a lock washer and nut to secure each shock mount to a metal bracket. 3. Using lock washers and nuts, loosely mount the optic heads onto the shock mounts, as indicated in Figure Follow the instructions below to complete the installation. You will align and adjust the heads (page 61) after you mount and wire the control. page 40 Chapter 2 Installation and Checkout

53 Shadow VI User Manual Shock mount (4 places) Lock washer (4 places) Nut (4 places) Universal mounting bracket Optic head (transmitter or receiver) Mounting surface Figure Mounting an Optic Head with Shock Mounts Installation and Checkout Chapter 2 page 41

54 Shadow VI User Manual Mounting the Control DANGER CONTROL AFFECTS LIGHT CURTAIN OPERATION Install the light curtain control in a location where access to it will not affect the operation of the light curtain. Failure to comply with these instructions will result in death or serious injury. DANGER CONTROL INSIDE THE GUARDED AREA FOR PERIMETER GUARDING Install the light curtain control outside the guarded area for perimeter guarding applications. Failure to comply with these instructions will result in death or serious injury. 1. Determine an appropriate location to mount the control. It should be mounted in an area where personnel can easily see the warning indicators and also have access to the circuitry, without interfering with the operation of the light curtains. The control must never be installed inside the protected area in perimeter guarding applications. The enclosure can be mounted to the press, on a free-standing pedestal, on a pendant, or at the entrance of a location used for area guarding. 2. Drill four holes for mounting, and tap, if necessary. Shock mount studs are 1/4-20. Mount the enclosure using the enclosed shock mounts and mounting flanges. Use a No. 7 drill and 1/4-20 tap. Refer to Figure 2-13 for mounting dimensions. Connecting RF (Radio Frequency) Ground To reduce electromagnetic interference, connect the RF ground terminal on the top of the control enclosure (Figure 2-13) to a clean ground using a low-impedance ground strap. If your installation does not experience electromagnetic interference, you may not need to use this additional grounding. NOTICE A clean ground is a connection to the earth separate from the electrical service (green wire) ground. A low-impedance ground strap is made from braid at least 1/2 (1.25 cm) wide. page 42 Chapter 2 Installation and Checkout

55 Shadow VI User Manual Connect this terminal to a clean ground using a low impedance ground strap. See Connecting to RF ground. inches (cm) 3.50 (8.89) 8-32 thread 0.31 (0.79) 4 places CURTAIN CLEAR FLOATING WINDOW STOP SIGNAL RESET REQUIRED 9.75 (24.76) 9.00 (22.86) OPERATE RESET LIGHT CURTAIN 5.00 (12.7) typical, 2 places 7.00 (17.78) Figure Shadow VI Control Enclosure Mounting Dimensions Installation and Checkout Chapter 2 page 43

56 Shadow VI User Manual 1 TB1 POWER TB1 OPTIC HEADS POWER LED DS4 F1 S2 CAUTION POWER TRANSFORMER 115 V OPTIC HEADS POWER LED DS3 VOLTAGE SWITCH DISPLAY CONNECTOR J11 F2 F3 K1 K2 F4 K3 FUSES OBSTRUCTION LEDS DS1 DS2 KEYLOCK SWITCH CONNECTOR J13 STATUS RELAY SS INDICATOR OUTPUTS GRN AMB RED YEL V-OUT TB5 1 1 SET/2 SETS JUMPERS J12 MPCE2 JUMPER MPCE1 JUMPER TB4 TRANSMITTER 1 FSD1 FSD2 STAT GND VCR VCC GNDSHUTDOWNSYNCSHIELD UPPER 1-10 TB3 1 UPPER 1-10 (#1) MPCE1 MPCE2 DS6 RESET XMTR INT J15 INT J14 STOP CIRCUITS DS5 ON OFF PWR UP RESET DISABLE TRANSMITTER LOWER LOWER (#2) MPCE2 LED MPCE1 LED VCR VCC GND SHUTDOWN SYNC SHIELD TRANSMITTER 2 TB2 1 1 SET FWIN VCC GND 1B 1A SYNC SHIELD FWIN VCC GND 2B 2A SYNC SHIELD RECEIVER 2 RECEIVER 1 UPPER 1-10 (#1) RECEIVER LOWER (#2) RESET ON LED TRANSMITTER ACTIVE LED DS8 RESET ON INTERRUPT FLOATING WINDOW STAT=GRN OPTIONS S4 S1 Figure Location of Components, Shadow VI Control (Important components shown and labeled) page 44 Chapter 2 Installation and Checkout

57 Shadow VI User Manual Wiring the Transmitter and Receiver to the Control DANGER 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 PRESS MAY CONTINUE TO MOVE AFTER INTRUSION Ensure that Shadow is wired to the emergency stop circuitry of the press. Ensure that any stop initiated by the light curtain is an immediate stop, one that occurs immediately after the stop signal is sent to the machinery. (If the light curtain is wired by mistake to the top-stop circuitry, the press continues its stroke until it reaches the top of the stroke, even after an intrusion or obstruction is detected.) Failure to comply with these instructions will result in death or serious injury. DANGER STOP CIRCUITS NON-OPERATIVE IN SOME MODES Wire the light curtain to your press control circuit so the stop signal from the light curtain stops the machine immediately in all modes of operation, including inch. Failure to comply with these instructions will result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD Ensure that the power source is off before you make any wiring connections. Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Ensure that all procedures are performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. NOTICE LOCKOUT MAY NOT BE REQUIRED If light curtains are installed so they are active in all press operating modes, it may not be necessary to lock out the press during routine die changes. Refer to the relevant safety standards for more details. Installation and Checkout Chapter 2 page 45

58 Shadow VI User Manual The instructions below describe how to wire the Shadow transmitter and receiver to the control. Terminating Shields of the Head Cables, next section Connecting the Head Cables to the Control, page 47 If You Have a Second Set of Shadow Optic Heads, page 49 Terminating Shields of the Head Cables The shields of the head cables must be terminated close to their entry into the control box. Follow the instructions in this document for terminating these cable shields. Follow the steps below to terminate the shields of the cables that connect to your light curtain heads. Refer to the figure above, the tables on the next page and the figure at the end of this document. 1. Strip the cable jackets back as far as the end of the conduit fittings. 2. Cut the drain wires to a length that they can reach and be inserted into the set screw terminal. 3. Loosen the set screw in the set screw terminal. Twist together the ends of the drain wires and insert in the hole in the set screw terminal under the end of the set screw. 4. Tighten the set screw and check that all drain wires are firmly connected. 5. Connect the rest of the wires in the cables to the terminal blocks as instructed in the next section. Set screw terminal Drain wires Figure Terminating Drain Wires to Set Screw Terminal Showing Connection for Two Pairs of Heads page 46 Chapter 2 Installation and Checkout

59 Shadow VI User Manual Connecting the Head Cables to the Control NOTICE Terminate the shields of the head cables as instructed in the previous section. 1. Find the two interchangeable quick connect cables, and plug them into the bottom of the transmitter and receiver. The connection is keyed. Twist the locknut so the connection is tight. 2. Run the cables through separate 1/2" flexible, liquid-tight conduits from the Shadow VI transmitter and receiver to the knockouts at the bottom of the control (receiver should go into right front knockout and transmitter into the center). Because the control enclosure is rated NEMA 2/IP52, you must use conduit of the same rating and make proper connections to ensure suitable protection with the enclosure. NOTICE If you have a second set of Shadow heads, wire them through the remaining knockouts. 3. Next you need to properly terminate the conduits at the transmitter and receiver. You can use either of these approaches or one of your own. In either case, you must supply your own parts. a. Use cord grips to secure the cables in the liquid-tight conduits and 1/2" hose clamps to support the conduits in place close to the transmitter and receiver. b. Use 2 junction boxes located near the transmitter and receiver to secure the cables and the liquid-tight conduits. 4. Open the control by loosening the locking screw. Terminate the cable shield for each cable as described in the next section. 5. Locate terminal blocks TB2 and TB3. Refer to the location of components pictured in Figure 2-14 earlier in this chapter. Notice that there are actually two connectors at TB2 and two at TB3. If you have only one set of Shadow heads, the receiver will be wired into the upper level TB2 connector, and the transmitter into the upper level TB3 connector. If you have a second set, they are wired into the lower levels of TB2 (receiver 2) and TB3 (transmitter 2). NOTICE LABEL CABLES CAREFULLY Carefully label the transmitter and receiver cables inside the control. This will help troubleshoot the light curtains after installation, if necessary. If you connect two sets of heads, be sure to separately label the cables for set #1 and set #2. 5. Measure the wires to fit and cut the wires as necessary. 6. Start by wiring the receiver. Remove the L-shaped connector from TB2 (upper level). Attach the wires to this connector as shown in Table 2-3 at the end of this section. You can also refer to Figure 1 at the end of this manual. Installation and Checkout Chapter 2 page 47

60 Shadow VI User Manual To connect a wire, find the correct terminal and loosen the screw over it by turning it counterclockwise. Strip the correct wire for this terminal 1/4" (6.4 mm) from end. Insert bare wire into the terminal 90% of the way. Tighten the screw. The metal tooth inside the terminal will clamp down on the bare wire for a tight connection. Make sure that the metal tooth is clamped down on the bare part of the wire, not on the insulation. 7. Once you have completed the wiring for the receiver, plug the L-shaped connector firmly back into its base. It only can go in one way. 8. Now wire the transmitter. Remove the L-shaped connector from TB3 (upper level). Attach the wires to this connector as shown in Table 2-4 at the end of this section. You can also refer to Figure 1 at the end of this manual. 9. Once you have completed the wiring, plug the L-shaped connector firmly back into its base. It only can go in one way. 10. Make sure you have properly connected all wires and have double checked all connections when done. Table 2-3. Connecting Light Curtain Receiver Head to TB2 in Controller Set #1 Heads to Upper Level; Set #2 Heads to Lower Level RCVR TB2 Wire color Terminal signal Pin #1 orange FWIN Pin #2 red VCC Pin #3 blue and black GND Pin #4 brown 1B Pin #5 green 1A Pin #6 yellow SYNC Terminate shield to set screw terminal near entry point. (See Terminating Shields of the Head Cables, page 46.) page 48 Chapter 2 Installation and Checkout

61 Shadow VI User Manual Table 2-4. Connecting Light Curtain Receiver Head to TB3 in Controller Set #1 Heads to Upper Level; Set #2 Heads to Lower Level XMTR TB3 Wire color Terminal signal Pin #1 orange VCR Pin #2 red VCC Pin #3 blue and black GND Pin #4 brown SHTD Pin #5 green SHTD Pin #6 yellow SYNC Terminate shield to set screw terminal near entry point. (See Terminating Shields of the Head Cables, page 46.) If You Have a Second Set of Shadow Optic Heads NOTICE W HEN USING TWO SETS OF HEADS Carefully label the transmitter and receiver cables for set #1 and set #2. This will help with troubleshooting your Shadow installation, if necessary. Run the cables for set #2 in a separate conduit from set #1 s cables. Set Jumper J12 to 2 SETS. See page 61. If you have a second set of optic heads, follow the steps in the previous section to connect the head cables of the second set of heads to the lower level of TB2 (receiver 2) and TB3 (transmitter 2) in the control. Run the cables in separate conduits. Refer to Tables 2-3 (for receiver) and 2-4 (for transmitter). Set Jumper J12 to 2 SETS. This enables operation of the second set of heads. See page 61. Installation and Checkout Chapter 2 page 49

62 Shadow VI User Manual Connecting AC Wiring to the Control WARNING ELECTRIC SHOCK HAZARD Ensure that the power source is off before you make any wiring connections. Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Ensure that all procedures are performed by qualified personnel. Complete all installation procedures before connecting wires to the AC power source. Failure to comply with these instructions could result in death or serious injury. Wiring is a straightforward and simple procedure. The control is wired to a 115 VAC Hz single phase power source. (Note: Shadow VI can also be used with 230 VAC, 50 Hz. Step 4 below explains how to switch to 230 VAC.) Follow these wiring guidelines: All wires can be run through a flexible liquid-tight conduit to the control as long as all circuits are the same voltage. If your emergency stop circuits are low voltage circuits (such as 24V), run two conduits for instance, one for 115V wires and one for 24V wires. Bring the wiring connections for AC power to a convenient point so that you can tie them to the appropriate connector. No. 16 wire is recommended for these circuits (No. 14, if local codes require it). Follow the steps below to connect AC wiring to your control. 1. Open the control. Near the top left of the control board, you will see the connector for AC power (terminal block TB1) and the power supply (to the right of TB1). TB1 Figure Terminal Block TB1 Connections 2. Determine how you will bring wiring from your 115 VAC power source (or 230V source if applicable) to the knockout hole at the top of the unit. These wires should be connected directly to the press control transformer. For 115 VAC, you need three wires high (red), neutral (white) and ground (green). page 50 Chapter 2 Installation and Checkout

63 Shadow VI User Manual Locate the 115V-230V voltage selector switch (S2) on the control board. It is located just below TB1. If your AC power is 115V, check to see that "115V" is displayed in the switch cavity. If your AC power is 230V, push the handle down. 115V Handle. Push down for 230V Figure Setting Voltage Selector Switch S2 4. Run the power wires to the control enclosure. If your stop circuits are 115V, the AC wiring and stop circuits will enter the enclosure through the same flexible, liquid-tight conduit (ideally, top). If the stop circuits are 24V, then 115V goes through the top knockout and 24V goes through the bottom left (refer to the next section for specific instructions). To maintain the control enclosure's NEMA 2/IP52 rating, you must use conduit of the same rating and make proper connections to the control. 5. Make proper AC wiring connections as shown in wiring diagram Figure 6 at the end of this manual. 6. Connect the electric service ground (green) wire to the set screw terminal on the inside left side of the enclosure, as shown below. Ground wire pre-wired to stud on case Connect AC ground wire (green) to set screw terminal TB Figure Connecting to Protective Earth Ground Set Screw Terminal Installation and Checkout Chapter 2 page 51

64 Shadow VI User Manual 7. Leave a service loop at the control to allow for later adjustment of the conduit. Cut the wires as necessary. Proceed to the next section "Connecting Stop Circuits to the Control". Do not connect wires to AC power source until you are done with all other installation procedures. Connecting Stop Circuits to the Control DANGER 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 PRESS MAY CONTINUE TO MOVE AFTER INTRUSION Ensure that Shadow is wired to the emergency stop circuitry of the press. Ensure that any stop initiated by the light curtain is an immediate stop, one that occurs immediately after the stop signal is sent to the machinery. If the light curtain is not correctly wired in this way, the press may continue its stroke after an intrusion is detected.( Failure to comply with these instructions will result in death or serious injury. DANGER STOP CIRCUITS NON-OPERATIVE IN SOME MODES Wire the light curtain in series with your press control circuit so the stop signal from the light curtain stops the machine immediately in all modes of operation, including inch. Failure to comply with these instructions will result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD Ensure that the power source is off before you make any wiring connections. Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Ensure that all procedures are performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. page 52 Chapter 2 Installation and Checkout

65 Shadow VI User Manual NOTICE LOCKOUT MAY NOT BE REQUIRED If light curtains are installed so they are active in all press operating modes, it may not be necessary to lock out the press during routine die changes. Refer to the relevant safety standards for more details. Wiring the control into your press's emergency stop or equivalent circuitry (e.g. emergency stop circuitry) ensures that whenever an obstruction or intrusion is detected, the press will stop as quickly as its clutch/brake system (or other system) will permit. Follow these instructions to connect to a traditional relay control. If you are connecting to a PLC, refer to the instructions at the end of this section. Bring the wiring connections for the emergency stop circuits to a convenient point so that you can tie them to the appropriate connector. No. 16 wire is recommended for these circuits (No. 14, if local codes require it). 1. Determine how you will connect the wires from the control to your press control emergency stop circuit. You wire the circuit at your press control. Refer to Figure 2 or Figure 3 at the end of this manual and your press control manual or other electrical prints. You need two wires for the emergency stop circuit. 2. As we mentioned in the previous section, if your stop circuits are 115V, the AC wiring and stop circuits will enter the control through the same conduit (ideally, top). If the stop circuits are 24V, then 115V goes through the top knockout and 24V goes through the bottom left. 3. If entering from the top, make sure that you carefully dress the two wires neatly to the left inside the control. CAUTION TERMINAL BLOCK TB4 WIRED INCORRECTLY Wire stop circuits to the upper level of terminal block TB4, not the lower level. If you wire to the lower level, this could damage components on the circuit board. Failure to comply with these instructions could result in property damage. 4. Now locate terminal block TB4 on the control circuit board to wire the emergency stop circuits. Notice that there are two levels at TB4 - "upper" and "lower". The stop circuits must be wired into the upper (higher) level connector. There is also a "lower" TB4 connector on the control circuit board. 5. There is one factory-installed jumper in place on the upper TB4 connector between pins 3 and 5 (see Figure 2 or Figure 3 at the end of this manual). Make sure this jumper is firmly installed. Do not remove this connector or the jumpers There is one factory-installed jumper (XMT INT) in place on the lower TB4 connector between pins 19 and 20 (see Figure 2 or Figure 3 at the end of this manual). Make sure this jumper is firmly installed. Do not remove this connector Remove this jumper only if you use an external transmitter interrupt. Installation and Checkout Chapter 2 page 53

66 Shadow VI User Manual If you plan to perform optional wiring (for instance MPCE monitor inputs or external interrupt), refer to the section "Optional Wiring", found later in this chapter for additional information. FSD1 (1-3) FSD2 (4-6) STATUS (7-9) TB4 immediate stop Figure Relays Wired to Emergency Stop Circuit, Typical active in all modes of operation When wiring Shadow VI into the press circuit, you should ensure that it is active in all modes of operation. This would include inch, single stroke, and continuous. Following this practice will provide safety for setup personnel as well as the operator. In some cases, having Shadow VI active in all modes may even eliminate the need for lockout during a die change. See OSHA "Lockout/Tagout" for details. (Note: For PLC connections, see step 8B.) The next set of instructions explains how to continue to wire the relays in series. Refer to the instructions below. The corresponding wiring schematics (Figure 2) can be found at the end of the manual. 6. Connecting in series with Machine Emergency Stop (Figure 2): CAUTION TERMINAL BLOCK TB4 WIRED INCORRECTLY Wire stop circuits to the upper level of terminal block TB4, not the lower level. If you wire to the lower level, this could damage components on the circuit board. Failure to comply with these instructions could result in property damage. Refer to Figure 2 to connect the two stop relays in series with the press's emergency stop circuit. The relays, which are labeled "FSD1" and "FSD2," are located on the upper level of the TB4 connector on the control circuit board. The descriptions of these terminal locations are as follows: FSD1: Final switching device #1 (stop output relay #1) FSD2: Final switching device #2 (stop output relay #2) At the upper level of TB4, connect pins #2 and #6 in series with the press's stop circuits. Do not remove the factory-installed jumper across #3 and #5. page 54 Chapter 2 Installation and Checkout

67 Shadow VI User Manual factory-installed jumper across #3 and #5 N/C Co m. N/O N/C Co m. N/O N/C Co m. N/O TB4 FSD1 (1-3) Stop output FSD2 (4-6) (7-9) Status output GND Figure Wiring "Upper" TB4 Connector in Control 7. Once you have completed the wiring of the relays (according to step 6), remember to leave a service loop at the control to allow for later adjustment of the conduit. Cut the wires as necessary. Keep going in this section to connect to WPC or a PLC. If you do not need to perform either if these installation procedures, skip to the next section "Making settings inside the control". NOTICE Guidelines for making these connections are covered in these steps: 8A. Wiring Shadow to the WPC 8B. Wiring Shadow to a programmable logic controller (PLC) 8A. Wiring Shadow to the WPC (One or Two Control Boxes) If you are connecting the control to WPC, see Figure 6 at the end of this manual. To connect 2 control boxes, refer to Figure 7 also found at the end of the manual. It shows how Shadow must be connected to the resolver-based WPC. If you have a WPC 1000 see Figure 10 at the end of the manual. If you have an older-model WPC, refer to Figure 9 at the end of the manual. Once you make connections, proceed to the next section "Making settings inside the control". If you have the optional Shadow VI-WPC control board, refer to Appendix C and Figure 8 for specific instructions. Installation and Checkout Chapter 2 page 55

68 Shadow VI User Manual 8B. Wiring Shadow to a PLC DANGER INCORRECT WIRING TO A PLC Ensure that the light curtain control is properly wired to your PLC. Follow the guidelines in the applicable ANSI standard, ANSI B11.1. The guidelines below serve as a reminder of the importance of connecting your light curtain correctly when using a PLC. Do not wire the outputs in series when connecting Shadow to a PLC. Be aware that the details of wiring and programming the PLC are solely your responsibility, and not Wintriss s. Use a single safety PLC or multiple non-safety PLCs. Failure to comply with these instructions will result in death or serious injury. CAUTION TERMINAL BLOCK TB4 WIRED INCORRECTLY Wire stop circuits to the upper level of terminal block TB4, not the lower level. If you wire to the lower level, this could damage components on the circuit board. Failure to comply with these instructions could result in property damage. When wiring the control to a Programmable Logic Controller (PLC) or other type of microprocessor-based control, two (or more) independent logic systems should be used to control the press's stop circuit. Wintriss does not provide specific step-by-step instructions for connecting Shadows to PLCs. This is because of the variety of PLCs and the various programming techniques used. Only general guidelines are supplied in this section. Refer to Figure 4 at the end of the manual for suggested wiring. We recommend you carefully study the ANSI guidelines in Appendix C of the ANSI B11.1 standards before connecting Shadow to a PLC. Appendix C gives detailed guidelines for using PLCs to control the clutch and brake on metal stamping presses. Appendix C is entitled "Some Considerations for Design of Microprocessor-Based Clutch/Brake Controls." To ensure maximum safety, you must wire and program the PLC so it can detect an internal component failure and immediately stop the press. Both outputs from Shadow's control relays must be connected separately to a PLC. These outputs are marked "FSD1" and "FSD2" (see Figure 2-20). You must remove the factory-installed jumper (as shown in Figure 4 at the end of the manual) when connecting to a PLC. Next, you must create a program that will check each input signal from the Shadow relays independently. The program should stop the press immediately if the input signals ever differ. That way, a component failure within the PLC will be immediately detected. Also, with Shadow relays wired to the PLC separately, if one of Shadow's control relay contacts were to weld shut preventing the stop signal to the PLC, the other relay contact would still open to send the stop signal. If you do not connect the control to the PLC properly, here is what could happen. A component in the PLC fails. This causes the PLC to incorrectly read the input signals. Even page 56 Chapter 2 Installation and Checkout

69 Shadow VI User Manual though Shadow signals a stop, the PLC does not stop the press. This situation must not be allowed to occur. If the control is connected to a PLC instead of directly to the machinery, then the PLC must be able to transfer Shadow's control reliability capability to the press stop circuit. If this capability is overridden or if the PLC cannot detect a failure of its own components, much of Shadow's protection features are lost even though Shadow is working properly. This is why it is essential that you do not override Shadow's control reliability features when using Shadow with a PLC. After completing this step, proceed to the next section. Shadow allows you to test your PLC's input modules, adding another level of safety to your operation. Wire the PLC to the transmitter interrupt at pins #19 and #20 on TB4 auxiliary connector. (Be sure to remove the factory-installed jumper at pins #19 and #20.) The PLC can momentarily interrupt the transmitter's function (#19, #20 at TB4), watch the redundant output relays open, and then resume the transmitter's operation and watch the relays close. If the input modules do not respond properly and simultaneously, the PLC can inhibit the press from further operation until the PLC inputs have been checked out. Optional Wiring This section provides instructions to wire various optional Shadow VI features, including remote reset, indicator outputs, and MPCE monitor input. Indicator Outputs DANGER 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 only the safety outputs for personnel protection. Failure to comply with these instructions will result in death or serious injury. You can wire up to 4 indicator outputs to customer-supplied solid-state relays. These outputs, which are open collectors to ground, allow you to view Shadow's operating status at a remote location by mimicking the indicators at the Shadow control. Connect the positive input wire from your 12VDC solid-state relay to pin #5 ("V out") at TB5 connector inside the control. Wire pins #1 (Green), #2 (Amber), #3 (Red), and #4 (Yellow) as needed according to Figure 5 at the end of the manual. Installation and Checkout Chapter 2 page 57

70 Shadow VI User Manual MPCE Monitor Inputs DANGER MPCE INSTALLATION NOT SUITABLE FOR SAFETY USE Install MPCE relays in pairs as instructed in this manual. Use only relays with forced guided type contacts for MPCE monitoring. Ensure that the response time of the MPCE circuitry is less than 25 ms. Use only the safety outputs for personnel protection. Failure to comply with these instructions will result in death or serious injury. To monitor the performance of your relays with the Machine Primary Control Element (MPCE) monitor inputs, connect the Shadow stop circuits to the interfacing relays, instead of connecting them in series with the machine s immediate stop circuit or with control reliable safety relay modules. See the figure below for an example of how to wire the MPCE inputs. Use normally closed contacts only. To monitor external MPCEs, place jumpers J14 and J15 in the EXT (external) position. See Figure Call Wintriss Tech Support for further information. Light Curtain Control FSD1 2 3 UPPER TB4 MPCE1 11 MPCE LOWER TB4 UPPER TB4 5 FSD2 6 USER POWER 8 1 K1 8 1 K2 Machine Primary Control Element (MPCE) Relays Figure Example of MPCE Usage page 58 Chapter 2 Installation and Checkout

71 TB3 1 TB2 1 Shadow VI User Manual TB1 DS4 INT J15 J14 INT J15 J14 F1 S2 115 V DS3 J11 F2 F3 K1 K2 F4 K3 DS1 DS2 For Internal place jumper on left-hand two pins. For External place jumper on right-hand two pins. J13 FSD1 FSD2 STAT GND GRN AMB RED YEL V-OUT TB5 1 TRANSMITTER 1 VCR VCC GNDSHUTDOWNSYNCSHIELD J12 1 SET RECEIVER 1 FWIN VCC GND 1B 1A SYNC SHIELD Set MPCE2 at JP15 TB4 MPCE1 MPCE2 DS6 RESET XMTR INT VCR VCC GND SHUTDOWN SYNC SHIELD ON OFF PWR UP RESET TRANSMITTER 2 DISABLE INT J15 J14 DS5 RESET ON INTERRUPT S4 DS8 FLOATING S1 WINDOW STAT=GRN FWIN VCC GND 2B 2A SYNC SHIELD RECEIVER 2 INT J15 J14 Set MPCE1 at JP14 Note: Factory setting is Internal (INT). OPTIONS Figure Setting MPCE Jumpers Making Settings Inside the Control Follow these steps to make the proper switch settings inside the control. Refer to the location of components found at Figure Also look at the illustrations that follow, which show the factory settings for the switch blocks S1 and S4 and jumper block J12. power up reset disable reset on interrupt S4 ON floating window status relay follows stop outputs S1 ON OFF OFF factory settings: OFF Figure Factory Settings for Switch Blocks S1 and S4 Installation and Checkout Chapter 2 page 59

72 Shadow VI User Manual S1 settings 1. Floating window: The "off" factory setting disables this feature. Set the switch to "on" when you want to enable this built-in floating window option. The feature provides a means for the random bypass of only one beam of the light curtain (refer to Chapter 1 of this manual for more detail). Notice that when this feature is enabled, the "floating window" indicators on the control and receiver will flash on and off. DANGER STATUS OUTPUT NOT SUITABLE FOR SAFETY USE DO NOT use the status output for personnel protection. It cannot be used to stop the machinery. It is intended only as a convenience to interface automation. Use only the safety outputs for personnel protection. Failure to comply with these instructions will result in death or serious injury. 2. Status relay follows stop outputs: The factory setting is "off" which disables this feature. When the switch is "on", the status relay "mimics" the output relays. This feature can be used to turn on an alarm or beacon whenever the light curtain goes "red". No matter how this feature is set, the status function is always active. S4 Settings 1. Power up reset disable: The "off" setting means that when Shadow is powered up, you must reset the system before proceeding. The "on" position disables the feature. It is useful to keep the setting at "off". This is a reminder for you to ensure that the daily tests on Shadow are performed as soon as the reset required condition has been cleared. If your the Shadow is wired to the resolver-based Wintriss Clutch/Brake Control (WPC), disable this functionality because WPC already has this feature. 2. Reset on interrupt: The factory setting is set to "off" which disables this feature. When the switch is set to "on", if one or more of the light curtain beams have been obstructed, then a reset required condition will occur. When the obstruction is removed, the light curtain does not reset to "green" automatically. You must clear the condition by resetting Shadow to resume operation. This is a useful feature for perimeter guarding applications when there is a walk-in hazard inside the guarded area. page 60 Chapter 2 Installation and Checkout

73 Shadow VI User Manual J12 Setting These instructions explain how to set Shadow for a second set of light curtains. The factory setting is "1 SET". If you are installing a second set of heads, follow these steps. 1. Locate jumper location J12 in the control (refer to Figure 2-14 for location of components). It is situated just above terminal block TB2 on the lower right-hand side of the board. Notice that the jumper is set on pins 2 and 3 for "1 SET." 2. Move the jumper so that it will be on pins 1 and 2 for "2 SET." J12 J12 ** notice that there are 2 jumpers side by side at J12 "1 SET" setting (Jumpers on bottom 2 pins) "2 SET" setting (Jumpers on top 2 pins) Figure Jumper Position for "1 SET" and "2 SET" 3. You will also have to perform some diagnostics to verify this setting. To do this, refer to the section, "Aligning and tightening down Shadow VI components." Plug in Connector and Replace Cover Now that you have completed the wiring of the control and made the proper switch settings, make sure all connections are properly plugged into position and that all conduits are in place. Close the cover and tighten the locking screw on the control. Leave the transmitter and receiver loose. Connect 115 VAC wires from the control to the 115 VAC source. Make sure power is off before making connections. Now go on to the next step aligning and tightening down your Shadow VI heads. Aligning and Tightening Down Shadow VI Components DANGER HAZARDOUS EQUIPMENT OPERATING Remove power from the press and other hazardous machinery while you are aligning the light curtain transmitter and receiver. Failure to comply with these instructions will result in death or serious injury. Installation and Checkout Chapter 2 page 61

74 Shadow VI User Manual You have wired and loosely mounted your Shadow transmitter and receiver as directed in the section "Loosely mounting Shadow VI transmitter and receiver". Now you need to test and align them. Once that is done you can tighten them using the appropriate adjustment method to keep them in alignment (such as rotating the universal mounts discussed at the beginning of this chapter). If you suspect a problem with Shadow, verify that the heads are properly aligned. If there is still a problem, be sure to perform the diagnostic tests at the end of this chapter. Alignment Procedure If you have read the material in this chapter, you already know a lot about alignment. If the Shadow light curtains are out of alignment, one or more light beams from the transmitter are not being detected by the receiver. Shadow will react as if a part of the light curtain is blocked. Its relays will be open and stay open, and your press will not operate. Proper alignment means each beam of light from the transmitter is detected by the appropriate phototransistor in the receiver. As long as you installed your brackets level and in the same plane (as described in Step 2), alignment will be very easy. Here is how to align your Shadow light curtains. 1. Make sure you have the Shadow light curtains mounted so the lenses are pointed at each another. 2. Turn on power to the Shadow light curtains. Do not start the press. You do not need to operate the press for this procedure. 3. Check the amber power light near the top of the transmitter cover. It should be on. If not re-check wiring. If you cannot find the problem, contact Wintriss Tech Support. 4. Make sure the light curtain is unobstructed. Then check the lights on the receiver. A green light means the Shadow light curtains are in alignment. A red light means they are not aligned. 5. Whether the light is green or red, experiment a little to get a feel for how precisely aligned you have to be. Your Shadow light curtains should be only loosely mounted. Tighten one unit so it will not move. Using the Shadow universal mounts mentioned at the beginning of this chapter, swivel the other one a little to see what happens. Move it a little vertically as far as the brackets will allow. Watch the lights. Note when the Shadow light curtains are aligned (green light on receiver on) and when they are not (red light on). 6. Now that you have a feel for what it takes to properly align the units, get them back in line. 7. Keep the units in alignment using the Shadow universal mounts or another method you designed. Tighten down the transmitter to take up slack, then work on the receiver. If the units go out of alignment, make adjustments, then start tightening again. When everything is right, tighten down each unit firmly. 8. Check the lights on the receiver again. The light must be green. If not, make sure the light beam is not obstructed. If the light is not green, you will have to loosen your mounting bolts, re-align, then re-tighten. page 62 Chapter 2 Installation and Checkout

75 Shadow VI User Manual Once your Shadow light curtains are tightened to their brackets and the light is green, you are done aligning and mounting your Shadow light curtains. Go on to the checkout procedure. Do not begin press operation until you have completed the checkout sequence. Diagnostic Steps to Perform Before Using Shadow 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 114) 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. If your Shadow light curtain does not operate correctly, use the following diagnostic steps to troubleshoot and correct problems. If you need help, call Wintriss Tech Support. No Power to Unit If your light curtain has no power, check the power fuse F1. Also check that power connections have been done correctly. These procedures are discussed in detail in the section "Connecting AC wiring to the control" earlier in this chapter. The Light Curtain Is in a "Reset Required" Condition Use the reset keyswitch to clear the reset required condition. If this is not successful, power the system down, then up. Again, reset the system using the reset keyswitch. If the reset required condition remains, check that you have correctly set the jumper settings for "1 set/2 sets". This is covered in "Making settings inside the control" in this chapter. If the Transmitter Has No Power or Is Not Functioning Verify your transmitter wiring and that the transmitter and receiver wiring is not reversed. Add labeling to the transmitter and receiver cables in the control if you have not already done so. Refer to "Wiring the transmitter and receiver to the control" in this chapter. Check Power and Indicator Lights Make sure the transmitter's amber light and red or green lights on the receiver and at the control are both on. Also check indicators DS3 and DS4, located in the upper right-hand corner of the control near the power supply. DS3 and DS4 light up green to indicate that the optic heads are receiving power. They should be on all the time. If they are not lit, this Installation and Checkout Chapter 2 page 63

76 Shadow VI User Manual means that either transmitter, receiver, or both may not be receiving power. If this is the case, run a few tests. First check that the power connections at the control have been performed correctly. (See location of components at Figure 2-14.) If DS4 is off, test the transmitter. Unplug the quick-connect connector at the transmitter. If DS4 turns on, this means the transmitter is defective. If the indicator stays off, reconnect the transmitter. Next unplug the transmitter connector TB3 inside the control. If DS4 turns on, this means the transmitter cable is shorted and needs replacement. If DS3 is off, test the transmitter as described above. Then test the receiver. Unplug the quick-connect connector at the receiver. If DS3 turns on, this indicates that the receiver is defective. If the indicator stays off, reconnect the receiver. Next unplug the receiver connector TB2 inside the control. If DS3 turns on, then the receiver cable is shorted and needs replacement. Continue by checking indicators DS1 and DS2, which are red indicators that are located just above the TB2 receiver connectors at the lower right-hand corner of the board. They light up red if you are using only 1 set of curtains and there is an obstruction, misalignment, or indication of an internal problem. If you have two sets, refer to the section further down in this chapter "If you have two sets of light curtains." Check Lens Window If both the amber and red lights and the indicators in the control are all on, your Shadow light curtains have power. You still need to get a green light (indicating Shadows are aligned). Make sure there is no object in the light field which you have overlooked. Then wipe off the lens window on each unit. It is possible that you got some substance on the lens window that is blocking a light beam. See "Checking lens window" in Chapter 4. If the green light comes on after you have cleaned the lens window, you are all set. Bring Shadow Heads Close Together If Shadow still is not working, the next step is to bring the optic heads closer. To do this, unbolt either the receiver or transmitter (whichever is more convenient). You will take the unbolted unit off its mounting and hold it right in front of the other. You may need to disconnect wiring so the heads will reach. Power down the control before connecting or disconnecting the wires to the heads. Once you have unbolted it and have wires connected, bring the unit within 6 to 11 inches of the other. Make sure the lenses are pointed directly at one another and you have the Shadow heads in the same plane (see Figure 2-8). Green Light On Shadow heads should align easily when placed very close together. If the green light is on now, you know there is a problem with your installation. Go over the mounting instructions in this chapter again to be sure you understand how Shadow heads should be mounted. Then adjust your brackets. The Shadow transmitter and receiver will then align. page 64 Chapter 2 Installation and Checkout

77 Shadow VI User Manual No Green Light If you did not get a green light even after bringing the Shadows close together, your Shadows probably have an internal problem. Call Wintriss Tech Support to discuss the problem. If You Have Two Sets of Shadow Heads If you have two sets of Shadow heads, you should already have completed the necessary wiring explained in "Wiring Shadow heads to the control." You also made jumper settings at J12 in the control, page 61. Next, check how the indicators DS1 and DS2 are lit up in the control when either of the two sets has been interrupted (see Figure 2-14 for location of components). DS1 and DS2 are located just above the TB2 receiver connector at the lower right-hand corner of the board. DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and TB3) is interrupted. DS2 corresponds with Set 2, which are wired to the lower connectors. Green Light On But Still Cannot Start Press WARNING ELECTRIC SHOCK HAZARD Ensure that the power source is off before checking or replacing fuses. Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Ensure that all procedures are performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. If everything seems to be all right, but you still cannot start the press, perform the following checks. Shut off power before checking relays so that you do not get a shock Check if one or more of the 3 output fuses (F2, F3, and F4) have failed. Replace if necessary. See "Checking and Replacing Fuses" in Chapter 4. If the press still will not start, check the control relays located above the TB4 connector inside the control. Relays have ty wraps around them to hold them tight in their sockets. Check to make sure the ty wraps are attached and relays are tight in their sockets. Also check to see if a relay has contacts that are welded shut. See Checking and Replacing Control Relays in Chapter 4 for relay location and procedure. Installation and Checkout Chapter 2 page 65

78 Shadow VI User Manual Final Checkout Sequence 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 114) 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. DANGER CHANGE IN STOPPING TIME REQUIRES SAFETY DISTANCE ADJUSTMENT Repair your machinery stopping mechanism if its stopping time increases beyond the acceptable limit. Re-calculate the light curtain safety distance, using the new stopping time. Adjust the location of the light curtain(s) accordingly. Perform the checkout sequence before operating the equipment. Failure to comply with these instructions will result in death or serious injury. You have followed the installation steps in this chapter to correctly install your Shadow safety light curtains. Now perform the checkout sequence to make sure your safety system is working properly. You must perform a checkout sequence after mounting and wiring are complete and before you use Shadow safety light curtains with your machine. It is also imperative to perform the checkout sequence every time any maintenance, repair or other modification is performed on a Shadow safety light curtain unit or on the machinery connected to the light curtain. NOTICE Use opaque test bars of 1 1/4" (32 mm) and 1/8 (3.2 mm) diameter for performing the checkout sequence. If you are using the Floating Window option, also use a 2" diameter test bar as instructed below. Perform the daily test in Appendix A every day before operating the press. Follow the checkout sequence below every time you repair, maintain or modify the press. page 66 Chapter 2 Installation and Checkout

79 Shadow VI User Manual Have ready 1-1/4" (32 mm) and 1/8 (3.2 mm) opaque test bars. If your light curtain has floating window, also have ready a 2 (50.8 mm) opaque test bar. Turn on power to Shadow safety light curtain and to the machine. 2. Make sure the floating window option has been disabled, if your light curtain has it, by setting the "floating window" switch at switch block S1 (in the control) to the OFF position (see Making Settings Inside the Control, page 59). NOTICE LIGHT CURTAINS EQUIPPED WITH FLOATING WINDOW OPTION Indicators on the receiver and on the control blink to indicate that floating window has been enabled. This indicator should be off when you perform this checkout procedure with the 1 ¼ test bar. Later you will enable floating window and repeat the test with the 2 bar. 3. Using the 1-1/4" (32 mm) diameter test bar, interrupt the sensing field on the receiver side by passing the test bar from the top to the bottom of the receiver's lens cover. The red light should come on while the test bar is in the sensing field. 4. Repeat step 3, passing the 1-1/4" (32 mm) diameter test bar from the top to the bottom of the transmitter's lens cover. The red light should stay on while the test bar is in the sensing field. 5. Block the light curtain so that the red light is on; verify that the machine will not start while the light curtain is obstructed. 6. Using the 1/8 (3.2 mm) diameter test bar, interrupt the sensing field on the receiver side by passing from the top to the bottom of the receiver s lens cover. The green light should remain on. If the red light comes on, realign the heads to prevent nuisance stops. 7. Repeat step 6, passing the 1/8 diameter test bar from the top to the bottom of the transmitter s lens cover. The green light should remain on. If the red light comes on, realign the heads to prevent nuisance stops. NOTICE If muting is used, interrupting the light curtain during the non-hazardous portion of the stroke (upstroke) will not stop the machine. To test, you must interrupt the stroke on the downstroke, which is the hazardous portion of the stroke. 8. Start the machine and interrupt the light field with the 1-1/4" (32 mm) diameter test bar. The red indicator light on the receiver should come on and the machine should stop immediately. NOTICE Step 9 applies specifically to presses with single cycle and cycle stop capability. If you cannot single stroke or top stop your press, carry out all steps except Step 9. You must ensure that your Shadow meets the requirements of the other steps before using the Shadow-equipped equipment. Remember, your press must be able to stop when the light beam is broken. Installation and Checkout Chapter 2 page 67

80 Shadow VI User Manual 9. Single stroke the machine and make sure it stops at top dead center. Make sure the machine's braking system is working properly. If the machine does not stop fast enough, adjust the braking system or increase the light curtain's safety distance. 10. Test the floating window option if you have it: If the light curtain does not have the floating window option, go to the next step. If your light curtains have floating window, enable it and repeat the steps above with the 2 (50.8 mm) test bar instead of the 1 ¼ test bar. 11. You have completed the Checkout Sequence. If your Shadow safety light curtain performed as described in the checkout sequence, you can now begin to operate your machinery. If your light curtain did not perform as indicated, and you are still experiencing problems, refer to the complete Troubleshooting guides in Chapter 4. For further technical assistance, call Wintriss Tech Support. If your Shadow safety light curtain did not work exactly as described in this chapter, there is a problem with your mounting or with the Shadow itself. DO NOT operate the machinery until all conditions of the checkout sequence are met. See "Chapter 4. Troubleshooting Shadow Safety Light Curtains" to see if you can solve the problem by making some simple checks described in that chapter. If the safety system still does not work properly, contact Wintriss Tech Support for assistance. page 68 Chapter 2 Installation and Checkout

81 Chapter 3 Fixed and Floating Blanking DANGER INCORRECT SAFETY DISTANCE Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. Failure to comply with these instructions will result in death or serious injury. External fixed blanking is an option available with Shadow. With fixed blanking, you can disable light beams in an area where a fixture penetrates the light field, and you can permit stationery objects to protrude into Shadow's sensing field. As an example, in a situation where a conveyor or work table extends into the light field, it would not be feasible to move the fixture. Therefore, by installing a blanking window on the Shadow receiver where the fixture penetrates the field, you disable the light beam that would normally have detected the fixture. However, if penetration occurs anywhere above or below the blanked beam, the light curtain will send a stop signal to the machinery. The built-in floating window feature provides a means for the random bypass of only one beam of the light curtain. It is useful in those applications where material or air ejected parts randomly travel through or within the sensing field. The floating window may only be used when material or parts take up a space no greater than 11/8" (2.9 cm) within the sensing field. Larger material would block more than one light beam at a time. As a result, the light curtain would generate a stop command. You can enable the floating window feature by turning a switch "on" inside the control. The orange indicators at the receiver and on the cover of the control flash to let you know floating window has been enabled. Floating window automatically alters the object sensitivity from 11/4" to 2". If you use this feature, even occasionally, the safety distance for mounting must be increased. Refer to "Calculating Safety Distance" in Chapter 2 of this manual. Floating window can also be used in conjunction with fixed blanking. For example, you can use both in an application where part of the tool protrudes into the light field and an airblow-off is ejecting parts. Instructions for installing and/or enabling both of these features are covered in this chapter. Shadow VI User Manual Fixed and Floating Blanking Chapter 3 page 69

82 Shadow VI User Manual Blanking Windows Affect Safety Distance DANGER INCORRECT SAFETY DISTANCE Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. Failure to comply with these instructions will result in death or serious injury. DANGER UNPROTECTED ZONE DUE TO EXTRA BLANKING WINDOWS DO NOT blank more than two beams of the light curtain unless a conveyor or other object completely fills the blanked area, or if you use barrier guards to block any unfilled areas. Remove blanking windows when they are no longer needed. Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. IMPORTANT Refer to Chapter 2 in this manual for more information on safety distance, object sensitivity, and depth penetration factor. If you use a blanking window or floating blanking window, safety distance is affected, because the sensitivity of the light curtain is altered. The minimum size that Shadow can sense is an object 11/4" (3.2 cm) in diameter. This diameter, called the object sensitivity of the light curtain, is the smallest diameter object that Shadow will detect anywhere in its field. Anything smaller might fit between two light beams. You must also consider the depth penetration factor (D pf ) which is 3.3" (8.4 cm) for an unblanked Shadow. This factor represents how far an object, such as an operator's hand, can move through the light path before the light curtain reacts. Depth penetration factor and object sensitivity are interrelated. A blanking window blocks one light beam, creating an additional 3/4" (1.9 cm) passageway through the light field where no object will be detected. Now the object sensitivity equals 2" (5.08 cm) wide (11/4"+ 3/4") and the depth penetration factor is 5.9" (15 cm). The ANSI safety distance formula stipulates that if object sensitivity increases, the safety distance must also be increased. This means that using fixed or floating blanking will require moving the light curtain farther back from the hazardous area. page 70 Chapter 3 Fixed and Floating Blanking

83 Shadow VI User Manual Adding to Safety Distance for Fixed Blanking DANGER INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. When more than one beam is blanked, but the blanked area is not completely obstructed, the depth protection factor is at least 36 (914.4 mm). Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage. Remove blanking windows when they are no longer needed. Failure to comply with these instructions will result in death or serious injury. Use this rule of thumb for increasing safety distance. Add 2.6" (6.6 cm) to the calculated safety distance for every blanking window used. On the other hand, if the blanked area is entirely blocked by a fixture from the transmitter to the receiver such that operator intrusion into this area is impossible, then you do not have to change the safety distance. For instance, you might have a work table that extends into the light field but takes up the whole space between the transmitter and receiver which is unprotected by the light curtain. Adding to Safety Distance for Floating Window DANGER INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. Add 2.6 (6.6 cm) to the calculated safety distance when you use floating window. This compensates for the change in object sensitivity to 2 from 1 ¼. Failure to comply with these instructions will result in death or serious injury. As with fixed blanking, using the floating blanking window feature affects safety distance because the sensitivity of the light curtain is altered. If you enable the floating window option in the control, add 2.6" (6.6 cm) to your calculated safety distance. By doing this, you compensate for the increased object sensitivity when floating window is enabled (from 11/4" to 2"). Fixed and Floating Blanking Chapter 3 page 71

84 Shadow VI User Manual Installing Blanking Windows Blanking windows are easy to install. If you are blanking more than one beam, you attach the master blanking window first and connect "slave" blanking windows above it. This increases the blanked area. The maximum number of beams that can be blanked is 5. Because blanking windows attach to the receiver, they are clearly visible to personnel. As a result, it is obvious when a beam is blanked. Installing the Master DANGER INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. When more than one beam is blanked, but the blanked area is not completely obstructed, the depth protection factor is at least 36 (914.4 mm). Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. DANGER UNPROTECTED ZONE DUE TO EXTRA BLANKING WINDOWS DO NOT blank more than two beams of the light curtain unless a conveyor or other object completely fills the blanked area, or if you use barrier guards to block any unfilled areas. Remove blanking windows when they are no longer needed. Maintain access to blanking master or slave windows under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. NOTICE Install the master blanking window at the lowest blanked beam. Install slaves above the master. Here are steps to install the master blanking window. If you are blanking more than one beam, you attach the master blanking window first and connect slave blanking windows above it (installing slaves is discussed in the next section). 1. Locate the master blanking window. Notice a cable is attached at one end. The other end of the cable has a connector that screws into the mating connector at the top of the receiver. See the illustration in Figure 3-1 to locate each component. 2. The master blanking window attaches to the receiver by sliding it down from the top (it can also be slid up from the bottom). Determine which light beam to blank. If you page 72 Chapter 3 Fixed and Floating Blanking

85 Shadow VI User Manual intend to blank more than 1 beam, install the master blanking window on the lowest blanked beam at this time. (The next section explains how to install the slave.) 3. Position the master blanking window over the front of the receiver. Loosen the thumbscrew on the right side. This will allow it to slide down easily. blanking window connector cable attaches at top (must not interfere with light beams) remove protective cap to attach cable master blanking window thumbscrew alignment indicators mating hole receiver Figure 3-1. Connecting Master Blanking Window Fixed and Floating Blanking Chapter 3 page 73

86 Shadow VI User Manual plastic coverings have been removed to allow stacked windows cut-away representing top of receiver part of master cable shown (no cable with slave) grooves on window helps fit one on top of the other thumbscrew slide blanking window up or down the groove on receiver alignment indicators Figure 3-2. Close-up Installing Blanking Window 4. Press down firmly on the blanking window, and line it up between the alignment indicators on the receiver. If you need to adjust the blanking window back up, press down on the top of the receiver end cap as you push the master upward. 5. Once the blanking window is in the desired location, retighten the thumbscrew so it fits firmly into the mating hole. 6. Next, guide the master blanking cable to the top of the receiver. NOTICE Be careful that the cable does not interfere in any way with the light path. If the cable is routed in front of the receiver, you may inadvertently be blocking other light beams. 7. Locate the plastic cap attached to the mating connector at the top of the receiver. If it is difficult to remove, carefully unfasten it from the threads by twisting and turning back and forth. Once the cap is removed, the cable connector goes into that location. 8. Position the blanking window connector directly over the keyed connector at the top of the receiver. The keyed connector has three pins which must fit into holes in the cable connector. Twist the connector slightly until you feel the pins fit into the base. Then screw the nut on the connector to tighten the cable connector in place. page 74 Chapter 3 Fixed and Floating Blanking

87 Shadow VI User Manual Notice the 2 tiny plastic coverings on the top of the master blanking window. These should remain in place unless you plan to add more slave blanking windows (next section). 10. You are done connecting the master blanking window. The beam you selected has been physically disabled. It will not detect any object penetrating the light path. Installing Slave Windows DANGER INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. When more than one beam is blanked, but the blanked area is not completely obstructed, the depth protection factor is at least 36 (914.4 mm). Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. DANGER UNPROTECTED ZONE DUE TO EXTRA BLANKING WINDOWS DO NOT blank more than two beams of the light curtain unless a conveyor or other object completely fills the blanked area, or if you use barrier guards to block any unfilled areas. Remove blanking windows when they are no longer needed. Maintain access to blanking master or slave windows under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. You can add up to 4 slave blanking windows to the master. Follow these steps. 1. Locate the slave blanking window. If you have more than 1 slave, repeat these steps for each. 2. Just as with the master, the slave blanking window attaches to the receiver by sliding it down from the top (must be above the master or another slave). See Figures 3-1 and 3-2 from the previous section. NOTICE The master blanking window must always be installed at the lowest blanked beam. Install slaves above the master. 3. Remove the 2 tiny plastic coverings on the top of the master blanking window. Remember these should only be removed when you plan to add slave blanking windows. 4. Position the slave window over the front of the receiver. Loosen the thumbscrew on the right side of the slave window. This will allow it to slide down easily. Fixed and Floating Blanking Chapter 3 page 75

88 Shadow VI User Manual 5. Press down firmly on the slave blanking window so that it lines up between the alignment indicators on either side of the receiver. Make sure that the pins in the slave blanking window fit properly into the mating connector holes on the top of the master. If you need to adjust the blanking window back up, press down on the top of the receiver end cap as you push the slave upward. 6. Retighten the thumbscrew on the slave window so it fits firmly into the mating hole. Notice that there is no cable or cable connection that needs to be made for the slave. 7. If you need a larger blanked area, you can add another slave window (up to 4 slaves). Repeat the previous steps. Remember to remove the 2 tiny plastic coverings at the top of the lower slave window. Then carefully fit the pins at the upper slave window into the mating holes at the lower one. page 76 Chapter 3 Fixed and Floating Blanking

89 Shadow VI User Manual Floating Window DANGER INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. Maintain access to blanking windows and floating window under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. The built-in floating window feature provides a means for the random bypass of only one beam of the light curtain. It is useful in those applications where material or air ejected parts must pass through, or move within the sensing field in a random pattern. The next illustration shows how coil stock cuts different light beams as the coil unwinds. As long as only one beam is cut at a time (no matter which one it is), Shadow continues to allow machinery to operate. light beams straightener coil stock Figure 3-3. Coil Stock Unwinding Using Floating Window The floating window may only be used when material or parts take up a space no greater than 11/8" (2.9 cm) within the sensing field. Larger material would block more than one light beam at a time and send a stop command. Fixed and Floating Blanking Chapter 3 page 77

90 Shadow VI User Manual Adding to Safety Distance for Floating Window DANGER INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. If you purchased Shadows with a floating window, you must add 2.6" (6.6 cm) to the safety distance. This 2.6" (6.6 cm) addition compensates for the change in object sensitivity of Shadows with floating windows (from 1 1/4" to 2"). Maintain access to blanking windows and floating window under supervisory control to avoid unauthorized usage. Failure to comply with these instructions will result in death or serious injury. As with fixed blanking, using the floating blanking window feature affects safety distance because the sensitivity of the light curtain is altered. If you enable the floating window option, add 2.6" (6.6 cm) to your calculated safety distance. By doing this, you compensate for the change in object sensitivity when floating window is enabled (from 11/4" to 2"). How to Enable the Floating Window The floating window feature is enabled by turning a switch "on" at switch block S1 inside the control. This procedure is explained in detail in the section "Making switch settings" in Chapter 2. The indicators both on the receiver and on the front of the control will flash, reminding you that floating window has been enabled. page 78 Chapter 3 Fixed and Floating Blanking

91 Chapter 4 Troubleshooting Shadow VI DANGER UNAUTHORIZED REPAIRS Replace only the control relays, fuses and indicator lamps. Obtain replacement control relays, fuses and indicator lamps from Wintriss Controls. DO NOT replace any other components. If you do, this will violate the warranty. Ensure that repairs are made by qualified personnel. Improper repair by unqualified personnel may put operators at risk of injury. Failure to comply with these instructions will result in death or serious injury. CAUTION MAKING OR BREAKING CONNECTIONS WITH POWER ON Power down Shadow before connection or disconnecting any connections at the control, transmitter or receiver. Failure to comply with these instructions could result in property damage. Shadow VI has complex electronics. You should not attempt to test or repair components on the Shadow circuit boards unless authorized to do so. That level of troubleshooting and repair must be left to technicians trained in Shadow operation. However, there are some tests and repairs you can perform yourself, and they are included in this chapter. In many cases, you will be able to get an inoperative Shadow working again just by changing a blown fuse, replacing control relays, or re-aligning. How to use this chapter This chapter covers how to make some Shadow repairs and adjustments and includes several troubleshooting procedures. Two charts found at the beginning can be used as quick troubleshooting reference guides. Start with Table 4-1. This chart is useful if your Shadow VI comes with either 1 or 2 sets of optic heads. The first column provides common symptoms. The next columns identify how the indicators will or will not light up when the symptoms occur. The "Action" column briefly recommends steps to take to correct the problem. The last column "Chapter Reference" tells you where to go in the manual (if applicable) for complete, detailed instructions. Table 4-2 refers to those systems with 2 sets of optic heads. In this chart there is an extra column (first one) which identifies which set of optic heads is affected and how it corresponds with the "indicator" columns. Following the charts there are checks that you can make yourself, if your Shadow stops working or gives you trouble. Shadow VI User Manual Troubleshooting Shadow VI Chapter 4 page 79

92 Shadow VI User Manual Checking and Cleaning Lens Window(s), page 87 Checking Alignment, page 87 Checking and Replacing Fuses, page 88 Checking and Replacing Control Relays, page 89 Checking and Correcting Cross Talk, page 91 For many of the procedures provided, you can correct the problem yourself. However, if you find serious problems, the defective component (optic head or control circuit board) must be factory-repaired. However, once you know which unit is bad, you may be able to substitute another unit for the faulty one until the repairs are made. Description of Shadow VI Indicators Shadow includes several indicators. Figure 1-1 in Chapter 1 shows the indicators on the transmitter and receiver, and Figure 1-2 illustrates the control. These indicators communicate Shadow's operating status. Use them to troubleshoot your light curtain (refer to the Troubleshooting guides that follow). If a contradiction exists between the indicator lights at the receiver and those at the control, make sure you compare your findings with the information in these troubleshooting guides to solve the problem immediately. At the Optic Heads The transmitter has an amber-colored power indicator which remains illuminated when Shadow has power. There are three indicators on the front of the receiver. The red indicator means that the light curtain has been interrupted. The orange indicator flashes when the floating window option is turned "on" at the control (see Chapter 2). The green indicator means the light curtain is unobstructed. At the Control Four indicators appear on the front cover of the control and are clearly labeled. The green "curtain clear" indicator means that the light curtain is unobstructed and the machinery will be allowed to operate (the control relay contacts are held closed or in the unobstructed/ energized state). The "floating window" indicator lights up amber when this blanking feature is enabled inside the control (see Chapter 2). The "stop signal" indicator goes red when the light curtain is obstructed, the control relay contacts are open (or in the deenergized state) and the press is disabled, or when Shadow has detected an internal malfunction. The yellow "reset required" indicator signifies that a reset-required condition exists. This could occur during power-up, when certain settings are enabled at the control (see Chapter 2), or if Shadow detects an internal malfunction with the components (transmitter, receiver, or control). page 80 Chapter 4 Troubleshooting Shadow VI

93 Shadow VI User Manual Inside the Control There are eight LED indicators on the circuit board inside the control (refer to Figure 2-14 in Chapter 2 for location of components). DS1 and DS2 are located just above the TB2 receiver connectors at the lower right-hand corner of the board, and do not light up under normal conditions. However, they light up red if you are using only 1 set of curtains and there is an obstruction. If you have 2 sets, DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and TB3) is interrupted. DS2 corresponds with Set 2, which are wired to the lower connectors. DS3 and DS4, located in the upper right-hand corner of the control near the power supply, normally light up green all the time, indicating that the optic heads are receiving power. DS5 and DS6 are located in the lower left corner of the board below TB4. They light up orange when you are using external MPCE monitoring and there is an obstruction in the light field. See External MPCE Monitoring: Checking DS5 and DS6 on page 85. DS7 is located in the lower left corner of the board below TB4. It is off under normal conditions, but lights up yellow when Reset is on. DS8 is located in the lower left corner of the board. Under normal conditions, it lights up green, indicating that the transmitter is active. Troubleshooting Shadow VI Chapter 4 page 81

94 Shadow VI User Manual Table 4-1. Shadow troubleshooting guide for 1 or 2 sets Control Description Transmitter Receiver Indicators No power to unit. Off Off All Off Optic heads are blocked. Machine will not start. (Scenario 1) Machine will not start. (Scenario 2) Amb Red Red Red 3 Grn 4 Grn * Off Off 7 Off 8 Off 7 Off 8 Grn Amb Grn Grn Off 3 Grn 4 Grn Amb Grn Red Red 3 Grn 4 Grn 7 Off 8 Grn 7 Off 8 Off Action 1. Check power fuse F1. 2. Check power connection. 1. Make sure a part of the machinery or other object is not inadvertently protruding into the light field. 2. Clean lens cover(s) if necessary. 3. Check alignment. Realign if necessary. 1. Check if one or more of the 3 output fuses (F2, F3 or F4) has failed. Replace if necessary. 2. Check if one or more of the 3 output relays has failed OPEN (high resistance). Replace if necessary. 3. If you are not using the MPCE or transmitter interrupt inputs, make sure the appropriate jumpers are in place at TB4. See Wiring Shadow 3 X Series Light Curtain. 4. If you are using one or more of the inputs listed above, the user interfacing relay circuit(s) should be CLOSED. If any user interfacing relay circuit is OPEN, replace the relay or repair the circuit as necessary. 5. To further troubleshoot your MPCE monitoring circuit, see External MPCE Monitoring: Checking DS5 and DS6 on page If you have an external Transmitter interrupt circuit, check to make sure it is operating properly. Repair if necessary. 2. If you do not have an external Transmitter Interrupt circuit, check the XT INT (transmitter interrupt) jumper on lower TB4, between pins 19 and 20, to make sure it is correctly installed and not loose. 3. Contact Wintriss Tech Support. Chapter ref , * Red = One or both of these LEDs light up red. Off = both are off. page 82 Chapter 4 Troubleshooting Shadow VI

95 . Shadow VI User Manual Table 4-1. Shadow troubleshooting guide for 1 or 2 sets (continued) Control Description Unit is in reset required condition. (Note NOTICE message below.) Cannot reset (Scenario 1) Cannot reset (Scenario 2) Transmitter Receiver Indicators Amb Grn Red + Yel Amb Red Red + Yel Amb Grn Red + Yel DS1 & 2 * Off Red Off 3 Grn 4 Grn 3 Grn 4 Grn 3 Grn 4 Grn 7 Off 8 Grn 7 Off 8 Grn 7 Yel 8 Grn Action 1. Turn reset keyswitch to Reset. 2. Power down, then up. Turn reset keyswitch to Reset. 3. Make sure that 115 V/230V switch inside control is set correctly. 4. Check both jumpers at J12 (1 SET vs. 2 SET designation) are set correctly. 5. Check for loose output relays. If any are loose, tighten ty-wraps. 6. Check that the factory-installed jumper at TB4 (stop outputs terminal block) is intact and not loose. 7. Check relays for weld shut or stuck open. 1. Remove any obstructions between the optic heads. Follow the instructions under Optic heads are blocked at beginning of this table. 1. Check reset key to see if it is stuck in the Reset position. If it is, contact Wintriss Tech Support. 2. Check your external reset circuit to see if it is stuck on. If it is, repair it. Chapter ref NOTICE You cannot clear a reset required condition unless the optic heads are properly aligned and the indicator(s) on the receiver(s) light up green. If the receiver(s) indicate a red condition, you will not be able to reset the system by turning the reset keyswitch on the control. You first must properly align the optic heads and check that the indicator(s) light up green. Transmitter has no power or is not functioning. Transmitter power supply is not functioning. Off Red Red Red (1 or both) 3 Grn 4 Grn Off Red Red Red 3 Grn 4 Off 7 Off 8 Grn 7 Off 8 Grn 1. Check transmitter wiring. 2. Check whether transmitter and receiver wiring is reversed. If you cannot trace the cables, go to the section that immediately follows Table 4-2 for further action. 1. Unplug transmitter connector at transmitter. If DS4 turns ON, transmitter is defective. 2. If DS4 stays OFF, reconnect transmitter. Unplug transmitter connector at control. If DS4 Turns ON, transmitter cable is shorted and must be replaced * Red = One or both of these LEDs light up red. Off = both are off. Troubleshooting Shadow VI Chapter 4 page 83

96 Shadow VI User Manual Table 4-1. Shadow troubleshooting guide for 1 or 2 sets (cont.) Control Description Receiver head is not getting power. OR Transmitter logic is not getting power. Receiver green, but control box red. (Scenario 1) Receiver green, but control box red. (Scenario 2) Transmitter Receiver Indicators DS1 & 2 Amb Off Red Red 3 Off 4 Grn Amb Grn Red Red 3 Grn 4 Grn Amb Grn Red Off 3 Grn 4 Grn * 7 Off 8 Grn 7 Off 8 Grn 7 Off 8 Grn Action 1. Unplug receiver connector at receiver. If DS3 turns ON, receiver is defective. 2. If DS3 stays OFF, reconnect receiver. Unplug receiver connector at control. If DS3 turns ON, receiver cable is shorted and must be replaced. 3. Unplug transmitter connector at transmitter. If DS4 turns ON, transmitter is defective. 4. If DS4 stays OFF, reconnect transmitter. Unplug transmitter connector at control. If DS4 Turns ON, transmitter cable is shorted and must be replaced. 1. Check wiring at control box terminal block (TB2), which goes to receiver. 2. Using a digital voltmeter, measure the AC voltage between outputs and ground: Set #1: between pins 4 & 7 and 5 & 7. Set #2: between pins 11 & 14 and 12 & 14. Voltage in each case should read between 5.1 and 5.2 volts. 3. If voltage is 0, receiver connector might be cross-threaded. Unscrew receiver quickconnect cable and plug back in. Remeasure the voltage as in step If voltage is still 0, replace cable. 5. If none of the above works, receiver has a hardware failure. Contact Wintriss Tech Support to replace receiver. 1. This indicates a power supply failure. Contact the factory for assistance. Chapter ref * Red = One or both of these LEDs light up red. Off = both are off. page 84 Chapter 4 Troubleshooting Shadow VI

97 . Shadow VI User Manual External MPCE Monitoring: Checking DS5 and DS6 These LEDs help diagnose problems relating to external MPCE monitoring. If you are using external MPCE monitoring do the following: 1. Block the light curtain and look at LEDs DS5 and DS6 (see Figure 2-14 for location). They should both light up orange. 2. If only one lights up, or if neither lights up, check the machine control circuit. 3. Verify that MPCE wiring is correct and check that MPCE jumpers J14 and J15 are both set for external. See Chapter 2. Table 4-2. Shadow Troubleshooting Guide for 2 Sets Control Set # Description Transmitter Receiver Indicators DS1 & 2 Action Chapter ref. #1 #2 #1 #2 #1 #2 #1 #2 Set #1 optic heads are blocked. Set #2 optic heads are blocked. Sets #1 and #2 optic heads are both blocked. OR Transmitter #1 is wired with receiver #2 and vice versa. Relays are chattering on and off. Amb Amb Amb Amb Amb Amb Amb Amb Red Grn Grn Red Red Red Grn Grn Red Red Red Flicker betw/ Grn & Red 1 Red 2 Off 1 Off 2 Red 1 Red 2 Red 1 Off 2 Off 3 Grn 4 Grn 3 Grn 4 Grn 3 Grn 4 Grn 3 Grn 4 Grn 7 Off 8 Grn 7 Off 8 Grn 7 Off 8 Grn 7 Off 8 Grn 1. Make sure a part of the machinery or - other object is not inadvertently protruding into the light field. 2. Check lens cover(s) for dirt buildup 4 and clean if necessary. 3. Check alignment. Realign if necessary Complete steps 1, 2 and 3, above. 2. If this does not solve the problem, check to see if transmitter and receiver connections are reversed. If you cannot trace the problem, go to the section that immediately follows this table for further instructions. 1. Optic head jumper setting is incorrect (1 set vs. 2 sets). Check that both 1 set/2 sets jumpers at J12 are set at 2 sets. 4, Troubleshooting Shadow VI Chapter 4 page 85

98 Shadow VI User Manual Shadow VI Optic Head Connector CAUTION MAKING OR BREAKING CONNECTIONS WITH POWER ON Power down Shadow before connection or disconnecting any connections at the control, transmitter or receiver. Failure to comply with these instructions could result in property damage. If you discovered in your troubleshooting that the transmitter had no power or was not functioning properly, we had suggested in the troubleshooting guides that you check the transmitter wiring to see if it was inadvertently reversed. If you cannot trace the cables, we suggest that you unplug all the connectors at the optic head connection. Next, disconnect all the head connectors inside the control except one. Power up Shadow. Next check pin #4 at the optic head connectors for 12 VDC (see the illustration below) until you find the right connector. Be sure that you carefully label the wiring in the control. For 1 set of light curtains, you need only perform this process once in order to differentiate between transmitter and receiver wiring. For 2 sets, you must repeat this procedure 3 times. Do this by disconnecting the connector inside the control that you just identified and plug in another unlabeled connector. Check which optic head connector pin #4 has 12 VDC. You will be repeating this process until you have carefully identified all the connectors. Plug Pin # Cable Wire Color 1 Shield Black 3 Brown 4 Red 5 Orange 6 Yellow 7 Green 8 Blue Figure 4-1. Optic Head Connector Pinout Orientation and Chart page 86 Chapter 4 Troubleshooting Shadow VI

99 Shadow VI User Manual Checking and Cleaning Lens Window(s) Sometimes dirt, oil, or another substance can get on the plastic lens window on each optic head, which could block a light beam and prevent press operation. This might be the case when the red light is on at the control and receiver with no objects in the light field. If your operation is particularly dusty, oily, or smoky, general build-up of dirt could also affect operation. Both problems are easily corrected by cleaning the lens window with a clean, particle-free cloth. Use a mild solution of detergent and water, a solvent (such as acetone), or an isopropyl-based cleanser. Make sure you avoid excessive rubbing. Checking Alignment Shadows can go out of alignment if the universal mounting brackets have been bent, if a unit has been hit (by a die cart or forklift, for example), or if mounting bolts have loosened, allowing the units to move slightly. You may have an alignment problem if the red indicator light stays on even with the light field clear. To check alignment, first loosen one optic head's universal mounting brackets at both ends. Then, rotate the head back and forth to see if this generates a green light. See "Aligning and tightening down your Shadows" in Chapter 2 for alignment procedures. If that does not solve the problem, remove either the receiver or transmitter (whichever is easier) from its bracket, and move it right up to the other unit within 6 to 11" (15.2 to 27.9 cm). Make sure that the connection to the control remains intact as you move it closer. Aim that unit so it is pointing directly at the mating optic head exactly in a straight line. See the alignment information and diagrams in Chapter 2 if you are not sure what this means. Shadows will always align at this close range if working properly. Alignment Problem or Bad Phototransistor Observe the lights at the receiver and the control as you test Shadow. If the green light comes on at close range, alignment may be the problem. However, you have to make one more check to be sure. Place both units on a bench so that they are aligned and the green light is on. Now start moving one unit away from the other, making sure you keep the beams aligned. If you find the red lights come on at further distances, but the green lights come on at close range, the problem may be a bad phototransistor or LED. Phototransistors are the devices inside the receiver that detect the light beams. When one becomes weak, it can detect a light beam close up, but not at greater distances. LEDs send the light from the transmitter to the phototransistors at the receiver. If they are weak, they cannot generate enough light at greater distances. If you suspect a bad LED or phototransistor, contact Wintriss Tech Support immediately to discuss return of the unit. If the green lights stay on even as you move the units apart, then your mounting on the machinery is the problem. A unit may have been hit and moved out of alignment or a bracket may have been bent, shifting the unit out of alignment. Check for the cause of misalignment and correct it. See Chapter 2 for proper alignment procedures. Troubleshooting Shadow VI Chapter 4 page 87

100 Shadow VI User Manual Checking and Replacing Fuses WARNING ELECTRIC SHOCK HAZARD Ensure that the power source is off before checking or replacing fuses. Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Ensure that all procedures are performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. Any time Shadow loses power or will not allow press operation, first check the fuses that are located in the control. They are easy to check and replace. The fuses are common 3AG glass cartridge fuses (1/4" dia. x 11/4" length) listed in Appendix D. The rating, 1/4 amp and 4 amp, is marked next to the fuse on the circuit board. Here is how to check the fuses inside the control. 1. Turn off power to Shadow. Never check or change fuses with the power on. 2. Open the hinged cover of the control by loosening the locking screws. 3. Locate the fuses on the circuit board. Refer to the location of components illustration in Chapter 2. There are 4 fuses - 1 power (at F1), 2 stop (at location F2 and F3), and 1 status (at F4). 4. Remove the plastic cover over the fuse. Look to see if the metallic strip inside any of the fuses is broken. Test with an ohmmeter if available. Put the ohmmeter leads on each side of the fuse. No resistance (0 ohms) means the fuse is good. 5. If the fuse has blown, pop it out of the holder by prying it out at the ends. Snap in a new fuse. 6. Replace all plastic fuse covers. WARNING ELECTRIC SHOCK HAZARD Replace plastic fuse covers after checking or replacing fuses. These covers help reduce the risk of electric shock. Failure to comply with these instructions could result in death or serious injury. 7. Close the control. Insert and tighten the locking screws. page 88 Chapter 4 Troubleshooting Shadow VI

101 Shadow VI User Manual Checking and Replacing Control Relays DANGER IMPROPER SAFETY RELAY REPAIR Replace the Shadow VI Control board before placing the safety product back into operation after the occurrence of a failed relay. If a relay fuses DO NOT reset the Shadow to restart the machine. Remove the Shadow from operation immediately and replace the Shadow VI Control board before operating the press again. Failure to comply with these instructions will result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON DO NOT touch electrical connections or circuit boards. Use test equipment only on the terminals specified in the instructions. Ensure that this test is performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD WHEN CHECKING OR REPLACING RELAYS Turn off and disconnect power from the Shadow safety light curtain and from the machinery it is connected to before checking relays or replacing the Shadow VI Control board unless the test requires power to be on. This includes disconnecting power to the machine control and motor. Ensure that all tests and repairs are performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. If the Relay Has Failed Completely If a relay has failed completely (will not energize to close contacts or the contacts are welded shut), Shadow immediately stops the machinery and will not allow further press operation. The red light will always be on. In this case, you cannot check relay contacts with a voltmeter (see next section). This is because Shadow will not allow relay operation if a relay failure occurs. Even the contacts of the good relay will be open and all voltages will be zero. You must replace the Shadow VI control board (see Replacing Safety Relays, page 91). Troubleshooting Shadow VI Chapter 4 page 89

102 Shadow VI User Manual Checking Relays with a Voltmeter WARNING ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON DO NOT touch electrical connections or circuit boards. Use test equipment only on the terminals specified in the instructions. Ensure that this test is performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. You can perform a test on the control relays in the control using a voltmeter. This test will tell you if a relay contact is pitted or burned. When this occurs, resistance at the contact may be so high that no current reaches the press control. Therefore, the press will not operate even though the Shadow relay contacts are closed and the indicator light is green. If you find a bad control relay, replace the Shadow VI Control board (see next section). To obtain a new Control board, contact Wintriss Tech Support. To check relays with a voltmeter, follow these steps. 1. Turn off power to Shadow. 2. Open the hinged cover of the control by loosening the locking screw. Locate the relays on the circuit board. Refer to the location of components illustration in Chapter 2. There are 3 relays - 2 stop relays (at location K1 and K2), and 1 status relay (at K3). Also find terminal block TB4 (upper level). (It is illustrated in the section "Connecting stop circuits to the control" in Chapter 2.) 3. Turn power on. Make sure the green light is on at the control. If it is not, the relays are bad (see the previous section for an explanation), and you must replace the Shadow VI Control board. If the green light does go on, continue with the following steps. 4. Test the input voltage to the relays at FSD1 and FSD2 (see location of components in Figure 2-14 of Chapter 2). If you are also using the third relay, labeled "SSD", test that relay also. Make sure your meter is properly calibrated. The voltmeter should read 120 VAC. Verify your wiring. NOTICE Your press control may use 24 VDC voltage or other voltage. If so, check for these voltages. 5. Now test the relay contacts. To test relay K1, place the voltmeter leads across the FSD1 terminals on the connector. Voltage should be 0. If it is not, replace the Shadow VI Control board. Check relay K2 by putting the leads across FSD2 terminals. If voltage is not 0, replace the Shadow VI Control board. If you are also using the third relay, labeled "SSD", test that relay also. page 90 Chapter 4 Troubleshooting Shadow VI

103 Shadow VI User Manual Replacing Safety Relays DANGER IMPROPER SAFETY RELAY REPAIR Replace the Shadow VI Control board before placing the safety product back into operation after the occurrence of a failed relay. Failure to comply with these instructions will result in death or serious injury. WARNING ELECTRIC SHOCK HAZARD Ensure that the power source is off before you make any wiring connections. Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor. Ensure that all procedures are performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury. 1. Turn off power to the Shadow VI control. CAUTION DAMAGE TO BOARD FROM STATIC DISCHARGE Ground yourself before touching circuit boards or chips by touching a large metal object such as the press. Static electricity can destroy electronic components. Failure to comply with these instructions could result in property damage. 2. Making sure that you are grounded, open the Shadow VI enclosure (see Figure 2-13, page 43). 3. Identify all cables with inputs on the Shadow VI Control board by the terminal block to which they connect (see Figure 2-14, page 44) and attach identifying labels. 4. Remove cable connectors from terminal blocks. 5. Unscrew the old Shadow VI Control board from its mounting studs and remove it from the enclosure. 6. Maintaining the orientation of the old board, place the new Shadow VI Control board on the mounting studs and screw down. CAUTION The cable connector can be inserted into the terminal block in only one direction. Do not try to force the connector into the terminal block; otherwise, you may damage one or both components. Failure to comply with these instructions could result in property damage. 7. Replace cable connectors in the appropriate terminal blocks, referring to the labels you created in step 3. Troubleshooting Shadow VI Chapter 4 page 91

104 Shadow VI User Manual 8. Set switches S1, S2, and S4 and jumpers J12, J14, and J15 on the new Shadow VI Control board in the positions they were in on the old board. (Instructions for setting switches and jumpers are provided on page 51 (S2) and pages ) 9. Perform the steps in the Final Checkout Sequence, page 66. Checking and Correcting Cross Talk In some cases, using two sets of Shadow optic heads in close proximity of each other may cause "cross talk". Cross talk occurs when the LEDs from the first set's transmitter are detected by the phototransistors from the second set's receiver. Cross talk could be the problem if the green and red lights on the receivers from set #1 and set #2 flicker back and forth even though there is no visible obstruction causing the light curtains to repeatedly change state. Diagnose the problem by performing this test. First, try to swap the transmitter with the receiver on one of the sets. If the symptoms go away, cross talk was the problem. You can also place an opaque barrier of some type (such as a wall or barrier) between the two sets. Make sure that the barrier runs all the way from the transmitter to the receiver. If the symptoms go away, cross talk was the problem. Refer to the section "Avoiding cross talk when mounting 2 sets of Shadows" in Chapter 2 which provides alternate ways of mounting 2 sets of light curtains so that you can eliminate the incidence of cross talk. page 92 Chapter 4 Troubleshooting Shadow VI

105 Appendix A Extracts from OSHA Regulations and ANSI Standards WARNING REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS The following extracts from OSHA and ANSI documents are provided for the user s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information. Failure to comply with these instructions could result in death or serious injury. This appendix provides extracts from the Occupational Safety and Health Administration (OSHA) regulations and the American National Standards Institute (ANSI) standards covering presence-sensing devices. Extracts from OSHA Regulation WARNING REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS The following extracts from OSHA and ANSI documents are provided for the user s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information. Failure to comply with these instructions could result in death or serious injury. Reprinted below are extracts from OSHA regulation pertaining to the use of presence-sensing devices for point-of-operation guarding on mechanical power presses. Also reprinted here are interpretations of selected regulations provided by the Precision Metalforming Association (PMA). Extracts from the OSHA regulation are printed in the left-hand column; interpretations by PMA are shown in the right-hand column. Wintriss makes no claim for the accuracy or effectiveness of the PMA interpretations, and persons making use of this material do so at their own risk. PMA interpretations should not be relied upon for use in any specific application. The material is provided, with PMA s permission, for informational purposes only. Refer to the most recent versions of OSHA documents. To obtain copies of OSHA regulations, write to: OSHA s Office of Information and Consumer Affairs, 200 Constitution Avenue NW, Room N3647, Washington, DC Tel (202) ; fax (202) Shadow VI User Manual Excerpts from OSHA Regulations and Appendix A page 93 ANSI Standards Daily Tests in French and English

106 Shadow VI User Manual Extracts from OSHA Regulation OSHA (c). OSHA Regulations (c) Safeguarding the point of operation. (1) General requirements. (i) It shall be the responsibility of the employer to provide and insure the usage of point of operation guards or properly applied and adjusted point of operation devices on every operation performed on a mechanical power press. See Table OSHA (c) (3) (i) (a) (3) Point of operation devices. (i) Point of operation devices shall protect the operator by: (a) Preventing and/or stopping normal stroking of the press if the operator s hands are inadvertently placed in the point of operation. OSHA (c) (3) (iii) (iii) A presence-sensing point of operation device shall protect the operator as provided in paragraph (c) (3) (i) (a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator s hand or other part of his body is within the sensing field of the device during the downstroke of the press slide. (a) The device may not be used on machines using full revolution clutches. (b) The device may not be used as a tripping means to initiate slide motion. (c) The device shall be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent the initiation of a successive stroke until the failure is corrected. The failure shall be indicated by the system. PMA Interpretation TABLE 0-10 Distance of opening Maximum width of from point of operation opening (inches) hazard (inches) 1/2 to 1 1/2... 1/4 1 1/2 to 2 1/2... 3/8 2 1/2 to 3 1/2... 1/2 3 1/2 to 5 1/2... 5/8 5 1/2 to 6 1/2... 3/4 6 1/2 to 7 1/2... 7/8 7 1/2 to 12 1/ /4 12 1/2 to 15 1/ /2 15 1/2 to 17 1/ /8 17 1/2 to 31 1/ /8 Presence-sensing device (c) (3) (i) (a) Refers to the functional requirement of a presence-sensing device which prevents and/or stops normal stroking of the press. European method (curtain of light) uses self trip safety system effectively. Variance applied for 11/17/73 by Interlake Stamping Company to use this fail safe system. When failure occurs, the best indication is the press won t run. page 94 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

107 Shadow VI User Manual Extracts from OSHA Regulation OSHA Regulations (d) Muting (bypassing of the protective function) of such device, during the upstroke of the press slide, is permitted for the purpose of parts ejection, circuit checking and feeding. (e) The safety distance (Ds) from the sensing field to the point of operation shall be greater than the distance determined by the following formula: Ds = 63 inches/second x Ts where Ds = minimum safety distance (inches); 63 inches/second = hand speed constant and Ts = stopping time of the press measured at approximately 90 position of crankshaft rotation (seconds) (f) Guards shall be used to protect all areas of entry to the point of operation not protected by the presence-sensing device. OSHA (c) (3) (5) (5) Additional requirements for safe-guarding. Where the operator feeds or removes parts by placing one or both hands in the point of operation, and a two hand control, presencesensing device, Type B gate or movable barrier (on a part revolving clutch) is used for safeguarding: PMA Interpretation Top of stroke is the point at which muting shall cease as it is not possible to set a point on the downstroke as the exact position where the hazard of die closing starts. Safety distance represents the distance an operator can move his hand during the time it takes a press to stop. The internationally recognized hand reach speed is 63 inches/second. To determine this safety distance, the stopping time of the press is measured with some appropriate measuring device. The measurement is taken such that the stop signal is given to the press at the 90 degree point of the crank position. Since some stopping time increase must be accommodated due to braking system deterioration, a percentage factor must be added to the measured time to obtain the factor for use in the equation for determining safety distance. A percentage factor of 20% is recommended for presses with new brakes or brakes of good condition. For older brakes, a 10% factor is recommended. Example: Measured stopping time = seconds Time factor = 1.2 x 0.19 = seconds Calculation = 63 x Safety distance = 14.4 inches (3) (iii) (f) Great care must be taken to assure that no access to the die area exists unguarded. This paragraph tells the condition under which a brake monitoring system is required after November 1, Excerpts from OSHA Regulations and Appendix A page 95 ANSI Standards Daily Tests in French and English

108 Shadow VI User Manual Extracts from OSHA Regulation OSHA Regulations OSHA (c) (3) (5) (cont) (i) The employer shall use a control system and brake monitor which comply with paragraphs (b) (13) and (14) of this section. This requirement should be complied with by November 1, OSHA (c) (3) (vii) (c) (c) The safety distance (Ds) between each two hand control device and the point of operation shall be greater than the distance determined by the following formula: Ds = 63 inches/second x Ts, where: Ds = minimum safety distance (inches); 63 inches/second = hand speed constant; and Ts = stopping time of the press measured at approximately 90 position of crankshaft rotation (seconds). OSHA (e) (1) (e) INSPECTION, MAINTENANCE, AND MODIFICATION OF PRESSES (i) It shall be the responsibility of the employer to establish and follow a program of periodic and regular inspections of his power presses to insure that all their parts, auxiliary equipment, and safeguards are in safe operating condition and adjustment. The employer shall maintain records of these inspections and the maintenance work performed. (ii) Each press shall be inspected and tested no less than weekly to determine the condition of the clutch/brake mechanism, anti-repeat feature and single stroke mechanism. Necessary maintenance or repair or both shall be performed and completed before the press is operated. The employer shall maintain records of these inspections and the maintenance work performed. These requirements do not apply to those presses which comply with paragraphs (b) (13) and (14) of this section. PMA Interpretation (b) (13) Control reliability (b) (14) Construction requirements. Example: Measured stopping Time = seconds Time Factor = 1.2 x 0.19 = seconds Calculation = 63 x Safety Distance = 14.4 inches Records of clutch and brake will be weekly. Other inspections are periodic subject to time factor determined by employer. If brake monitoring system is installed, weekly inspection and records are not required for clutch/brake mechanism. Other parts of the press will require periodic inspections and records. page 96 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

109 Shadow VI User Manual Extracts from ANSI Standards for Presence-sensing Devices WARNING REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS The following extracts from OSHA and ANSI documents are provided for the user s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information. Failure to comply with these instructions could result in death or serious injury. Reprinted below are the American National Standards Institute (ANSI) standards for presence-sensing devices (light curtains). ANSI, a national federation of trade associations, technical societies, professional groups, and consumer organizations, is the United States clearinghouse and coordinating body for voluntary standards activity. Approximately 1000 companies are affiliated with the Institute as company members. ANSI creates voluntary standards to eliminate duplication and to weld conflicting standards into single, nationally accepted standards under the designation American National Standards. The standards reflect a national consensus of manufacturers; consumers; scientific, technical, and professional organizations; and governmental agencies. Shown below are extracts of standards requirements and explanatory information from ANSI B and ANSI B for presence-sensing devices (light curtains). Complete versions of these documents can be obtained by writing to: ANSI, 1430 Broadway, New York, NY Excerpts from OSHA Regulations and Appendix A page 97 ANSI Standards Daily Tests in French and English

110 Shadow VI User Manual Extracts from ANSI B Standards Requirements Each operator s hand controls shall be located at a distance from the point-ofoperation so that the operator(s) cannot release either hand actuating control and reach into the point-of-operation during the hazardous portion of the cycle. Explanatory Information E The total stopping time of the press should include the total response time of the control system and the time it takes hazardous motion to stop. The following formula should be used when calculating the safety distance (Ds): Ds = K (Ts + Tc + Tbm) Where: K = 63 inches/second (hand speed constant). Ts = the stop time of the press measured from the final de-energized control element, usually the air valve. Tc = the response time of the control. Tbm = the additional time allowed by the stopping-performance monitor (brake monitor) before it detects stop time deterioration. NOTE - Ts + Tc are usually measured by a stop time measuring device. When the press stopping-performance monitor setting is changed, the safety distance should be recalculated. See also Annex C. page 98 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

111 Shadow VI User Manual Extracts from ANSI B Standards Requirements Explanatory Information Presence-sensing safeguarding device A presence-sensing device, when used for safeguarding, shall protect the operator as specified in E8.6.1 (a) The device shall interface with the control circuit to prevent or stop slide motion if any object is within the sensing field of the device during the hazardous portion of the cycle The device shall not be used for safeguarding the point-of-operation on presses using full-revolution clutches When the sensing field has been interrupted, use of the normal press cycleactuating means shall be required after clearing the sensing field to resume press operation When the device is used in the PSDI mode, re-initiation of the press motion shall be in accordance with E Various presence-sensing devices employ different sensing and adjustment techniques. The point at which a device responds to an intrusion can vary. Safety mats and area scanners may not be suitable (effective) safeguards when utilized as primary point-of-operation safeguarding. Factors which can affect this suitability include but are not limited to: a) response time; b) minimum object sensitivity; c) measurement accuracy; d) breach ability; e) penetration before detection; f) single point of failure; g) large safety distances. These devices may be utilized as supplemental safeguarding. E The device should be located or adjusted so that the device always responds to the intrusion at or prior to the safety distance Ds. Also, care should be taken when installing the device so that it does not detect false signals from other devices or equipment in the area. The presence-sensing device cannot protect against a catastrophic failure of the press, which causes unintended cycling action. See Annex A, Figure A.3. Excerpts from OSHA Regulations and Appendix A page 99 ANSI Standards Daily Tests in French and English

112 Shadow VI User Manual Extracts from ANSI B Standards Requirements Muting of the device shall be permitted only during the non-hazardous portion of the press cycle Muting of the device shall be accomplished in a manner that conforms to the requirements of 6.11 and The device shall have an identifiable minimum object sensitivity so that an obstruction of an equal or greater size will be detected anywhere within the sensing field regardless of the plane of intrusion The device shall have a maximum response time, which shall not be affected by object sensitivity adjustments or environmental changes Devices which require adjustments to accommodate variations in operating conditions, or which incorporate fixed blanking or floating blanking features, shall be designed so that the adjustments or features are capable of supervisory control by the user. Explanatory Information E Muting is typically accomplished by interface circuits or auxiliary controls. The die closing portion of the cycle is always considered hazardous. In some cases, feeding and transfer automation or die features can cause additional hazardous conditions even during the opening portion of the cycle (upstroke). See also ANSI B11.19 for additional information. E Muting is typically accomplished by interface circuits or auxiliary controls. The muting element should incorporate a similar level of control reliability as the presencesensing device itself. A simple cam-operated limit switch wired in parallel with the device s output is inadequate as its failure can remain undetected. E The device should have a minimum object sensitivity stated by the device supplier. For example, an electro-optical device may detect a 32 mm (1-1/4 inch) diameter opaque object anywhere in its sensing field but allow 25 mm (1 inch) obstructions to pass undetected at certain points in the field. E The device supplier should state the maximum total response time, including output devices, of the presence-sensing device. E Typically, these adjustments or controls are key-operated or located under lockable covers. page 100 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

113 Shadow VI User Manual Extracts from ANSI B Standards Requirements The device shall be provided with a means that visibly indicates when it is functioning properly. Indication that the sensing field is being blanked shall be provided. For fixed blanking, the blanked area shall be identified. Supplemental safeguarding shall be provided to prevent access to the hazard through the fixed blanked area. If means are provided to bypass the device, visible indication that the device is bypassed shall be provided The device shall not fail to respond to the presence of the individual s hand or other body part due to the presence of a reflective object or workpiece. Explanatory Information E Red and green indicators or other means that can be easily seen by the operator and others should be provided to indicate that the device is functioning. The blanking function of a presence-sensing safeguarding device desensitizes a portion of the sensing field by disabling one or more channels such that a specific interruption is ignored. Presence-sensing devices can be provided with either fixed or floating blanking. For fixed blanking, the desensitized area does not move or change once configured. Floating blanking allows the blanked area to move within the sensing field. Means to identify the desensitized area may include but are not limited to: a) Indicators within the device; b) Signage or marking of the fixed blanked area; c) The physical location of the object in the blanked area if movement or removal of the object can be detected and it results in a stop command. Means of supplemental safeguarding can include completely filling the fixed blanked area to restrict access to the hazard, installing the device at a distance that accounts for the worse case object sensitivity (see ), or alternate safe-guarding may be provided to prevent access to the hazard. Means to provide visible indication may include but are not limited to: a) colored indicator lights; b) signage; c) physical position; d) awareness barrier (i.e., safety tape); e) other means. Excerpts from OSHA Regulations and Appendix A page 101 ANSI Standards Daily Tests in French and English

114 Shadow VI User Manual Extracts from ANSI B Standards Requirements The device shall conform to the requirements of 6.11 and 8.8. In the event of a power failure to the device, the device shall initiate a stop command to the press control system The interface of the presence-sensing device to the press control shall conform to the requirements of 6.11 and The sensitivity of the device to intrusion shall not be adversely affected by changing conditions around the press The effective sensing field of the device shall be located at distance from the nearest point-of-operation hazard so that individuals cannot reach into the point of operation with a hand or other body part before cessation of motion during the hazardous portion of the cycle. Explanatory Information E The total stopping time of the press should include the total response time of the presence-sensing device, as stated by the supplier, the response time of the interface, the response time of the control system, and the time it takes the press to cease slide motion. The following formula should be used when calculating the safety distance: Ds = K (Ts + Tc + Tr + Tbm) + Dpf where K = 63 inches/second (hand speed constant) Ts = the stop time of the press measured from the final de-energized control element, usually the air valve. Tc = the response time of the press control. Tr = the response time of the presence-sensing device and its interface, if any, as stated by the supplier or measured by the user. Tbm = the additional stopping time allowed by the stopping-performance monitor before it detects stop time deterioration. Dpf = the added distance due to the penetration factor as recommended in ANSI B11.19, Annex D, Figure D.2. The minimum object sensitivity is stated by the supplier. If beam blankouts or floating window features are used, these figures should be added to the object sensitivity figure before using the chart. page 102 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

115 Shadow VI User Manual Extracts from ANSI B Standards Requirements Explanatory Information (cont) NOTE - Ts + Tc is usually measured by a stop time measuring device. See also ANSI B11.19, Annex C and D. Whenever the press-cycle STOP command or stopping-performance monitor time or angle setting is changed, the safety distance should be recalculated. See also stoppingperformance monitor (6.12). NOTE No increase in safety distance is required for fixed blanking applications if the blanked area is entirely occupied by the material or fixtures. In some instances, the use of blanking does not allow efficient production of certain piece parts. Horizontal placement of the sensing field, so that it detects the operator s waist area, may present a solution. In this application, the operator may freely manipulate the workpiece and operate the press as long as the operator stands outside of the horizontal sensing field. The sensing field should be located so that the operator cannot reach the point-of-operation prior to interrupting the sensing field and completion of the stopping action. Where possible, the sensing field should be of sufficient depth to prevent the operator from standing between the field and the point-of-operation. See also ANSI B11.19, Annex C and D If the position of the device will allow the operator or others to place themselves between the sensing field and the point-ofoperation, additional means shall be provided in conjunction with the device to prevent the operator or others from exposure to the point-ofoperation hazard. E Additional means may include manual reset outside of the sensing field of the device or additional barrier guards, safety mats, light curtains or other devices. Operator controls for each operator located outside of the sensing field of the presencesensing device may be used. As an alternative to the reset control and to prevent an individual from stepping behind the sensing field of a PSD, the maximum distance between the light curtain and the machine structure should not exceed 75mm (3 inches). Supplemental safeguarding may be utilized to eliminate a space greater than 75mm. Excerpts from OSHA Regulations and Appendix A page 103 ANSI Standards Daily Tests in French and English

116 Shadow VI User Manual Extracts from ANSI B Standards Requirements The device shall not be affected by ambient light or by light-source decay so that the increase in response time or object sensitivity is greater than the value used to calculate the safety distance All areas of entry to the point-ofoperation not protected by the presence-sensing device shall be otherwise safeguarded Press production systems with a configuration that would allow an individual to enter, pass through, and become clear of the presence sensing device sensing field shall not be operated in the PSDI mode of operation When a device is used on a press production system and the protection of the operator is dependent upon the stopping action of the press, a stopping-performance monitor shall be required in conformance with See section for exceptions. Explanatory Information E Examples of ambient light are associated with windows, light fixtures, skylights, bay doors, or die lights. E Usually the electro-optical presencesensing device is used in a manner that provides a protected zone in front of the primary work area with auxiliary devices or guards used to protect secondary access areas. In some cases, mirrors may be used in conjunction with the device to provide two-, three- or four-sided protection. E For PSDI applications see Clause 10. page 104 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

117 Shadow VI User Manual Extracts from ANSI B Standards Requirements 8.3 Electro-Optical, RF, and area scanning presence-sensing safeguarding devices Design and Construction The presence-sensing device shall be designed and constructed to create a field that detects the presence of an individual(s). The presence-sensing device shall not create a hazard in and of itself The electro-optical presence-sensing device shall have a minimum object sensitivity such that an obstruction of a same or greater size will always be detected anywhere within its sensing field, regardless of the plane of intrusion The device shall not fail to change its output state, if not muted, when it detects the presence of an individual Adjustment or configuration of presence-sensing devices shall be capable of being supervised by the user. Explanatory Information E The device should be designed and constructed such that it does not present hazards to individuals from: sharp edge or pinch point hazards; radiated light or energy hazards; electromagnetic interference hazards; electrical shock hazards. E The presence-sensing device should have a minimum object sensitivity stated by the supplier. For example, an electro-optical device may detect an opaque object with a diameter of 32 mm (1-1/4 inch) anywhere in its sensing field, but allow an obstruction with a diameter of 25 mm (1 inch) to pass undetected at certain points in the field. E Muting may be accomplished by the device, its interface, auxiliary controls, or the machine control system. When the device provides the muting, its output may or may not change state. E Methods of meeting this requirement include, but are not limited to, the use of key operated controls or controls located under lockable covers. Adjustments or configuration can include, but are not limited to: muting; blanking; power adjustments; sensing field configuration; reset functions. Excerpts from OSHA Regulations and Appendix A page 105 ANSI Standards Daily Tests in French and English

118 Shadow VI User Manual Extracts from ANSI B Standards Requirements The presence-sensing device shall incorporate visual means to indicate that the device is detecting an individual within the effective sensing field of the device The presence-sensing device shall have a maximum response time that shall not be affected by object sensitivity or environmental changes. The safeguarding supplier shall provide the maximum response time of the presencesensing device The RF (radio frequency) presencesensing device shall provide means to adjust the sensitivity of the field. The field, once adjusted, shall not decrease in sensitivity below this established level The electro-optical device shall not be affected by ambient light conditions or by changes in the device light source characteristics, such that an increase in response time or object sensitivity occurs Components, subassemblies or modules of electro-optical, RF, and area scanning presence-sensing safeguarding devices shall be designed and constructed to meet the requirements of 6.1. Explanatory Information E Indicators (usually red and green), displays or meters should be provided to indicate the status of the device. The visual means may be integral to the device or part of the interface or machine control system. Due to the prevalence of color blindness, methods such as unambiguous positioning, patterning, labeling or flashing of the indicators may be effective in providing the indication required. E When the electro-optical device is exposed to signals from other electro-optical devices or to changes in ambient light commonly associated with windows, light fixtures, skylights, bay doors or work area lights, the response time or object sensitivity should not be adversely affected. page 106 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

119 Shadow VI User Manual Extracts from ANSI B Standards Requirements The area scanning device shall provide a means or operating mode to verify the size, shape, and detection capabilities of the detection area or zone. Information shall be provided by the area scanning device supplier to identify the: a) maximum safeguarding range; b) minimum object sensitivity within the stated safeguarding range; c) maximum field of view in degrees; d) tolerance in the range measurement; and e) detection capabilities with respect to the reflectivity of an object versus the distance to the object. Explanatory Information E These devices typically operate on the principle of diffuse reflectance," which is a principle of transmitting beam(s) of light to form a detection area or zone. When an object enters the detection area, it reflects the transmitted light back to the device, which then evaluates the object's position. The amount of reflected light (degree of reflectance in percent) that can be reliably detected typically ranges from 1.8% to over 90% and can be represented graphically by reflectivity versus distance. For more information, see IEC 61496, parts 1 and 3. Excerpts from OSHA Regulations and Appendix A page 107 ANSI Standards Daily Tests in French and English

120 Shadow VI User Manual Extracts from ANSI B Standards Requirements Installation, operation, and maintenance Exposure to the hazard(s) shall not be possible by reaching over, under or around the sensing field of the device. Additional guards or safeguarding devices shall be provided to protect those areas. The effective sensing field shall be of adequate height, width, and depth so that entry of the individual into the hazard area is detected. Explanatory Information E The user should select a presencesensing device adequate to prevent individuals from reaching over, under or around the sensing field during the hazardous portion of the machine cycle. Additional safeguarding may be required in conjunction with the device to meet this requirement. If individuals can place themselves between the sensing field and the hazard area, additional safeguarding should be used in conjunction with the device to prevent the individual from exposure to the hazard. When an individual can pass through the sensing field, see the requirements of The electro-optical presence-sensing device may fail to detect an individual's presence due to reflective workpieces or objects in the vicinity of the device. Care should be used to ensure that these reflections do not render the device ineffective. Some examples of reflective objects include, but are not limited to: machine surfaces; tooling; work pieces; hand tools; auxiliary equipment; workholding tables and fixtures. Testing each set-up for minimum object sensitivity should be done with an appropriate test rod, following the supplier's recommendation. Where objects are placed within the defined sensing field of an area optical laser scanner, care should be taken to ensure that: a) No shadows exist behind the objects such that the device is rendered ineffective; b) Removal of the object will not allow undetected access to a hazard area. page 108 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

121 Shadow VI User Manual Extracts from ANSI B Standards Requirements The device shall be installed such that it does not create additional hazards The presence-sensing device shall be installed at a location so that the effective sensing field prevents individuals from reaching the hazard(s) during the hazardous portion of the machine cycle. Explanatory Information Some installation hazards include, but are not limited to: pinch point hazards created by interference between the device and moving members of the machine; tripping hazards; electrical shock hazards; overhead or other "strike against" hazards; thermal hazards. Where such conditions can exist, additional safeguarding may be required. E The safety distance calculation is dependent upon the: total response time of the device as stated by the safeguarding supplier; response time of the interface; response time of the control system; time it takes the machine to stop hazardous motion; and depth penetration factor of the device. See Annex D for the formula(e) to calculate the safety distance. Radio frequency devices have sensing fields that can vary due to: antenna(e) design; effects of adjacent machinery and equipment; field sensitivity adjustments; and environmental factors (such as humidity or temperature). Before the machine is used for production purposes, the RF device should be checked to ensure that the effective field protects individuals at the safety distance. Excerpts from OSHA Regulations and Appendix A page 109 ANSI Standards Daily Tests in French and English

122 Shadow VI User Manual Extracts from ANSI B Standards Requirements The presence-sensing device shall protect individuals from hazards by initiating an immediate stop command to the machine control system when the sensing field of the device is interrupted during the hazardous portion of the machine cycle. It shall require reinitiation of the normal actuating means prior to the start or continuation of motion of the machine. When an individual can pass through the sensing field of the presence-sensing device, the device shall initiate an immediate stop command to the machine control system and shall require that the device or machine control be manually reset before hazardous motion can occur. The reset device shall be located outside of the safeguarded area such that it cannot be reached from within the safeguarded area. Reset of the device or machine control shall not occur until verification that the safeguarded area is clear of individuals Components, subassemblies or modules of the interface or machine control system shall meet the requirements of Muting of the device shall be permitted during the non-hazardous portion of the machine cycle. Muting of the device shall be accomplished such that a single failure of a component, a subassembly or a module of the system / device that affects the performance of the safety-related functions shall not prevent a normal stop command from being initiated, or shall cause an immediate stop command. In the event of a failure, re-initiation of the machine shall be prevented until the failure is corrected or the system or device is manually reset. In the presence of a failure, repetitive manual reset of the system or device shall not be used for production. Explanatory Information The operator should ensure that no individual is in the safeguarded area before re-setting the device or machine control and initiating hazardous motion. Key lock reset switches located at various positions around the safeguarded area may be one method of accomplishing this requirement. E Muting is typically accomplished by interface circuits or auxiliary controls. The muting element should incorporate a similar level of control reliability as the presencesensing device itself. A simple cam-operated limit switch wired in parallel with the device's output is inadequate, as its failure can remain undetected. The intention of a manual reset is to encourage the diagnosis of a failed component, subassembly, device or module. A second failure may occur during the diagnostic or troubleshooting process, negating the safety function(s). Additional safeguarding should be used to protect individuals during this process. See the definition for control reliability and page 110 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

123 Shadow VI User Manual Extracts from ANSI B Standards Requirements If the machine has reversing capability where a muting hazard is possible, the control system shall include an automatic means so muting is only permitted in the forward direction. If an individual can pass through a sensing field when the device is muted, means shall be provided to ensure that the individual is outside of the hazard area, or that the machine ceases hazardous motion when the muting is removed Bypassing of the device shall be capable of being supervised by the user. Indication that the device is active or bypassed shall be provided and shall be readily observable by individuals protected by the device. When bypassed, the device, interface or control system shall not indicate any state other than "bypass." When the device is bypassed, other safeguarding must be provided and used The radio frequency device shall not be adversely affected by changes around the machine that may alter the sensitivity of the device such that individuals are no longer detected in the sensing field at the proper safety distance. Explanatory Information Annex C for further information. One method of meeting this requirement is by the use of a control circuit interlock on the drive motor starter (forward direction contact) to allow "muting" only in the forward direction when the starter is energized. See E Care should be taken to ensure that the operators and other individuals are aware that the device has been bypassed so that individuals do not assume that the device is active and they are safeguarded when, in fact, the device is bypassed. An amber indicator lamp or other means may be used to meet this requirement. When bypassed, the device's normal status indicators can be misleading if still active. One method that may be used to meet this requirement is to remove power to the device or to disable the normal status indicators when it is bypassed or not being used. Due to the prevalence of color blindness, methods such as unambiguous positioning, patterning, labeling or flashing of the indicators may be effective in providing the indication required. E The radio frequency device may be affected by changes in the conditions around the machine such as ambient conditions, the placement of parts and tote boxes, grounding conditions of the operator, or the movement of industrial trucks. These changes should not adversely affect the performance of the device. Excerpts from OSHA Regulations and Appendix A page 111 ANSI Standards Daily Tests in French and English

124 Shadow VI User Manual Extracts from ANSI B Standards Requirements The total tolerance in the range measurement of an area scanning device shall be included in determining the distance from the nearest recognized hazard to the detection area or zone. This detection area shall be identified and tested to ensure that the device is able to detect individuals entering the detection area. The effective sensing field shall be verified for proper size and coverage upon installation, replacement, or changes of the detection area. Explanatory Information E When the device is horizontally mounted, the detection area or zone should be visibly marked on the floor. This verification can be accomplished by using a programming device or by physically identifying the perimeter of the detection area with an appropriate test rod, following the supplier's recommendation. This verification is to ensure that a preprogrammed device with a small or improper detection area is not used by mistake in an installation requiring a larger field. Area scanners may not be suitable (effective) safeguards when used to protect an individual's hands or fingers from hazards. Items which can affect this suitability are: response time; minimum object sensitivity; measurement accuracy. page 112 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

125 Shadow VI User Manual Daily Tests in English Perform these tests daily to make sure the light curtain and the machine's control systems work properly. Also perform these tests after any modification or maintenance to the light curtain or the machine. NOTICE Use an opaque 1¼" diameter test bar for performing the daily tests on the Light Curtain. If you are using the Floating Window option, enable it and use a 2" diameter test bar to perform the daily tests. 1. Turn on power to the light curtain and to the machine. Observe the LEDs at the receiver. If the red and green lights are on at the same time, clear the light curtain to the green state by momentarily interrupting the sensing field with a test bar. 2. Interrupt the sensing field on the receiver side by passing the test bar from the top to the bottom of the receiver lens cover. The red LED on the receiver should come on while the bar is in the sensing field. 3. Repeat step 2, passing the bar from the top to the bottom of the transmitter lens cover. Make sure the red LED comes on when the bar is anywhere in the sensing field. 4. Start the machine and interrupt the sensing field with the test bar. The red LED should come on and the machine should immediately stop. NOTICE When muting is used, interrupting the Light Curtain during the MUTED (nonhazardous) portion of the cycle will NOT stop the machine. 5. Single stroke the machine and make sure it stops at top dead center and that the machine's braking system is working properly. If the machine does not brake fast enough, adjust the braking system or increase the light curtain's safety distance. 6. If either the light curtain or the machine fails any of these tests, DO NOT RUN THE MACHINE. Notify the supervisor immediately. 7. When using the light curtain on mechanical power presses, all OSHA Safety and Health Standards (29 CFR ) must be met. DO NOT USE THE LIGHT CURTAIN ON FULL-REVOLUTION CLUTCH MACHINES. Excerpts from OSHA Regulations and Appendix A page 113 ANSI Standards Daily Tests in French and English

126 Shadow VI User Manual Tests Quotidiens du Rideau de Lumiere Daily Tests in French Effectuer ces tests quotidiennement pour s'assurer que le rideau de lumière et le système de commande de la machine fonctionnent comme if faut. Effectuer également ces tests après toute modification ou tout entretien du rideau de lumière ou de la machine. REMARQUE Utiliser une barre de test opaque de 3,15 cm de diamètre pour effectuer les tests quotidiens sur les appareils. Utiliser une barre de test de 5,08 cm de diamètre pour effectuer les tests quotidiens sur les appareils à plage élargie. 1. Mettre le rideau et la machine sous tension. Si les voyants rouge et vert s'allument en même temps, mettre le rideau dans son état vert en bloquant momentanément le champ de détection à l'aide d'une barre de test. 2. Si votre rideau est muni d'une fenêtre flottante, mettre ce système hors fonction. S'assurer que le voyant de la fenêtre flottante s'éteint. 3. Bloquer le champ de détection du côté du récepteur en faisant passer la barre de test de haut en bas le long du cache-lentille du récepteur. Le voyant rouge devrait s'allumer quand la barre traverse le champ de détection. 4. Recommencer l'étape No 3 en faisant passer la barre de haut en bas le long du cache lentille de l'émetteur. S'assurer que le voyant rouge s'allume dès que la barre bloque une partie quelconque du champ de détection. 5. Mettre la machine en marche et bloquer le champ de détection au moyen de la barre de test. Le voyant rouge du récepteur devrait s'allumer et la machine devrait s'arrêter immédiatement. REMARQUE Quand la fonction d'assourdissement est en service, le blocage du rideau de lumière pendant la partie non dangereuse de la course (vers le haut) n'arrêtera pas la machine. 6. Faire marcher la machine pendant une seule course, et s'assurer qu'elle s'arrête au point mort supérieur et que le système de freinage de la machine fonctionne comme il faut. Si la machine ne freine pas assez vite, ajuster le système de freinage ou augmenter la distance de sécurité du rideau. 7. Si la machine ou le rideau de lumière ne passe pas avec succès l'un quelconque de ces tests, ne pas faire fonctionner la machine. Avertir le contremaître immédiatement. 8. Quand le rideau est utilisé sur des presses mécaniques, toutes les normes de sécurité et de santé d'osha (Etats-Unis) [29 CFR ] doivent être respectées. Ne pas utiliser le rideau sur les machines avec embrayage à rotation complète. page 114 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

127 Appendix B Shadow VI Panel Mount This appendix explains how to install your Shadow VI panel mount. Refer to Chapter 2 for the remainder of the installation steps. Standard Enclosure Versus Optional Panel Mount Shadow VI is available either with an enclosure or as a panel mount. The panel mount can be mounted from the inside or outside. Be sure to allow at least 8" (20.3 cm) of clearance behind the panel mounting plane to allow enough room for the electronics. Preparation for Mounting Shadow Using Your Enclosure DANGER ACCESSING CONTROL AFFECTS LIGHT CURTAIN OPERATION Install the light curtain control in a location where access to it will not affect the operation of the light curtain. Failure to comply with these instructions will result in death or serious injury. DANGER CONTROL INSIDE THE GUARDED AREA FOR PERIMETER GUARDING Install the light curtain control outside the guarded area for perimeter guarding applications. Failure to comply with these instructions will result in death or serious injury. To prepare for mounting Shadow VI using your panel enclosure, follow these steps: 1. Determine an appropriate location to mount the control panel mount. It should be mounted in an area where personnel can easily see the warning indicators, important labels, and also have access to the circuitry, without interfering with the operation of the optic heads. The control must never be installed inside the protected area in perimeter guarding applications. The enclosure can be mounted to the press, on a free-standing pedestal, on a pendant, or at the entrance of a location used for area guarding. 2. Cut out a hole in your panel enclosure, and drill and tap ten holes for 1/4-20 screws. Refer to Figure B-2 for mounting dimensions. 3. Prop Shadow near the location where it will ultimately be mounted. Allow at least 12 inches of service loop when performing the wiring connections. Also make sure all cables will reach. 4. Refer to Chapter 2 of the Shadow VI user manual to complete the entire installation. Shadow VI User Manual Shadow VI Panel Mount Appendix B page 115

128 Shadow VI User Manual About Shadow VI Panel Mount Labels DANGER DAILY TESTS LABEL INACCESSIBLE Affix the Daily Tests label where operators can clearly read the instructions. The daily tests are critical to operator safety and must be run every day before operating the press. Failure to comply with these instructions will result in death or serious injury. NOTICE The information on the Operator Instructions label is used for maintenance purposes. Affix the label where it can be easily read. You should have received 2 labels with your panel mount assembly: "Daily tests" and "Operator instructions." See Figures B-1A and B-1B, below. page 116 Appendix B Shadow VI Panel Mount

129 Shadow VI User Manual CAUTION Perform these tests daily to ensure the Light Curtain and the machine's control system work properly. These tests should also be performed after any modification or maintenance to the Light Curtain or the machine. ATTENTION Des essais doivent être effectués chaque jour pour s'assurer que le rideau de lumière et le système de commande de la machine fonctionnent comme il faut. Ces tests doivent également être effectués après toute modification ou tout entretien du rideau de lumière ou de la machine. LIGHT CURTAIN DAILY TESTS Perform these tests daily to make sure the Light Curtain and the machine's control system work properly. Also, perform these tests after any modification or maintenance to the Light Curtain or the machine. NOTE: Use an opaque 1 1/4" diameter test bar for performing the daily tests. 1. Turn on power to the Light Curtain and the machine. If the red and green lights are on at the same time, clear the Light Curtain to green state by momentarily interrupting the sensing field with a test bar. 2. If your Light Curtain has a Floating Window, shut off the Floating Window system. Make sure the Floating Window indicator light goes off. 3. Interrupt the sensing field on the receiver side by passing the test bar from the top to the bottom of the receiver lens cover. The red light should come on while the bar is in the sensing field. 4. Repeat step 3, passing the bar from the top to the bottom of the transmitter lens cover. Make sure the red light comes on when the bar is in the sensing field. 5. Start the machine and interrupt the sensing field with the test bar. The red indicator light on the receiver should come on and the machine should immediately stop. NOTE: When muting is used, interrupting the Light Curtain during the muted portion of the stroke will NOT stop the machine. 6. Cycle the machine and make sure it stops at the proper position and that the machine's braking system is working properly. If the machine does not brake fast enough, adjust the braking system or increase the Light Curtain's safety distance. 7. If the machine or Light Curtain fails any of these tests, DO NOT RUN THE MACHINE. Notify the supervisor immediately. 8. When using the Light Curtain with mechanical power presses, all OSHA Safety and Health Standards (29 CFR ) must be met. DO NOT USE THE LIGHT CURTAIN ON FULL REVOLUTION CLUTCH MACHINES. C42254 Rev FUSE F1 1/4 A SLO-BLO, INPUT POWER FUSES F2, F3, F4 4 A SLO-BLO, RELAY OUTPUTS FSD1 FSD2 STAT GND ACTIVE REMOTE INTERRUPT D43087 Rev RELAY OUTPUTS 1 E-STOP E-STOP STATUS 10 SHIPPED WITH FACTORY TB4 INSTALLED JUMPERS DS7 11 MPCE1 MPCE2 RESET ON DS8 XMTR AUX INPUTS J15 INT/EXT MPCE CK INTERNAL SELECTION JUMPERS J14 S3 20 RESET XMTR INT DS6 EXT MPCE2 CK (DE-ENERGISED) DS5 EXT MPCE1 CK (DE-ENERGISED) POWER UP RESET DISABLE GRN AMB RED YEL V-OUT DS1 DS2 REMOTE INDICATORS HEAD INTERRUPT INDICATORS J12 IN 1 SET MODE, BOTH ON, HEAD SELECTION 2 SETS IN 2 SETS MODE, JUMPERS DS1 ON = SET 1 RED, 1 SET DS2 ON = SET 2 RED TRANSMITTER ON OFF TRANSMITTER/RECEIVER CABLE COLOR CODE S4 RESET ON INTERRUPT FLOATING WINDOW STATUS RELAY FOLLOWS S1 STOP OUTPUTS OPTIONS TB3 TRANSMITTER ORG RED BLK/ BLU RECEIVER TB2 RECEIVER 2 BRN GRN YEL SHIELD DATA INSTRUMENTS 75 Discovery Way, Acton MA U.S.A. FOR ASSISTANCE CALL Figure B-1. Daily Tests Label (left) and Operator instructions Label (right) Shadow VI Panel Mount Appendix B page 117

130 Shadow VI User Manual Final assembly Once the final checkout has been confirmed and Shadow is working satisfactorily while it has been sitting outside the enclosure, you are ready to completely install the Shadow VI panel mount into your enclosure. Remember earlier you had cut out a hole in your panel enclosure. Mount the Shadow panel assembly into this cavity using the ten 1/4-20 screws. Refer to Figure B-2 for mounting and cutout dimensions for Shadow VI panel and your enclosure. 10 (25.4) 9.5 (24.1) 4 (10.2) 2 plcs. 8 (20.3) cutout size 3" x 9" (7.6 x 22.9 cm) 2.5 (6.4) dia. (0.55) 10 plcs. 3.5 (8.9) 4 (10.2) allow minimum 8" clearance behind panel mounting plane Figure B-2. Shadow VI Panel Mount Control Dimensions page 118 Appendix B Shadow VI Panel Mount

131 Appendix C Installation of Shadow VI-WPC Control Board This appendix explains how to install, wire, and operate the optional Shadow VI-WPC control board assembly in conjunction with your Wintriss Clutch/Brake Control (WPC). This control board replaces the standard Shadow VI control box. The Shadow VI-WPC control board can only be used with Shadow VI Light Curtains (all sizes) and Wintriss Clutch/Brake Control. It cannot be used with any other press control or any other model of light curtain. NOTICE This appendix explains specific differences when installing the Shadow VI-WPC board. Refer to Chapter 2 and related illustrations for complete installation information where noted. If you ordered WPC with the Shadow VI-WPC control board factory-installed and premounted, you can disregard most of the installation sections in this appendix. You need only to connect the optic heads to the control board and make appropriate settings. Mounting Dimensions and Required Clearance 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. Refer to Figure C-2 for mounting dimensions and required clearance information for the Shadow VI-WPC control board. The Shadow VI-WPC control board comes assembled with eight standoffs for each mounting hole. Each standoff is size 6-32 and 1/2" in length. Recommended screw size is 6-32 x 3/8". Be careful to protect existing electronics, PC boards, etc. in the enclosure while drilling and mounting components. If you are installing this control board inside a standard resolver-based WPC enclosure, we recommend that you mount it on the right side of the enclosure. If your display is mounted on the right side, install this board on the door. When mounted on the door, dress the wires carefully across the hinge. Use a loom to protect the wires from getting caught in the hinge. Shadow VI User Manual Installation of Shadow VI-WPC Control Board Appendix C page 119

132 Shadow VI User Manual Mount the control board assembly near the WPC assembly so that important components on the board are readily accessible to personnel during installation and maintenance. Make sure that there is enough room to access the board whenever necessary. About Shadow VI-WPC Control Board Labels DANGER DAILY TESTS LABEL INACCESSIBLE Affix the Daily Tests label where operators can clearly read the instructions. The daily tests are critical to operator safety and must be run every day before operating the press. Failure to comply with these instructions will result in death or serious injury. NOTICE The information on the Operator Instructions label is used for maintenance purposes. Affix the label where it can be easily read. With your panel mount assembly you should have received the three labels shown below: "Daily tests, Shadow VI and Warning. Place these labels where they are clearly visible. page 120 Appendix C Installation of Shadow VI-WPC Control Board

133 Shadow VI User Manual CAUTION Perform these tests daily to ensure the Light Curtain and the machine's control system work properly. These tests should also be performed after any modification or maintenance to the Light Curtain or the machine. ATTENTION Des essais doivent être effectués chaque jour pour s'assurer que le rideau de lumière et le système de commande de la machine fonctionnent comme il faut. Ces tests doivent également être effectués après toute modification ou tout entretien du rideau de lumière ou de la machine. LIGHT CURTAIN DAILY TESTS Perform these tests daily to make sure the Light Curtain and the machine's control system work properly. Also, perform these tests after any modification or maintenance to the Light Curtain or the machine. NOTE: Use an opaque 1 1/4" diameter test bar for performing the daily tests. 1. Turn on power to the Light Curtain and the machine. If the red and green lights are on at the same time, clear the Light Curtain to green state by momentarily interrupting the sensing field with a test bar. 2. If your Light Curtain has a Floating Window, shut off the Floating Window system. Make sure the Floating Window indicator light goes off. 3. Interrupt the sensing field on the receiver side by passing the test bar from the top to the bottom of the receiver lens cover. The red light should come on while the bar is in the sensing field. 4. Repeat step 3, passing the bar from the top to the bottom of the transmitter lens cover. Make sure the red light comes on when the bar is in the sensing field. 5. Start the machine and interrupt the sensing field with the test bar. The red indicator light on the receiver should come on and the machine should immediately stop. NOTE: When muting is used, interrupting the Light Curtain during the muted portion of the stroke will NOT stop the machine. 6. Cycle the machine and make sure it stops at the proper position and that the machine's braking system is working properly. If the machine does not brake fast enough, adjust the braking system or increase the Light Curtain's safety distance. 7. If the machine or Light Curtain fails any of these tests, DO NOT RUN THE MACHINE. Notify the supervisor immediately. 8. When using the Light Curtain with mechanical power presses, all OSHA Safety and Health Standards (29 CFR ) must be met. DO NOT USE THE LIGHT CURTAIN ON FULL REVOLUTION CLUTCH MACHINES. C42254 Rev WARNING Substitution of components may impair operator safety. shadow VI WINTRISS LIGHT CURTAIN MAX RESPONSE TIME <40mS INPUT POWER 115/230 VAC 1/4 A 50-60Hz MAX 20 VA SOLID STATE OUTPUTS MAX 20 ma/24vdc SEE CONTROLLER BOARD FOR ITEM & SERIAL NUMBERS AVERTISSEMENT La substitution d éléments constitutifs peut compromettre la sécurité d l operateur. Figure C-1. Shadow VI - WPC Labels "Daily tests" label (left), "Shadow VI" label showing response time (upper right), Warning label (lower right) Installation of Shadow VI-WPC Control Board Appendix C page 121

134 Shadow VI User Manual The LED indicators, switches, and terminal blocks listed below are on the control board (see Figure C-3 in this appendix) that should be readily accessible to personnel. The indicators include: DS1: Set #1 optic heads blocked DS5: "Curtain clear" DS2: Set #2 optic heads blocked DS6: "Floating" DS3 & DS4: Power DS7: Reset Required The switches include: S1: Floating window enable J2: 1 or 2 sets S2: 115/230 voltage S3: Reset button The terminal blocks include: TB2: Receiver(s) TB1: Power TB3: Transmitter(s) TB4: Stop outputs xx.x = inches (xx.x x) = cm 9.50 (24.13) (25.40) 6.00 (15.24) allow at least 5" clearance above board and 1" clearance around 3.25 (8.26) 8 standoffs (size 6-32, 1/2" long) are provided with processor board 2.75 (6.99) 3.25 (8.26) Figure C-2. Mounting Dimensions and Required Space for Control Board page 122 Appendix C Installation of Shadow VI-WPC Control Board

135 Shadow VI User Manual mounting holes (8 places) Power TB1 PE formerly "CHAS" Fuse F1 Voltage Selector S2 CAUTION Power Transformer DS4 DS3 LEDs FLOATING WINDOW S1 (shown set to "OFF") X XMTR M T W PWR RP R RCVR CV R PWR RP W R DS5 DS6 DS1 DS7 DS2 DS2 DS7 CLEAR FLOAT SET1 BLOCK SET2 BLOCK RESET REQUIRED Labels shown here do not appear same on on actual board. RESET BUTTON S3 STOP OUTPUTS TB4 2SET / 1 SET Jumpers J12 TRANSMITTER(S) TB3 upper - Set 1 lower - Set 2 RECEIVER(S) TB2 upper - Set 1 lower - Set 2 Figure C-3. Important Components - Shadow VI-WPC Control board Installation of Shadow VI-WPC Control Board Appendix C page 123