..... R 4700 Series Installation and Operating Manual for MC4700, MCF4700, MCJ4700, MS4700 & MSF4700 Series Scientific Technologies Inc. Optical Sensor Division Manufacturing and Sales Office 6550 Dumbarton Circle Fremont CA 94555 USA 1 / 888 / 510-4357 Tel: 510/608-3400 Fax: 510/744-1442 www.sti.com (c) STI 0806 PN99584-0050 Rev.D NOTE: This manual provides information for MC4700, MCF4700, MCJ4700, MS4700 and the MSF4700 transmitters and receivers, for use with both the LCM metal enclosure as well as the DIN box controller. Where information is common the term "4700 system" is used. Where information is specific to a certain version the exact model number (example: safe mounting distance calculation) is provided. The specifications and detailed information of the MCF4700, MCJ4700, MS4700 and the MSF4700 information are located at the back of the manual. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 0 ..... 4700 Series Safety Light Curtain Table of Contents Section 1--Important Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9 Section 2--Significant Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10 2.1--Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10 2.2--Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10 Section 3--System Access, Components and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11 3.1--Access to Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11 3.1.1--LCM DIN Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11 3.1.2--LCM Metal Chassis Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12 3.2--Location of the components and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13 Section 4--System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.1--Operating States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.1.1--Machine Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.1.2--Machine Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.1.3--Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.1.4--Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.2--Operating Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.2.1--Automatic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16 4.2.2--Start Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17 4.2.3--Start/Restart Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17 4.3--Operating Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18 4.4--Start Switch Type Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18 Section 5--Detection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18 5.1--Exact Channel Select (ECS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19 5.2--Multi Channel Select (MCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19 5.3--Floating Blanking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 5.4--Using Exact Channel Select with Floating Blanking . . . . . . . . . . . . . . . . . . . . . . . page 21 5.4.1--The Effect of Exact Channel Select and Floating Blanking on Minimum Object Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 5.5--Activating and Programming Exact Channel Select . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 1 5.6--MCS Programing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23 5.7--Activating Floating Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24 5.8--Additional Guarding When Using Exact Channel Select . . . . . . . . . . . . . . . . . . . .page 24 Section 6--Diagnostic and Test Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25 6.1.--Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25 6.2--Individual Beam Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25 6.3--Machine Primary Control Element (MPCE) Monitoring . . . . . . . . . . . . . . . . . . . .page 25 6.3.1--Activating and Deactivating MPCE Monitoring . . . . . . . . . . . . . . . . . . . . . page 26 6.3.2--Activating and Deactivating MPCE Monitoring on the Metal Chassis ControllerRelay Output Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26 6.4.--Status Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26 6.4.1--Safety Output status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26 6.4.2--Interlock Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26 6.4.3--Alarm Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26 6.4.4--Exact Channel Select and Floating Blanking Status . . . . . . . . . . . . . . . . .page 26 Section 7--Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27 7.1--Safety Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27 7.1.1--Din Controller and Metal Chassis Solid State Version . . . . . . . . . . . . . . . .page 27 7.2.2--metal chassis Controller - Relay Output Version . . . . . . . . . . . . . . . . . . . .page 27 7.2.--Auxiliary Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27 7.2.1--DIN Controller and Metal Chassis Solid State Version . . . . . . . . . . . . . . . .page 27 7.2.2--metal chassis Controller - Relay Output Version . . . . . . . . . . . . . . . . . . . .page 27 7.2.3--Auxiliary Output Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 27 Section 8--Safe Mounting Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28 8.1--US Safe Distance Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28 8.2--European Safety Distance Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29 8.2.1--Safety Distance Formula for Systems with a Minimum Object Resolution of 40 mm or Less . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29 8.2.2--Safety Distance Formula for Systems with a Minimum Object Resolution Greater Than 40 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30 8.2.3--Factors Affecting The Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . page 30 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 2 ..... Section 9--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31 9.1--Reflective Surface Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31 9.2.--Connecting Transmitter and Receiver to Controller . . . . . . . . . . . . . . . . . . . . . . . page 33 9.2.1--Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33 9.2.2--Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33 9.3--General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34 9.3.1--Additional Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34 9.3.2--Installation of Multiple Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35 9.3.3--Detection Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36 9.3.4--Marking Minimum Object Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36 9.3.5--Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36 9.3.6--Input Power Requirements/Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36 9.3.7--Special Requirements for Perimeter Guarding . . . . . . . . . . . . . . . . . . . . . . page 36 9.3.8--Presence Sensing Device Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36 Section 10--Connecting To The Machine Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . page 37 10.1--Din Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37 10.1.1--Connecting to a Safety Monitoring Device . . . . . . . . . . . . . . . . . . . . . . . . page 38 10.1.2--Connecting Via an RM-1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39 10.1.3--Connecting Via Two Force-Guided Relays . . . . . . . . . . . . . . . . . . . . . . . . . page 40 10.2--Metal Chassis Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41 10.2.1--Connecting Via Two Normally Open Relay Safety Outputs . . . . . . . . . . . page 41 10.2.2--Connecting Via One Normally Open One Normally Closed Safety Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42 10.2.3--Connecting Solid State Safety Outputs to Two Force-Guided Relays . . . page 43 10.2.4--Connecting Via a Safety Monitoring Device . . . . . . . . . . . . . . . . . . . . . . . page 44 Section 11--Checkout and Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45 11.1--Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45 11.2--Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45 11.3--Using the Test Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 3 11.4--Test Considerations When Using Exact Channel Select or Floating Blanking . .page 46 Section 12--Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 46 Section 13--Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 48 Section 14--Specifications and Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . page 49 14.1--System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 49 14.2--MicroSafe MC4700 Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 49 14.2.1--MC4700 Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54 14.2.2--MC4700 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 14.3--MicroSafe Flexible MCF4700 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54 14.3.1--MCF4700 Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54 14.3.2--MCF4700 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 59 14.4--MicroSafe Jointed MCJ4700 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 64 14.4.1--MCJ4700 Segment Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 64 14.4.2--90 Jointed MicroSafe MCJ4700 Dimensions . . . . . . . . . . . . . . . . . . . .page 55 14.4.3--Sensor Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 14.4.4--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 14.4.5--Minimum Object Resolution at Joints . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 14.4.6--MCJ4700 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 55 14.5--MiniSafe MS4700 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 70 14.5.1--MS4700 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 70 14.5.2--MS4700 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 72 14.6--MiniSafe Flexible MsF4700 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 76 14.6.1--MSF4700 Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 77 14.6.2--MSF4700 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 78 14.7--DIN and LCM NEMA Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 83 Section 15--Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 88 15.1--Glossary Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 88 Section 16--Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99 16.1--Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99 16.2--Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99 16.3--Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99 16.4--Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 4 ..... 16.5--Documentation Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 99 Appendix A --Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 89 A.1--Checkout Procedure Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 89 Appendix B --Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 90 B.1--Test Procedure Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 90 Appendix C --DeviceNet Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 91 C.1--Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 91 C.2--Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 91 C.2.1--System identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 91 C.2.2--System status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 91 C.2.3--System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 91 C.2.4--Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 92 C.3--Basic DeviceNet Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 94 C.4--LCM-2XX series internal D-Net Wire Colors and Pin Outs . . . . . . . . . . . . . . . . . . page 94 C.4.1--Screw Connectors for LCM-2XX series D-Net interface module . . . . . . . . page 94 C.5--DeviceNet Configuration Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 96 C.5.1--Switch Function Selection Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 97 C.6 Quick Disconnect Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 98 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 5 Table of Figures Figure 3-1--Accessing the Configuration Switches on the LCM DIN Controller . . . . . . . . .page 11 Figure 3-2--Accessing the Configuration Switches on the LCM-Metal Chassis Controller .page 12 Figure 3-3--4700 Transmitter and Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13 Figure 3-4--DIN Controller Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14 Figure 3-5--Metal Chassis Controller Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15 Figure 4-1--Functional Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17 Figure 5-1--Connection Recommendations for LCM Metal Enclosure . . . . . . . . . . . . . . . . .page 20 Figure 5-2--Connection Recommendations for LCM DIN Box . . . . . . . . . . . . . . . . . . . . . . . page 20 Figure 5-3--Adding Hard guarding to Light Curtain when Using Channel Select . . . . . . . .page 23 Figure 8-1--Safe Mounting Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 28 Figure 9-1--Correct Mounting Example with Proper Alignment. . . . . . . . . . . . . . . . . . . . . . page 31 Figure 9-2--Unsafe Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 31 Figure 9-3--Unsafe Mounting Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 32 Figure 9-4--Worst Case Alignment Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 32 Figure 9-5--Minimum Distance from a Reflective Surface as a Function of Range . . . . . . .page 32 Figure 9-6--Correct Light Curtain Installation Examples. . . . . . . . . . . . . . . . . . . . . . . . . . . page 34 Figure 9-7--Multiple Light Curtain Installation Configurations . . . . . . . . . . . . . . . . . . . . . . page 35 Figure 9-8--Mounting Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 35 Figure 10-1--Connecting to a Safety Monitoring Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38 Figure 10-2--Connecting via an RM-1 Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39 Figure 10-3--Connecting Via Two Force-guided Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 40 Figure 10-4--Connecting with Two Normally Open Safety Outputs . . . . . . . . . . . . . . . . . . .page 41 Figure 10-5--Connecting with One Normally Open One Normally Closed Safety Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 42 Figure 10-6--Connecting with Two Force Guided Relay Outputs . . . . . . . . . . . . . . . . . . . . . page 43 Figure 10-7--Connecting with Safety Monitoring Device . . . . . . . . . . . . . . . . . . . . . . . . . . . page 44 Figure 11-1--Test Object Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 45 Figure 14-1--MC4700 Series Dimensional Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54 Figure 14-2--MicroSafe Flexible MCF4700 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 57 Figure 14-3--MicroSafe Jointed MCJ4700 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 64 Figure 14-4--90 Jointed MicroSafe MCJ4700 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . page 65 Figure 14-5--Assembly Instructions Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 66 Figure 14-6--MS4700 Mechanical Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 70 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 6 ..... Figure 14-7--MiniSafe Flexible MSF4700 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 76 Figure 14-8--DIN Controller Dimension Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 83 Figure 14-9--LCM Nema Metal Chassis Controller Dimension Drawing . . . . . . . . . . . . . . . page 84 Figure 15-1--DeviceNet Install Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 98 Figure 15-2--DevieNet Wiring with Optional M12 Connector . . . . . . . . . . . . . . . . . . . . . . . . page 98 Figure C-1--Basic DeviceNet configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 94 Figure C-2--Pin Outs for Internal Screw Connectors used internally in the LCM-2XX . . . . page 95 Figure C-3--Pin Outs for Micro_Style Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 95 Figure C-4--Pin Outs for Phoenix-style connectors used in the STI MC4700, LCM-2 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 96 Figure C-5--LCM-2 Power/DeviceNet board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 96 Table of Tables Table 3-1--System Component Identification for the 4700 Transmitter and Receiver . . . . . page 13 Table 3-2--System Component Identification for the LCM-1, LCM-2 and LCM-3 Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14 Table 4-1--Operating Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18 Table 5-1--System Response to Exact Channel Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19 Table 5-3--System Response to Floating Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 Table 5-4--Icon Key for Tables 5-1 and 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21 Table 5-5--Sample S and Dpf Factors for 12 mm Resolution Systems . . . . . . . . . . . . . . . . . page 22 Table 5-6--Sample S and Dpf Factors for 14 mm resolution Systems . . . . . . . . . . . . . . . . . . page 22 Table 5-7--Sample S and Dpf Factors for 20mm resolution Systems . . . . . . . . . . . . . . . . . . page 22 Table 5-8--Sample S and Dpf Factors for 30 mm resolution Systems . . . . . . . . . . . . . . . . . . page 23 Table 5-9--Switch Settings, Exact Channel Select and Floating Blanking . . . . . . . . . . . . . . page 24 Table 6-1--Operational Display Code Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25 Table 6-2--MPCE Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26 Table 7-1--Auxiliary Output Operating Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . page 28 Table 9-1--Color Code/Terminal Number Cross Reference for DIN Controllers . . . . . . . . . . page 33 Table 9-2--Color Code/Terminal Number Cross Reference Metal Chassis Controllers . . . . . page 33 Table 12-1--Operational Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 46 Table 12-2--DIP Switch Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 7 Table 12-3--Safety Output (OSSD) Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47 Table 12-4--MPCE Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 47 Table 12-5--Controller Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 48 Table 14-1--Response Time for 12 mm MC4700 and MS4700 . . . . . . . . . . . . . . . . . . . . . . . . page 51 Table 14-2--Response Time for 14 mm and 20 mm MC4700 and MS4700 . . . . . . . . . . . . . .page 51 Table 14-3--Response Times for 30 mm MC4700 and MS4700 systems . . . . . . . . . . . . . . . .page 52 Table 14-4--12mm transmitter and Receiver Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 54 Table 14-5--14mm, 20 mm and 30 mmTransmitter and Receiver Lengths. . . . . . . . . . . . . .page 54 Table 14-6--MC4700-12 Spare Transmitter and Receiver Model Number . . . . . . . . . . . . . . .page 55 Table 14-7--MC4700-14 Spare Transmitter and Receiver Model Number . . . . . . . . . . . . . . .page 55 Table 14-8--MC4700-20 Spare Transmitter and Receiver Model Number . . . . . . . . . . . . . . .page 56 Table 14-9--MC4700-30 Spare Transmitter and Receiver Model Number . . . . . . . . . . . . . . .page 56 Table 14-10--MCF4700-12 Dimensions First & Middle Segment . . . . . . . . . . . . . . . . . . . . . . page 58 Table 14-11--MCF4700-12 Dimensions Last Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 58 Table 14-12--MCF4700-14, MCF4700-20 and MCF4700-30 First and Middle Segment . . . .page 58 Table 14-13--MCF4700-14, MCF4700-20 and MCF4700-30 Last Segment . . . . . . . . . . . . . .page 59 Table 14-14--Transmitter and Receiver Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 59 Table 14-15--MCJ470-12 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 67 Table 14-16--MCJ4700 Joint Resolution (Resolution at the Corner) . . . . . . . . . . . . . . . . . . .page 67 Table 14-17--Transmitter and Receiver Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 67 Table 14-18--MS4700-12 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 70 Table 14-19--MS4700-14 & MS4700-20 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 71 Table 14-20--MS4700-30 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 71 Table 14-21--Transmitter and Receiver Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 72 Table C-1--Specifications for 4700 System Controller with DeviceNet . . . . . . . . . . . . . . . . .page 92 Table C-2--4700 Status Information Sent in Response to a poll command . . . . . . . . . . . . .page 93 Table C-3--I/O Data for Change of State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 93 Table C-4--I/O Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 93 Table C-5--Configuration Switches for Device-Net . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 97 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 8 ..... 1 1 I MPORTANT S AFETY W ARNINGS !! WARNING! Read and understand this section prior to installing a 4700 system. A 4700 system is a general purpose presence sensing device designed to guard personnel working around moving machinery. Whether a specific machine application and light curtain installation complies with safety regulations depends on the proper application, installation, maintenance and operation of the light curtain. These items are the responsibility of the purchaser, installer and employer. The employer is responsible for the selection and training of personnel to properly install, operate, and maintain the machine and its safeguarding systems. A 4700 system should only be installed, verified and maintained by a qualified person. A qualified person is defined as "a person or persons who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training or experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work." (ANSI B30.2-1983) To use a 4700 series safety light curtain the following requirements must be met: -- The guarded machine must be able to stop anywhere in its cycle. Do not use a safety light curtain on a press with a full-revolution clutch. -- The guarded machine must not present a hazard from flying parts. -- The guarded machine must have a consistent stopping time and adequate control mechanisms. -- Severe smoke, particulate matter and corrosives may degrade the efficiency of a safety light curtain. Do not use a 4700 system in this type of environment. -- All applicable governmental and local rules, codes, and regulations must be satisfied. This is the employer's responsibility. -- All safety-related machine control elements must be designed so that a alarm in the control logic or failure of the control circuit does not lead to a failure to danger. -- Additional guarding may be required for access to dangerous areas not covered by the 4700 series system. -- Perform the STI test procedure at installation and after maintenance, adjustment, repair or modification to the machine controls, tooling, dies or machine, or the 4700 series system. -- Perform only the test and repair procedures outlined in this manual. -- Follow all procedures in this manual for proper operation of the 4700 series system. The enforcement of these requirements is beyond the control of STI. The employer has the sole responsibility to follow the preceding requirements and any other procedures, conditions and requirements specific to his machinery. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 9 2 2 2 S IGNIFICANT F EATURES 2.1 S T A N D A R D F E A T U R E S Individual Beam Indicators External Device Monitoring (MPCE Monitoring) Automatic Start Mode Start Interlock Mode Start/Restart Interlock Mode Adjustable Mounting Brackets Floating Blanking Exact Channel Select Two Safety (PNP) Outputs Auxiliary Output Start Switch Input Selectable NO or NC 2.2 O P T I O N A L F E A T U R E S Relay Safety Outputs (Metal Chassis Controllers only) DeviceNet Multi-Channel Select (Non-CE) R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 10 ..... 3 S YSTEM A CCESS , C OMPONENTS AND 3 I NDICATORS 3.1 A C C E S S T O C O N F I G U R A T I O N S W I T C H E S 3.1.1 LCM DIN C ONTROLLER Switches for configuring system features are located under the front cover of the controller. Access to these switches is gained by the following procedure: 1. Remove the four screws holding the cover in place (see Figure 3-1 for location). 2. Place the blade of a thin flat-blade screwdriver between the cover and the main controller housing and gently lift the cover off. See Figure 3-1 for detail. The cover is not hinged and will be completely removed. To replace the cover: 1. Correctly position one end and push down on the opposite end to snap it in place. 2. Replace the four screws to properly retain the cover. Figure 3-1 Accessing the Configuration Switches on the LCM DIN Controller R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 11 3 3.1.2 LCM M ETAL C HASSIS C ONTROLLER Switches for configuring system features are located inside the front cover of the controller. Access to these switches is gained by the unlocking the clasp on the right-hand side of the controller box. The Clasp has provisions to accept a user-provided padlock. Only a qualified p erson should have possession of the key to the padlock, or to the optional Program/Start keyswitch. R Scientific Technologies Inc, Fremont, CA 94555 U.S.A. 1/888/510-4357 ! W http://www.sti.com A R N I N G RUN PROGRAM START RUN STOP INTERLOCK FB/CS Optional Keyswitch Diagnostic Codes: 00 Normal Operation 01 Normal Operation, waiting for Start signal 02 Normal Operation, Floating Blanking active 03 Normal Operation, Exact Channel Select active 04 Normal Operation, Exact Channel Select and Floating Blanking active 20 General DIP switch fault 21 Invalid switch setting 22 DIP switch settings changed during operation 23 Invalid Channel Select or MPCE switch settings 30 40 41 43 50 51 52 53 General Safety Output fault General MPCE fault MPCE open before safety output (OSSD) activation MPCE open when power is applied Internal controller fault Receiver fault Transmitter fault Transmitter and receiver length mismatch or transmitter and receiver not connected 59 24 VDC power supply fault TEST PROCEDURE To test the light curtain, use the appropriate STIsupplied test object, or properly sized opaque cylindrical object. If you are using the Channel Select or Floating Blanking features and the object to be ignored does not completely prevent access to the hazardous area, either (1) use a mechanical guard or other means to block access or (2) increase the minimum safe distance and use a larger test object diameter as explained in the Installation and Operating Manual. 1. Disable the machine. Power on the light curtain. 2. Inspect the machine to ensure entry to the hazardous area is only through the light curtain sensing field. If not, additional guarding, including mechanical barriers may be required. 3. Verify that the mounting distance of the light curtain is equal to or greater than the minimum safe distance from the hazardous point. Ensure the operator is not able to stand undetected between the light curtain and the hazard. 4. Check for external damage to the light curtain, the machine, electrical cables and wiring. 5. Interrupt the sensing field with the test object to check the effectiveness of the light curtain. Move the test object inside the perimeter (along the top, sides and bottom) of the sensing field and up and down through the center of the sensing field. Verify that the Red indicator is ON and the Green indicator is OFF while the test object is anywhere in the sensing field. watch for any unprotected access to the point of hazard. 6. Start the machine. Interrupt the sensing field with the test object. The machine should stop immediately. Never insert the test object into the dangerous parts of the machine! With the machine at rest, interrupt the sensing field with the test object. that the machine will not start with the test object in the sensing field. 7. Ensure the braking and machine stop systems are working properly in accordance with the machine manufacturer s requirements. If the machine does not stop fast enough, adjust the braking system or increase the distance from the light curtain to the point hazard. 8. If the safety devices or machine fail any of these tests, do not run the machine. Immediately lockout the machine to prevent its use and notify the supervisor 9. If the Channel Select is reprogrammed or disabled, you must repeat these test procedures. 10. Close and lock the light curtain contr enclosure door, if applicable. Clasp Do Not Remove Or Cover This Label STI Label P/N 28621-0010 re Figure 3-2 Accessing the Configuration Switches on the LCM-Metal Chassis Controller R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 12 ..... 3.2 L O C A T I O N O F T H E C O M P O N E N T S A N D I N D I C A T O R S Refer to Figure 3-3, Figure 3-4 and Figure 3-5 for the location of the components and indicators listed below. Table 3-1 System Component Identification for the 4700 Transmitter and Receiver Chart # 1 RECEIVER 2 Individual Beam Indicators (one for each beam) - Red 3 Channel Select or Floating Blanking Indicator - Amber 4 Interlock or Fault Indicator - Yellow 5 Machine Stop Indicator - Red 6 Machine Run Indicator - Green 7 TRANSMITTER 8 Detection Zone RECEIVER DETECTION ZONE RECEIVER TRANSMITTER DETECTION ZONE "A" 3. GRN 1. AMBER 2. YEL 4. RED 1. CHANNEL SELECT or FLOATING BLANKING INDICATOR-AMBER 2. INTERLOCK or FAULT INDICATOR-YEL 3. MACHINE STOP INDICATOR-RED 4. MACHINE RUN INDICATOR-GRN RX MS4700 LED INDICATORS MS4700 4. RED - STOP/BLOCKED RX LED INDICATORS TRANSMITTER MC4700 3. GRN - RUN/CLEAR MC4700 1. AMBER - FLOATING BLANKING OR CHANNEL SELECT 2. YEL - INTERLOCK 1 GRN AMBER 2 YEL RED 4 3 TX Figure 3-3 4700 Transmitter and Receiver R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 13 3 Table 3-2 System Component Identification for the LCM-1, LCM-2 and LCM-3 Controllers Chart # 4 EXact Channel Select 1 beam 5 EXact Channel Select 2 beams 6 EXact Channel Select 3 beams 7 EXact Channel Select Return 9 Channel Selector Floating Blanking Indicator - Amber 10 Interlock or Alarm Indicator - Yellow 11 Machine Stop Indicator - Red 12 Machine Run Indicator - Green 13 Diagnostic Code Display 14 Switch A 15 Program Button 16 Switch B 17 Removable Terminal Blocks for input and output connections 18 DeviceNet status indicators (optional) 19 Start Switch Type Jumper 20 Relay Board (metal chassis only) 21 Power In (metal chassis only) 22 MPCE Monitoring (metal chassis only) 23 Multi-channel Select terminals 24 Optional Keyswitch NOTE: For DeviceNet Option, LCM-2 Series, Terminals 13 to 17 are indicated below. NOTE: For Multi Channel Select Option, LCM-3 Series, Terminals 4 to 7 are indicated on below. Channel Select DeviceNet 5 4 ECS 2 ECS 1 DATA H 6 CS Prog Not Used 13 12 11 10 9 8 7 6 5 4 Not Used Not Used MPCE MPCE RETURN START RETURN START PROG RET PROGRAM Not Used Not Used Power 3 2 1 +24 VDC 0 VDC Remote 14 DATA Not Used MPCE 16 15 Not Used RS232 17 9 7 PROGRAM 13 ECS Return 14 CAN + CAN V-- 16 15 DATA L 17 WARNING SAFETY DEVICE ! Do not defeat or bypass. Severe injury to personnel could result. R Fremont, CA, USA Tel: 510/608-3400, Fax: 510/744-1442 www.sti.com Output Xmtr Xmtr/Rcvr Rcvr 31 32 33 34 RED 30 YELLOW 29 VIOLET 28 GRAY 27 TAN 26 PINK 25 BROWN 24 WHITE 23 BLUE OSSD RETURN AUX1 OUT OSSD 2 OSSD 1 22 BLACK 21 SHIELD 20 AUX2 OUT 19 ORANGE 18 LCM-1 Series Scientific Technologies Inc. FB/CS Run Stop 12 Interlock 11 23 13 10 19 1 2 3 18 13 14 17 16 15 Figure 3-4 DIN Controller Components R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 14 ..... Inside Front Lid of the metal chassis controller 19 J1 N.C. N.O. START 8 7 6 5 4 3 2 1 15 J2 KEYSWITCH PROGRAM TB5 RX R Scientific Technologies Inc, Fremont, CA 94555 U.S.A. 1/888/510-4357 13 W R N I N 23 G TB7 -Note: Shown with optional Relay Board. RUN PROGRAM 18 J3 http://www.sti.com A TB6 TX OPTIONAL DEVICENET BOARD J1 ! 5 4 3 2 1 START SWA 1 MCS 2 1 2 PROG 1 START 2 1 MPCE 2 SWB 22 MPCE MON JMP2 RUN OFFON STOP INTERLOCK FB/CS 24 Diagnostic Codes: 00 Normal Operation 01 Normal Operation, waiting for Start signal 02 Normal Operation, Floating Blanking active 03 Normal Operation, Exact Channel Select active 04 Normal Operation, Exact Channel Select and Floating Blanking active 20 General DIP switch fault 21 Invalid switch setting 22 DIP switch settings changed during operation 23 Invalid Channel Select or MPCE switch settings 30 40 41 43 50 51 52 53 59 General Safety Output fault General MPCE fault MPCE open before safety output (OSSD) activation MPCE open when power is applied Internal controller fault Receiver fault Transmitter fault Transmitter and receiver length mismatch or transmitter and receiver not connected 24 VDC power supply fault 12 11 10 9 14 16 K1 P2 K2 PS1 AUX 20 TEST PROCEDURE To test the light curtain, use the appropriate STIsupplied test object, or properly sized opaque cylindrical object. If you are using the Channel Select or Floating Blanking features and the object to be ignored does not completely prevent access to the hazardous area, either (1) use a mechanical guard or other means to block access or (2) increase the minimum safe distance and use a larger test object diameter as explained in the Installation and Operating Manual. 1. Disable the machine. Power on the light curtain. 2. Inspect the machine to ensure entry to the hazardous area is only through the light curtain sensing field. If not, additional guarding, including mechanical barriers may be required. 3. Verify that the mounting distance of the light curtain is equal to or greater than the minimum safe distance from the hazardous point. Ensure the operator is not able to stand undetected between the light curtain and the hazard. 4. Check for external damage to the light curtain, the machine, electrical cables and wiring. 5. Interrupt the sensing field with the test object to check the effectiveness of the light curtain. Move the test object inside the perimeter (along the top, sides and bottom) of the sensing field and up and down through the center of the sensing field. Verify that the Red indicator is ON and the Green indicator is OFF while the test object is anywhere in the sensing field. watch for any unprotected access to the point of hazard. 6. Start the machine. Interrupt the sensing field with the test object. The machine should stop immediately. Never insert the test object into the dangerous parts of the machine! With the machine at rest, interrupt the sensing field with the test object. that the machine will not start with the test object in the sensing field. 7. Ensure the braking and machine stop systems are working properly in accordance with the machine manufacturer s requirements. If the machine does not stop fast enough, adjust the braking system or increase the distance from the light curtain to the point hazard. 8. If the safety devices or machine fail any of these tests, do not run the machine. Immediately lockout the machine to prevent its use and notify the supervisor 9. If the Channel Select is reprogrammed or disabled, you must repeat these test procedures. 10. Close and lock the light curtain contr enclosure door, if applicable. 0SSD1 0SSD2 RV1 R45 R44 C9 17 AUX TB2 TB1 F1 TB3 C8 L N 21 TB1 TB4 Do Not Remove Or Cover This Label STI Label P/N 28621-0010 re + _ Shown with DC Solid State Configuration Note: For Solid State Configuration, JMP2 and PS1 are not available. Figure 3-5 Metal Chassis Controller Components R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 15 4 4 4 S YSTEM O PERATION The 4700 system is a microprocessor-controlled, infrared transmitted-beam safety light curtain. The system consists of a receiver assembly and a transmitter assembly. Quick disconnect cables link the controller to the transmitter and receiver. The safety light curtain is often used where personnel protection is required. Typical applications include mechanical power presses, robotic work cells, filter presses, injection molders, food processing equipment and automated assembly equipment. 4.1 O P E R A T I N G S T A T E S The operating condition of a 4700 system is described in terms of states. The following operating states exist for the 4700 system. 4.1.1 M ACHINE R UN The two system safety outputs are in the ON state, the green machine run indicator is lit, and the auxiliary output is in a state consistent with its configuration. See Section 7 on page 27. The protected machine is allowed to operate. Pressing and releasing the start button has no effect. 4.1.2 M ACHINE S TOP The two system safety outputs are in the OFF state, the red machine stop indicator is lit, and the auxiliary output is in a state consistent with its configuration. See section Section 7 on page 27. The protected machine is not allowed to operate. Press and releasing the start switch has no effect. 4.1.3 I NTERLOCK The two system safety outputs are in the OFF state, the red machine stop indicator and yellow interlock indicator are lit. The auxiliary output is in a state consistent with its configuration. See Section 7 on page 27. The interlock state does not allow the protected machine to operate until the detection zone is clear of obstructions and the start button is pressed and released. 4.1.4 A LARM The two system safety outputs are in the OFF state, the red machine stop indicator is lit, the yellow interlock indicator is flashing, and the auxiliary output is in the OFF state. The alarm state does not allow the protected machine to operate. The primary difference between alarm and interlock is that the 4700 system will remain in the alarm state until power is recycled or the start switch is pressed and released and the system has run a self-test. 4.2 O P E R A T I N G M O D E S System operating modes determine the start-up and operating behavior of the 4700 system. Operating mode definitions rely on the operating states presented above. Operating mode selection is performed via configuration switches under the front cover of the controller. NOTE! If internal faults are detected by the 4700 system during power-up or operation, it will enter the alarm state with its safety outputs in the OFF state. 4.2.1 A UTOMATIC S TART The 4700 system will power-up with its safety outputs OFF, and perform system initialization and self tests. The 4700 system will enter the machine run state if no obstructions are present in the detection zone. In this state, when an object is sensed entering the detection zone, the 4700 system will change from machine run to machine stop and remain in this state until the obstruction is R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 16 ..... removed. Once the detection zone is clear, the 4700 system will automatically change from machine stop to machine run. 4.2.2 S TART I NTERLOCK The 4700 system will power-up with its safety outputs OFF and perform system initialization and self-tests. If no obstructions are detected in the protected zone, (or an exact channel select pattern satisfied), the 4700 system enters the interlock state. To enter the machine run state, the detection zone must be clear (or an exact channel select pattern satisfied), and then the operator must press and release the start switch. In the machine run state, when an object is sensed entering the detection zone the 4700 system will change from machine run to machine stop. Once the detection zone is clear, the 4700 system will automatically change from machine stop to machine run. 4.2.3 S TART /R ESTART I NTERLOCK The 4700 system will power-up with its safety outputs OFF, and, if no faults are detected, enter the interlock state. To enter the machine run state, the detection zone must be clear (or an exact channel select pattern satisfied), and then the operator must press and release the start switch. In the machine run state, when an object is sensed entering the detection zone the 4700 will change from machine run to interlock. The 4700 system will remain in the interlock state even after the obstruction is removed from the detection zone. To enter the machine run state, the operator must press and release the start switch. If any obstruction is present in the detection zone when the start switch is pressed and released, the 4700 will remain in the interlock state. NOTE! The definitions above mention a start switch. See Section 10-"Connecting to the Machine Control Circuit" for wiring of the start switch. Power-Up No Start Pressed & Released Yes Power-On Self-Test Machine run Yes Fault Failure Yes No Yes Yes Machine Stop Failure Failure Beam blocked Yes No Beam Cleared No Start/ Restart Interlock Yes No Yes Yes Failure Interlock No Yes Beam Blocked No Start Pressed & Released Yes Figure 4-1 Functional Flow Diagram R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 17 5 4.3 O P E R A T I N G M O D E S E L E C T I O N Operating mode is selected by setting positions 1 and 2 of Switches A and B, located under the controller cover. Refer to Table 4-1. Any mismatch between the settings of Switch A and B will result in an alarm condition. In addition, if the configuration switch settings change while the system is on, it will enter the alarm state with the safety outputs off. ! Warning! Disconnect power before accessing the controller assembly. Table 4-1 Operating Mode Switch Settings SWITCH A SWITCH B OPERATING MODE 1 2 1 2 Automatic Start (default setting) CLOSED/ON CLOSED/ON CLOSED/ON CLOSED/ON CLOSED/ON Start interlock OPEN/OFF CLOSED/ON OPEN/OFF Start/Restart interlock OPEN/OFF OPEN/OFF OPEN/OFF OPEN/OFF Not Allowed CLOSED/ON OPEN/OFF CLOSED/ON OPEN/OFF 4.4 S T A R T S W I T C H T Y P E S E L E C T I O N The type of Start switch (Normally Open or Normally Closed) used by the 4700 system is selectable by a jumper located under the controller cover. Refer to Figure 3-4--DIN Controller Components and Figure 3-5--Metal Chassis Controller Components. Placing the jumper between Pins 1 and 2 of JMP 1 selects a Normally Closed Start Switch. Placing the jumper between 2 and 3 selects a Normally Open Start switch. Note: If there is a mismatch between the type of Start selected and used, (i.e. jumper between Pins 1 and 2 and Normally Open Start Switch used) the switch must be pressed and released twice before the system will enter a Run state. 5 5 D ETECTION O PTIONS ! Warning! Use of Exact Channel Select and/or Floating Blanking will make the 4700 system less sensitive to objects in the detection zone. Improper use of either can result in severe injury to personnel. Exact Channel Select may require a hard barrier guard (see Section 5.8--Additional Guarding When Using Exact Channel Select), Exact Channel Select or Floating Blanking requires an increase in the safety distance. Read the following section carefully. - To prevent unauthorized modification of the detection zone. The system controller should be installed in an enclosure with supervisor-controlled access. - If the object to be ignored by the Channel Selected beams does not completely prevent access to the hazardous area, then either use a hard guard or other means to block access or increase the minimum safe distance as required by the proper formula. - Any beams which are not in alignment at the time of Channel Select programming may be inadvertently deselected. Use the STI Test Procedure to verify the correct configuration. - Floating Blanking increases the minimum safety distance therefore test object size will increase. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 18 ..... - After programming or activating Channel Select or Floating Blanking, to avoid unexpected areas where the system may not sense an intrusion into the detection zone, use a proper size test object to perform the STI Test Procedure. 5.1 E X A C T C H A N N E L S E L E C T ( E C S ) ECS disables selected, fixed areas of the detection zone by masking off specific, fixed beam locations. ECS is helpful when stationary objects such as tooling and fixtures permanently obstruct a portion of the detection zone. ECS requires that any portion of the detection zone which is blocked remain blocked. If the obstruction is removed the 4700 system will enter a machine stop state. When selecting channels to be masked, one channel must remain unblocked. A channel is defined as one transmitter/receiver pair or "beam". See Table 5-1, "System Response to Exact Channel Select" for a diagram of 4700 system response during operation with ECS active. Table 5-1 System Response to Exact Channel Select Channel Select Status Exact Channel Select Inactive Exact Channel Select Inactive Exact Channel Select Active Exact Channel Select Active Exact Channel Select Active machine run machine stop machine run machine stop machine stop Channel 1 Channel 2 Channel 3 Channel 4 Channel 5... System Response 5.2 M U L T I C H A N N E L S E L E C T ( M C S ) MCS stores up to four patterns of selected beams. Just as the ECS disables selected, fixed areas of the detection zone by masking off specific, fixed beam locations, the MCS can be programmed to store four different patterns. MCS is helpful when a machine requires multiple setups where stationary objects such as tooling, fixtures, or material frequently obstruct a portion of the detection zone. Access and programming is performed using a PLC or switch inputs. The suggested logic patterns for identification of the stored program are in Table 5-2 on page 20. Refer to drawings Figure 5-1 and Figure 5-2 for connection recommendations. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 19 5 1 2 1 2 2 1 0vdc 2 1 2 Switch Selection Connection MCS Out 2 Prog MCS 1 Out 1 Start 2 2 Prog 1 Start 2 1 SW2 PLC TB7 SW1 MPCE 1 LCM-3XX TB7 MPCE LCM-3XX PLC Selection Connection Figure 5-1 Connection Recommendations for LCM Metal Enclosure LCM-3 LCM-3 RET 7 PLC 7 RET 6 6 ECS 2 SW2 5 SW1 ECS 2 5 Out 1 ECS 1 4 Out 0 ECS 1 4 +24 VDC 3 +24 VDC 3 Earth 2 Earth 2 0 vdc 1 0 vdc 1 Switch Selection Connection 0vdc ref. PLC Selection Connection Figure 5-2 Connection Recommendations for LCM DIN Box Switch Switch 2 Switch 1 Pattern1 0 0 Pattern 2 0 1 Pattern 3 1 0 Pattern 4 1 1 Note: 0 = Open, 1 = Closed. Table 5-2 Switches for Multi Channel Select R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 20 ..... 5.3 F L O A T I N G B L A N K I N G Up to two channels can be disabled at any location in the detection zone without the 4700 system going to the machine stop state. The disabled channels are not fixed at a single location but "float" through the detection zone. See Table 5-3 for a diagram of 4700 system response during operation with Floating Blanking active. Table 5-3 System Response to Floating Blanking 1 1 1 1 2 2 2 2 2 2 2 Channel Channel Channel Channel Channel Channel Channel Channel Channel Channel Channel Floating Floating Floating Floating Floating Floating Floating Floating Floating Floating Floating Floating Blanking Blanking Blanking Blanking Blanking Blanking Blanking Blanking Blanking Blanking Blanking Blanking Inactive Active Active Active Active Active Active Active Active Active Active Active Channel 1 Channel 2 Channel 3 Channel 4 Channel 5... 0 1 Exception Exceptions System Response machine stop machine run 0 2 2 1 Exception Exceptions Exceptions Exceptions machine machine stop machine stop machine run run 1 Exception machine run 2 Exceptions machine run 3 3 3 2 Exceptions Exceptions Exceptions Exceptions machine machine stop machine stop machine stop run Table 5-4 Icon Key for Tables 5-1 and 5-2 Symbol Description Optical channel is not blocked. Optical channel is blocked. Optical channel is selected by Exact Channel Select. Optical channel is selected by Exact Channel Select and is blocked. 5.4 U S I N G E X A C T C H A N N E L S E L E C T W I T H F L O A T I N G B L A N K I N G ! Warning! Using Exact Channel Select with Floating Blanking is an advanced feature. All situations which may occur to the 4700 system detection zone must be carefully considered. The 4700 system is less sensitive to objects in the detection zone. The safety distance must be increased. Failure to do so may cause serious injur y. When both Exact Channel Select and Floating Blanking are selected, the floating channels are allowed to occur anywhere within the detection zone, even within the area selected by Exact Channel Select. In these areas, a channel that should normally be blocked is allowed to be clear. 5.4.1 T HE E FFECT OF E XACT C HANNEL S ELECT AND F LOATING B LANKING ON M INIMUM O BJECT R ESOLUTION When Exact Channel Select and/or Floating Blanking is active, the safety distance is affected. Exact Channel Select and Floating Blanking desensitize the light curtain and increase the size of the minimum object detected. The increase is equal to the channel spacing distance for each channel that is disabled. * A 4700 system with 12 mm minimum object resolution and one channel disabled has a minimum object sensitivity of: R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 21 5 12 mm + 6.25 mm = 18.25 mm (0.72 inches). * A 4700 system with 12 mm minimum object resolution and two channels disabled has a minimum object sensitivity of: 12 mm + 6.25 mm + 6.25 mm = 24.5 mm (0.96 inches). If the size of the object detected by the 4700 system increases, the minimum safe distance must increase. Use the minimum object sensitivity given in Table 5-5, Table 5-6, Table 5-7 & Table 5-8 to determine the new figure to use when computing the safety distance. Table 5-5 Sample S and Dpf Factors for 12 mm Resolution Systems Total Number of Beams Disabled by Exact Channel Select and/or Floating Blanking Minimum Object Resolution S Depth Penetration Factor, Dpf for use with ANSI Formula (Dpf = 3.4 (S-.276) inches) None 12 mm (0.47 inches) 0.67 inches (16.96 mm) 1 Beam 19 mm (0.75 inches) 1.61 inches (40.93 mm) 2 Beams 26 mm (1.02 inches) 2.53 inches (64.25 mm) 3 Beams 33 mm (1.30 inches) 3.48 inches (88.43 mm) 4 Beams 40 mm (1.57 inches) 4.40 inches (111.75 mm) 5 Beams 47 mm (1.85 inches) 5.35 inches (135.93 mm) etc... Table 5-6 Sample S and Dpf Factors for 14 mm resolution Systems Total Number of Beams Disabled by Exact Channel Select and/or Floating Blanking Minimum Object Resolution S Depth Penetration Factor, Dpf for use with ANSI Formula (Dpf = 3.4 (S-.276) inches) None 14 mm (0.55 inches) 0.9 inches (24 mm) 1 Beam 25 mm (0.98 inches) 2.4 inches (61 mm) 2 Beams 36 mm (1.42 inches) 3.9 inches (99 mm) 3 Beams 47 mm (1.85 inches) 5.4 inches (136 mm) 4 Beams 58 mm (2.28 inches) 6.8 inches (173 mm) 5 Beams 69 mm (2.72 inches) 8.3 inches (211 mm) etc... Table 5-7 Sample S and Dpf Factors for 20mm resolution Systems Total Number of Beams Disabled by Exact Channel Select and/or Floating Blanking Minimum Object Resolution S Depth Penetration Factor, Dpf for use with ANSI Formula (Dpf = 3.4 (S-.276) inches) 1.75 inches (44.45 mm) None 20 mm (0.79 inches) 1 Beam 31 mm (1.22 inches) 3.21 inches (81.53 mm) 2 Beams 42 mm (1.65 inches) 4.60 inches (118.96 mm) 3 Beams 53 mm (2.09 inches) 6.16 inches (156.86 mm) 4 Beams 64 mm (2.52 inches) 7.63 inches (193.76 mm) 5 Beams 75 mm (2.95 inches) 9.1 inches (231.16 mm) etc... R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 22 ..... Table 5-8 Sample S and Dpf Factors for 30 mm resolution Systems Total Number of Beams Disabled by Exact Channel Select and/or Floating Blanking Minimum Object Resolution S Depth Penetration Factor, Dpf for use with ANSI Formula (Dpf = 3.4 (S-.276) inches) None 30 mm (1.18 inches) 3.07 inches (78.0 mm) 1 Beam 52 mm (2.05 inches) 6.03 inches (153.2 mm) 2 Beams 74 mm (2.01 inches) 8.96 inches (227.6 mm) 3 Beams 96 mm (3.78 inches) 11.91 inches (302.5 mm) 4 Beams 118 mm (4.65 inches) 14.87 inches (377.7 mm) 5 Beams 140 mm (5.51 inches)` 17.80 inches (452.0 mm) etc... Hard guarding refers to mechanical barriers such as sheet or expanded metal, etc. See Figure 5-3 Adding Hard guarding to Light Curtain when Using Channel Select for an example. Channel Select Area Detection Zone Floating Blanking changes the resolution (object size) of the 4700 system and will require different mounting distance. Obstruction Light Curtain Light Curtain Figure 5-3 Adding Hard guarding to Light Curtain when Using Channel Select 5.5 A C T I V A T I N G A N D P R O G R A M M I N G E X A C T C H A N N E L S E L E C T ! Warning! To prevent unauthorized modification of the sense field, the system controller should be installed in an enclosure with supervisor-controlled access. Exact Channel Select is activated by setting position 4 of Switches A and B, located under the controller cover. Refer to Figure 3-1. Any mismatch between the settings of the switches will result in a alarm condition. To program an ECS pattern, the 4700 system must be in the machine stop state. An ECS pattern is stored by blocking the appropriate area of the detection zone and pressing, then releasing the program button (See Figure 3-4 and Figure 3-5 for locations). The MCS works the same as the ECS except in addition to blocking the appropriate area of the detection zone, an four position binary switch or PLC or two SPST switches are needed to differentiate the four possible pattern. 5.6 MCS PROGRAMING 1. Ensure that power is supplied to the controller, and that the light curtain is green and showing all beams are clear. The display should read "00". R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 23 5 2. Set position 4 of switches A and B to the closed position and press "Start", the display should red "03". 3. Set the Pattern select inputs, see Table 5-2--Switches for Multi Channel Select. 4. Place the desired object in field (block beams) and press the "program" button, the display should read "01". 5. Push the "start" button, and the display should read "03". The light curtain will enter the Machine Run state. 6. To add more patterns (a total of eight possible) Set the Pattern select inputs to another program the display will read "27", press the start button and continue to step 4. Repeat steps 4 and 5. 7. To change from one pattern to another, change the ECS inputs to the desired program and push the start button. The 4700 system will then enter the interlock or machine stop condition, regardless of the operating mode. The Start button may be pressed-and-released or power may be cycled to enter the machine run state. Subsequent power cycles will result in operation in accordance with the configured operating mode. A new ECS pattern is recorded when the system is in the machine stop state with no alarms, the configuration switches are correctly set, and the Program button is pressed and released. If the configuration switches are subsequently set to disable ECS, the stored ECS pattern is cleared. NOTE! Replace controller cover after changing system configuration. See Section 3.1.1 on page 11 and Section 3.1.2 on page 12 for details. SWITCH A 5 SWITCH B OPERATING MODE 4 6 Exact Channel Select Active CLOSED CLOSED Exact Channel Select Inactive (default setting) OPEN /OFF OPEN /OFF /ON 4 5 6 /ON One-channel Floating Blanking Active CLOSED OPEN /OFF CLOSED OPEN /OFF Two-channel Floating Blanking Active OPEN /OFF CLOSED /ON OPEN /OFF CLOSED Floating Blanking Inactive (default setting) OPEN /OFF OPEN /OFF OPEN /OFF OPEN /OFF Not Allowed - alarm Condition CLOSED CLOSED CLOSED CLOSED /ON /ON /ON /ON /ON /ON /ON Table 5-9 Switch Settings, Exact Channel Select and Floating Blanking 5.7 A C T I V A T I N G F L O A T I N G B L A N K I N G Floating Blanking (either one- or two- beam) is activated by setting positions 5 and 6 of Switches A and B located under the controller cover. Refer to . Any mismatch between the settings of Switches will result in an alarm condition. Use of the program button is not required. 5.8 A D D I T I O N A L G U A R D I N G W H E N U S I N G E X A C T C H A N N E L S E L E C T Exact Channel Select creates "holes" in the detection zone. These "holes" are required for certain applications. If an obstruction does not completely fill these "holes" one of two actions will need to happen: (Refer to Figure 5-3 Adding Hard guarding to Light Curtain when Using Channel Select). 1. The safe mounting distance will need to be increased to account for the larger opening in the curtain. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 24 ..... 2. The area not filled by an obstruction must be guarded, typically by some method of hard guarding. 6 6 D IAGNOSTIC AND T EST F EATURES 6.1. D I A G N O S T I C D I S P L A Y A two-digit numeric display on the front of the controller indicates system status. The table below provides the operating mode codes. A full listing of diagnostic codes can be found in Section 12-- Troubleshooting. Table 6-1 Operational Display Code Summary Display Code Description 00 Normal Operation 01 Waiting for Start or Program Input 02 Normal Operation Floating Blanking Active 03 Normal Operation Channel Select Active 04 Normal Operation Floating Blanking and Channel Select Active 6.2 I N D I V I D U A L B E A M I N D I C A T O R S The 4700 system has a visible, red Individual Beam Indicator (IBI), adjacent to each infrared beam. These IBI's are located on the receiver. The IBI will light when the infrared beam fails to meet the conditions necessary for the 4700 system to remain in the machine run state. IBI's are not a safety critical component. An IBI failure will not cause an alarm condition and the 4700 system will continue to operate. 6.3 M A C H I N E P R I M A R Y C O N T R O L E L E M E N T ( M P C E ) M O N I T O R I N G MPCE monitoring is an important safety function. It monitors the 4700 system interface to the guarded machine and checks to ensure that the control elements are responding correctly to the light curtain and to detect any inconsistency between the two machine MPCE. Connections for MPCE monitoring are made at the controller on terminals 10 and 11 for the DIN controller and on TB7 terminals 1 and 2 for the metal chassis controller. For a detailed diagram, see Section 10--Connecting To The Machine Control Circuit. On power-up, the 4700 system looks for an MPCE closed condition. If this is found, it will enter a state consistent with the selected operating mode. When the 4700 system enables its safety outputs, it monitors the MPCE for a closed-to-open transition. This transition must occur within 300 ms or the 4700 system considers the MPCE faulted. The 4700 system will then enter an alarm state. Additionally, if the MPCE connections are incorrectly wired, the 4700 will enter an alarm state. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 25 6 Upon entering a machine stop state, the MPCE input must close within 300 ms of the safety output switching or the system will enter the alarm state. The ability to disable MPCE monitoring is provided using the configuration switches located in the controller. NOTE! When MPCE is not active, place a jumper between the terminals MPCE and MPCE RTN for the DIN controller (or place a jumper between terminals 1 and 2 of TB7 for the Solid State Output Version of the metal chassis controller). 6.3.1 A CTIVATING AND D EACTIVATING MPCE M ONITORING (on Din Controller and Metal Chassis Solid State Version) MPCE monitoring is activated by setting position 3 of Switches A and B located under the controller cover. Refer to Table 6-2. Any mismatch between the settings of Switches A and B will result in an alarm condition. Table 6-2 MPCE Switch Settings SWITCH A MPCE MONITORING Active Not Active (default setting) SWITCH B 3 3 OPEN/OFF OPEN/OFF CLOSED/ON CLOSED/ON NOTE! Replace controller cover and retention screws after changing system configuration. See Section 3.1.1 on page 11 and Section 3.1.2 on page 12 for details. 6.3.2 A CTIVATING AND D EACTIVATING MPCE M ONITORING ON THE M ETAL C HASSIS C ONTROLLER R ELAY O UTPUT V ERSION MPCE monitoring is activated by setting Jumper 2 in the ON position located on the main controller board of the metal chassis controllers. Position 3 of the dipswitch does not affect the operation of Relay version controller. 6.4. S T A T U S I N D I C A T O R L I G H T S The following status indicator lights are found on both the receiver and the controller. 6.4.1 S AFETY O UTPUT STATUS When the 4700 system is in the machine run state, the green indicator LEDs on the receiver and controller illuminate, indicating that the safety outputs are ON. 6.4.2 I NTERLOCK S TATUS When the 4700 system enters an interlock state, the yellow interlock and red LEDs on the receiver and controller are continuously illuminated. 6.4.3 A LARM S TATUS When the 4700 system enters an alarm state, the yellow LEDs on the receiver and controller flash periodically. Additionally, a code indicating the type of fault is displayed on the two-digit diagnostic display located on the controller. Error codes are defined in Section 12--Troubleshooting. 6.4.4 E XACT C HANNEL S ELECT AND F LOATING B LANKING S TATUS When Exact Channel Select and/or Floating Blanking is active, the amber LEDs on the receiver and controller are illuminated. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 26 ..... 7 7 O UTPUTS 7.1 S A F E T Y O U T P U T S 7.1.1 D IN C ONTROLLER AND M ETAL C HASSIS S OLID S TATE V ERSION The 4700 system supplies two independent PNP-type, safety outputs to provide Run/Stop signals to the guarded machine. In the machine Run state, the safety outputs are electrically conducting and source 650 milliamps of current at 24 VDC. In the Machine Stop state, the outputs are not electrically conducting. !! 7.1.2 WARNING! This product is designed for use on a 24 VDC, negative ground (protective earth) electrical system only. Never connect the 4700 system to a positive ground (protective earth) system. With a positive ground (protective earth) wiring scheme, certain simultaneous shorts of both safety outputs may not be detected and the guarded machine may not stop resulting is severe operator injur y. M ETAL C HASSIS C ONTROLLER - R ELAY O UTPUT V ERSION The 4700 system supplies 1 N.O. and 1 N.C/N.O. dry relay contacts, safety outputs to provide Run/Stop signals to the guarded machine. In the Run state the N.O. contacts are closed and will conduct the supplied voltage. In the Machine Stop state, the N.O. contacts are open. The N.C. contact will open in a Run state and close in a Stop state. 7.2. A U X I L I A R Y O U T P U T S 7.2.1 DIN C ONTROLLER AND M ETAL C HASSIS S OLID S TATE V ERSION Two auxiliary outputs are provided. Auxiliary output AUX1 OUT is NPN and sinks up to 100 mA to system ground when in the on condition. Auxiliary output AUX2 OUT is PNP and sources 250 mA at 24 VDC when in the on condition. 7.2.2 METAL CHASSIS C ONTROLLER - R ELAY O UTPUT V ERSION N.O./N.C. auxiliary outputs are provided. These outputs are intended for light curtain Status indication. The auxiliary output is user configurable for Alarm mode and Follow mode. 7.2.3 A UXILIARY O UTPUT O PERATING M ODES The auxiliary outputs can be set to enter an ON condition either when: *The safety outputs are in the machine run state (Follow Mode), or *The 4700 system enters an alarm state (Alarm Mode). The auxiliary output operating mode is selected by setting position 7 of Switches A and B located under the controller cover. Refer to Table 7-1. Any mismatch between the settings of the switches will result in an alarm conditions. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 27 8 Table 7-1 Auxiliary Output Operating Mode Switch Settings SWITCH A Auxiliary Output Operating Mode SWITCH B 7 7 Auxiliary Outputs on in RUN (Follow) state OPEN/OFF OPEN/OFF Auxiliary Outputs on in FAULT (Alarm) state CLOSED/ON CLOSED/ON NOTE! Replace controller cover and retention screws after changing system configuration. See Section 3.1 for details. 8 S AFE M OUNTING D ISTANCE 8 ! WARNING! Never install a 4700 system without regard to the safety distance. If the 4700 system is mounted too close to the point of operation hazard, the machine may not stop in time to prevent an operator injury. Light Curtain A 4700 system must be mounted far enough from the machine danger zone so the machine will stop before a hand or other body part reaches the hazardous area. This distance is called the safety distance. It is a calculated number based on a formula. See Figure 8-1--Safe Mounting Distance for an illustration of the safety distance. Ds Ds is the minimum safe distance between the light curtain sensing field and the point of operation hazard (pinch point). Regardless of the calculated distance, a 4700 system should never be mounted closer to the point of operation hazard than allowed by Table 0-10 in OSHA 1910.217. Figure 8-1 Safe Mounting Distance 8.1 US S A F E D I S T A N C E F O R M U L A S In the United States two formulas exist to properly determine the safety distance. STI recommends the formula provided by the American National Standards Institute (ANSI) which incorporates additional factors when compared to the formula required by OSHA. The ANSI formula given below is for a normal approach to the light curtain. Ds = K x (Ts + Tc + Tr + Tbm) + Dpf Where: Ds = minimum safety distance, in inches, between the 4700 system detection zone and the nearest point of operation hazard. K = hand speed constant in inches per second. The ANSI standard value is 63 inches/second which assumes the operator starts a hand motion toward the point of operation from rest. According to ANSI B11.19-1990, "The value of the hand speed constant, K, has been determined by various studies and although these studies indicate speeds of 63 in./sec. to over 100 in./sec., they are not considered conclusive determinations. The user should consider all factors, including the physical ability of the operator, when determining the value of K to be used." R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 28 ..... Ts = the stop time of the press (or machine) in seconds, measured from the final de-energized control element. Measured at maximum closing velocity. Tc = the response time, in seconds, of the press or machine control circuit to activate the machine's brake. NOTE! Ts + Tc is usually measured together by a stop time measuring device. Tr = the response time of the 4700 system, in seconds. This response time is given in Table 14-1, Table 14-2 and Table 14-3. ! WARNING! When using a STI RM-1 with the 4700, add 0.008 seconds to the response times stated in Table 14-1, Table 14-2 and Table 14-3. Tbm = the additional stopping time, in seconds, allowed by the brake performance monitor before it detects stop time deterioration. The Tbm factor allows consideration for brake wear, adding extra stop time allowed by the brake monitor. Therefore, Tbm = Brake monitor set point - (Ts + Tc). NOTE! If the guarded machine is not equipped with a stop time performance monitor, a percentage increase factor should be applied to the stop time of the machine to allow for braking system wear. Contact your machine manufacturer for information. Dpf = This is related to the minimum object sensitivity of the 4700 system. By knowing the minimum object sensitivity, S, of the 4700 system, Dpf is read directly from Table 5-5, Table 5-6, Table 5-7 or Table 5-8. For a 4700 system with 12 mm minimum object resolution and without Exact Channel Select or Floating Blanking active: S = 0.47 inches (12 mm) and Dpf = 0.67 inches (16.96 mm) For a 4700 system with 20 mm minimum object resolution and without Exact Channel Select or Floating Blanking active: S = 0.79 inches (20 mm) and Dpf = 1.75 inches (44.45 mm) 8.2 E U R O P E A N S A F E T Y D I S T A N C E F O R M U L A S The following discussion is based on standard EN999 and applies to light curtains used in industrial environments. 8.2.1 S AFETY D ISTANCE F ORMULA FOR S YSTEMS WITH A M INIMUM O BJECT R ESOLUTION OF 40 MM OR L ESS When the minimum object resolution of the system is 40 mm or less, use the following formula: S = (K x T) + C where: S = the minimum distance in millimeters, from the danger zone to the detection point, line, plane or zone. K = 2000 mm/s T = the overall system stopping performance in seconds. T = t 1 + t2 t1 = response time of the safety light curtain in seconds. This response time is given in Table 14-1, Table 14-2 and Table 14-3. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 29 8 t2 = maximum stopping time of the machine in seconds. C = 8(d-14 mm), but not less than zero. d = the minimum object detection of the 4700 in millimeters. i.e.: S = (2000 mm/s x T) + 8(d - 14 mm) This formula applies for all minimum distances of S up to and including 500 mm. The minimum value of S shall not be less than 100 mm. If S is found to be greater than 500 mm using the formula above, then the formula below can be used. In this case the minimum value of S shall not be less than 500 mm. S = (1600 mm/s x T) + 8(d - 14 mm) 8.2.2 S AFETY D ISTANCE F ORMULA FOR S YSTEMS WITH A M INIMUM O BJECT R ESOLUTION G REATER T HAN 40 MM When the minimum object resolution of the system is greater than 40 mm, use the following formula: S = (K x T) + C where: S = the minimum distance in millimeters, from the danger zone to the detection point, line, plane or zone. K = 1600 mm/s T = the overall system stopping performance in seconds. T = t 1 + t2 t1 = response time of the safety light curtain in seconds. This response time is given in Table 14-1, Table 14-2 and Table 14-3. t2 = maximum stopping time of the machine is seconds. C = 850 mm. i.e.: S = (1600 mm/s x T) + 850 mm 8.2.3 F ACTORS A FFECTING T HE S AFETY D ISTANCE F ORMULA When light curtains are used for machine initiation, their minimum object resolution must be 30 mm or smaller (based on EN999, other standards may vary). In this case the formula given in 8.2.1--Safety Distance Formula for Systems with a Minimum Object Resolution of 40 mm or Less applies except that the minimum distance S shall be greater than 150 mm. For parallel approach the formula C becomes: C = 1200mm - (0.4 x H), but not less than 850 mm. H = the height of the detection zone above the floor in mm. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 30 ..... 9 9 I NSTALLATION 9.1 R E F L E C T I V E S U R F A C E I N T E R F E R E N C E A reflective surface adjacent to the detection zone can deflect the optical beam and may cause an obstruction in the zone not to be detected. (See Figure 9-2 and Figure 9-3.) The reflective surface may be part of the machine, mechanical guard or workpiece. Therefore, a minimum distance (d) must exist between the reflective object and the center line of the 4700 system detection zone. The Test Procedure (Appendix B) must be used to test for this condition. Operating Range, R Approach direction Beam Angle, a Interruption a Light beam interrupted Central beam Receiver Transmitter d Reflective Surface Perimeter of danger area Figure 9-1 Correct Mounting Example with Proper Alignment The interruption is clearly detected. The reflective object is outside of the beam angle Approach direction Beam Angle, a Interruption a Light beam interrupted Central beam Transmitter Receiver d Reflection Reflective Surface Perimeter of danger area Figure 9-2 Unsafe Mounting Example The interruption is not detected because of the reflection. The reflective object is inside the beam angle. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 31 9 Sensing Field Interruption a Reflection Transmitter Receiver Reflective Surface Perimter of danger area Figure 9-3 Unsafe Mounting Example Interruption is not detected because of the reflection. Reflective surface interference may also appear above and below the sensing field. Operating Range, R a Transmitter Receiver a Beam Angle, a d Reflective Surface Perimeter of danger area Figure 9-4 Worst Case Alignment Example This example shows the minimum distance from the reflective surface, d, to one side of the beam center line. 1.3m Minimum distance 1.1m 900 700 d(mm) 500 300 100 0 0.3m 2m 4m 6m 8m 10m 12m 14m 16m 18m 20m Range (m) Figure 9-5 Minimum Distance from a Reflective Surface as a Function of Range R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 32 ..... 9.2. C O N N E C T I N G T R A N S M I T T E R A N D R E C E I V E R T O C O N T R O L L E R 9.2.1 C ABLE A SSEMBLIES Receiver cable connectors are color-coded red and transmitter cable connectors are color-coded black. 9.2.2 C ABLE C ONNECTIONS Transmitter and receiver connections are made at terminal positions 23 through 34. Insert and secure the appropriate color conductor in the numbered position. Positions 26, 27, and 28 accept identically colored conductors from both the transmitter and receiver. For ease of installation, the terminal block can be removed from the controller. See the table below for a color code/terminal number cross-reference. Table 9-1 Color Code/Terminal Number Cross Reference for DIN Controllers Terminal Number Component Conductor Color 23 Transmitter Orange 24 Transmitter Blue 25 Transmitter Black 26 Transmitter and Receiver Shield 27 Transmitter and Receiver White 28 Transmitter and Receiver Brown 29 Receiver Pink 30 Receiver Violet 31 Receiver Gray 32 Receiver Tan 33 Receiver Yellow 34 Receiver Red Table 9-2 Color Code/Terminal Number Cross Reference Metal Chassis Controllers R TB5 Terminals Component Conductor Color 1 Receiver White 2 Receiver Brown 3 Receiver Tan 4 Receiver Yellow 5 Receiver Red 6 Receiver Grey 7 Receiver Violet 8 Receiver Pink TB6 Terminals Component Conductor Color 1 Transmitter White 2 Transmitter Brown 3 Transmitter Blue 4 Transmitter Black 5 Transmitter Orange SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 33 9 9.3 G E N E R A L C O N S I D E R A T I O N S 9.3.1 A DDITIONAL G UARDING Areas of access to the point of hazardous operation not guarded by the 4700 system must be protected by suitable means such as a fixed barrier guard, an interlocked guard or a safety mat. See Figure 9-6. Ds LIGHT CURTAIN Supplemental Guarding Hazard Zone Mechanical Barrier Supplemental Guarding Example Supplemental Guarding Supplemental Guarding Supplemental Guarding Figure 9-6 Correct Light Curtain Installation Examples R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 34 ..... 9.3.2 I NSTALLATION OF M ULTIPLE S YSTEMS light curtains. Transmitter Receiver PREFERRED INSTALLATION The receivers are mounted back to back. Machine 2 Transmitter Machine 1 Receiver This arrangement may be subject to interference between the two Machine 2 Receiver Transmitter Machine 1 NOT RECOMMENDED INSTALLATION Receiver Transmitter Receiver Transmitter When two or more 4700 systems are mounted in close proximity and in alignment with each other, precautions should be taken to avoid one curtain interfering with another. This can be corrected by mounting the transmitters and receivers back-to-back or stacked. See Figure 9-7 for reference. PREFERRED INSTALLATION An alternating receiver to Receiver Transmitter transmitter orientation is suggested. Machine 1 Figure 9-7 Multiple Light Curtain Installation Configurations Corner access and grey shaded area needs mechanical guarding. Corner access and grey shaded area needs mechanical guarding. Beam starts here Beam starts here Beam starts here Corner access and grey shaded area needs mechanical guarding. Corner access and grey shaded area needs mechanical guarding. Beam starts here STI recommends overlapping the light curtains in corder to have better coverage. Figure 9-8 Mounting Orientation R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 35 9 9.3.3 D ETECTION Z ONE The 4700 detection zone is delineated by the inside edge of the transmitter and receiver endcaps. The area outside these marks is not protected. Position the 4700 so that it is only possible to access the danger point through the detection zone. 9.3.4 M ARKING M INIMUM O BJECT R ESOLUTION Serial number labels on the transmitter and receiver indicate three possible minimum object resolutions. During installation, use a permanent marker to obscure the object resolutions not set. This will depend on whether no floating blanking, 1-beam or 2-beam floating blanking is set. See Section 5.5 on page 23 for information. 9.3.5 A LIGNMENT Physical alignment of the transmitter and receiver units is easiest when the 4700 system is in the automatic start operating mode with Exact Channel Select inactive. The units should be in the same plane and at equal height. The Individual Beam Indicators will light when a beam is out of alignment. See Section 6.2-- Individual Beam Indicators for details. 9.3.6 I NPUT P OWER R EQUIREMENTS /C ONNECTIONS * DIN controller and DC metal chassis controller: The 4700 system operates directly from 24 VDC 20%, 2.25A*. Power to the 4700 system must come from a dedicated power supply which must meet the requirements of IEC60204-1 and IEC 61496-1, STI part number 42992 or equivalent. The 4700 system internally generates voltages for its own use. No other devices should be connected to these voltages. *Internal consumption of power by the controller is less than 10 watts (415mA) * AC metal chassis controller: 100 - 230 VAC @ 30 VA. 9.3.7 S PECIAL R EQUIREMENTS FOR P ERIMETER G UARDING In perimeter guarding applications the 4700 detection zone is placed around the outside perimeter of a guarded machine or robot. This placement leaves space for personnel to stand between the detection zone and the hazardous machine. In this case, the guarded machine must only be restarted using a switch located outside and with a full view of the area of hazardous motion. Operation of the 4700 system in the start/restart interlock operating mode is suitable for perimeter guarding. 9.3.8 P RESENCE S ENSING D EVICE I NITIATION Using the light curtain to initiate a machine after an object is removed from the sensing area is called Presence Sensing Device Initiation (PSDI). Use of PSDI places additional requirements on the guarding and safety controls. It can restrict advanced light curtain features such as Floating Blanking and Exact Channel Select. Contact STI for further information. Good sources of reference for PSDI include: ANSI RIA 15.06-1999, OSHA 1910.217(h), and ANSI B11.2-1995. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 36 ..... 10 C ONNECTING T O T HE M ACHINE C ONTROL C IRCUIT 10 10.1 D I N C O N T R O L L E R ! WARNING! This product is designed for use on a 24 VDC, negative ground (protective earth) electrical system only. Never connect the 4700 to a positive ground (protective earth) system. With a positive ground (protective earth) wiring scheme, certain simultaneous shorts of both safety outputs may not be detected and the guarded machine may not stop resulting is severe operator injury. ! WARNING! Never use only a single safety output to control the machine. Should this single output fail, the machine may not stop, resulting in severe operator injur y. The machine must be connected using both safety outputs. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 37 10 10.1.1 C ONNECTING TO A S AFETY M ONITORING D EVICE The wiring from the 4700 system to the machine control circuit must be control reliable as described in ANSI B11.19-1990. Normally PLCs are not designed to be control reliable. Safety devices, such as the 4700 system should not depend on a PLC to stop a guarded machine. However, safety related monitoring devices are now available. See Figure 10-1 for connection to such a device. Note that all safety inputs are directed to the monitoring device which also performs the MPCE monitoring function. POWER SUPPLY 0 VDC Receiver EARTH Transmitter 2.25A 24 VDC 54VA +24 VDC 1 0 VDC 2 34 33 TAN 32 4 GRAY 31 5 VIOLET 30 PINK 29 BROWN 28 WHITE 27 3 Must be accessible only by key. RED YELLOW +24VDC 6 PROGRAM 7 3 8 START 9 START RETURN MPCE RETURN BLACK 25 MPCE BLUE 24 ORANGE 23 10 11 26 12 13 CAN V+ 14 DATA H AUX 2 OUT AUX 1 OUT 15 16 DATA L 17 CAN V- FB/CS 22 2 21 1 Auxiliary Output 1: NPN, 100 mA max., 30 VDC max. 2 Auxiliary Output 2: PNP, 500 mA max., Vsupply -2V 3 If remote START is not used, connect START output to START RETURN. Arc Suppressor OSSD 2 20 OSSD RTN 19 OSSD1 18 Interlock 1 LCM INPUT 1 Output 1 LCM INPUT 2 Output 2 MPCE 1 Arc Suppressor Stop MPCE 2 SAFETY INTERLOCK INPUTS Run OTHER SAFETY DEVICES LCM Controller MPCE 1 MPCE Monitoring MPCE 2 Safety Monitoring Device Figure 10-1 Connecting to a Safety Monitoring Device R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 38 ..... 10.1.2 C ONNECTING V IA AN RM-1 M ODULE The STI RM-1 Module provides force-guided relay outputs for machine control. (OSSD) Safety outputs 1 and 2 are connected to the RM-1 and provide the power necessary to energize its relays. See Figure 10-2 for the preferred connection method using the RM-1. The auxiliary non-safety output of the 4700 system can be used to signal light curtain status to a PLC. POWER SUPPLY Receiver Transmitter 2.25A 24 VDC 54VA +24 VDC GROUND 0 VDC 1 0 VDC 2 34 33 TAN 32 4 GRAY 31 5 VIOLET 30 6 PINK 29 BROWN 28 WHITE 27 3 Must be accessible only by key. RED YELLOW +24VDC 7 4 8 START 9 START RETURN MPCE RETURN BLACK 25 MPCE BLUE 24 ORANGE 23 10 MPCE 1 MPCE 2 11 13 14 AUX 2 OUT AUX 1 OUT CAN V+ DATA H 15 16 17 DATA L 2 3 26 12 3 1 FB/CS CAN V- 22 2 21 1 OSSD 2 20 OSSD RTN 19 OSSD1 18 Interlock 4 Auxiliary Output 1: NPN, 100 mA max., 30 VDC max. Auxiliary Output 2: PNP, 500 mA max., Vsupply -2V MPCE sensing must be used with the RM1. The user can choose to monitor the MPCE contacts of the guarded machine directly or the safety relay outputs of the RM1. If remote START is not used, connect START output to START RETURN. 42 OSSD 1 41 Stop 32 OSSD 2 Run 31 24 0 VDC Control Voltage 23 14 Monitor 13 Arc Suppressor MPCE 2 Arc Suppressor MPCE 1 RM1 MODULE Figure 10-2 Connecting via an RM-1 Module R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 39 10 10.1.3 C ONNECTING V IA T WO F ORCE -G UIDED R ELAYS FGR series relays provide force-guided relay outputs for machine control. See Figure 10-3 for the preferred connection method using two force-guided relays. POWER SUPPLY Receiver Transmitter 2.25A 24 VDC 54VA +24 VDC EARTH 0 VDC 1 RED 0 VDC 2 32 GRAY 31 5 VIOLET 30 PINK 29 BROWN 28 WHITE 27 PROGRAM 7 4 8 START 9 START RETURN MPCE RETURN BLACK 25 MPCE BLUE 24 10 5 11 ORANGE MPCE 2 13 CAN V+ 14 DATA H AUX 2 OUT AUX 1 OUT 15 16 17 DATA L 1 2 3 26 12 MPCE 1 33 4 +24VDC 6 3 34 TAN 3 Must be accessible only by key. YELLOW FB/CS CAN V- 5 23 22 2 21 1 OSSD 2 20 OSSD RTN 19 OSSD1 18 Interlock 4 6 Arc Suppressor MPCE 1 6 Auxiliary Output 1: NPN, 100 mA max., 30 VDC max. Auxiliary Output 2: PNP, 500 mA max., Vsupply -2V For the purpose of bench testing prior to installation, the user may select MPCE OFF. In this case, the MPCE input must be connected to MPCE RETURN. If remote START is not used, connect START output to START RETURN. MPCE monitoring must be used when force-guided relays are used as the Final Switching Devices. Connect the MPCE output to MPCE RETURN through the NC contacts. The MPCE coils must be suppressed with the arc suppressor provided in the documentation kit. 6 Arc Suppressor Stop MPCE 2 Run LCM Controller Figure 10-3 Connecting Via Two Force-guided Relays R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 40 ..... 10.2 M E T A L C H A S S I S C O N T R O L L E R S 10.2.1 C ONNECTING V IA T WO N ORMALLY O PEN R ELAY S AFETY O UTPUTS See Figure 10-4 for the preferred connection diagram for a Two Normally Open contact arrangement control circuit. Preferred Connection Diagram for Two Normally Open Contacts Terminals on Main Board Line / 24 VDC TB1 Verify correct voltage requirement before applying power. Neutral / 0 VDC System control voltage Terminals on Relay Board TB2 arc suppressor OSSD 1 MPCE 1 1 MPCE 1 MPCE 1 arc suppressor OSSD 2 1 Machine control contacts MPCE 2 TB3 1 Auxiliary 2 Terminals on Main Board TB7 1 MCS 2 1 3 Sel 1 Sel 2 Must be accessible only by key. Program 2 4 Notes: Arc suppression devices should only be installed across the coils of the machine control relays. Never install arc suppressors across the contacts of the safety light curtain. Failure of the arc suppressor in a short condition, across the contacts, will result in an unsafe condition. No external power is to be applied to terminals on TB7. The relay contacts on the MPCE1and MPCE2 must be force-guided contacts. To activate this function, Jumper 2 on the main board needs to be installed in the ON position. See Figure 3-5, item 22. A N.C. or N.O. Remote Start input is selectable; a momentary N.O contact is shown. The selection jumper, Jumper 1 is located under the lid. See Figure 3-5, item 19. 1 4 START 2 2 MPCE 1 MPCE 1 3 MPCE 2 Figure 10-4 Connecting with Two Normally Open Safety Outputs R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 41 10 10.2.2 C ONNECTING V IA O NE N ORMALLY O PEN O NE N ORMALLY C LOSED S AFETY R ELAY O UTPUTS See Figure 10-5 for preferred connection diagram for a One Normally Open, One Normally Closed contact arrangement control circuit. Preferred Connection Diagram for One Normally Open, One Normally Closed Contacts Terminals on Main Board Line / 24 VDC TB1 Verify correct voltage requirement before applying power. Neutral / 0 VDC System control voltage Terminals on Relay Board arc suppressor TB2 MPCE 1 OSSD 1 1 MPCE 1 MPCE 2 arc suppressor OSSD 2 1 Machine control contacts MPCE 2 TB3 1 Auxiliary 2 No external power is to be applied to terminals on TB7. 3 The relay contacts on the MPCE1and MPCE2 must be force-guided contacts. To activate this function, Jumper 2 on the main board needs to be installed in the ON position. See Figure 3.5, item 22. A N.C. or N.O. Remote Start input is selectable; a momentary N.O contact is shown. The selection jumper, Jumper 1 is located under the lid. See Figure 3-5, item 19. Terminals on Main Board TB7 1 MCS 2 1 Sel 1 Sel 2 Must be accessible only by key. 4 Program 2 Notes: Arc suppression devices should only be installed across the coils of the machine control relays. Never install arc suppressors across the contacts of the safety light curtain. Failure of the arc suppressor in a short condition, across the contacts, will result in an unsafe condition. 1 4 START 2 2 MPCE 1 MPCE 1 3 MPCE 2 Figure 10-5 Connecting with One Normally Open One Normally Closed Safety Outputs R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 42 ..... 10.2.3 C ONNECTING S OLID S TATE S AFETY O UTPUTS TO T WO F ORCE -G UIDED R ELAYS See Figure 10-6 for preferred connection diagram when connecting via Two FGR (force guided) relays. The FGR relays provide force-guided contacts for the machine control circuit. Preferred Connection Diagram when Connecting Via Two Force-Guided Relays Terminals on Main Board TB1 +24 VDC 24VDC Supply Voltage 0 VDC TVS TB4 1 MPCE 1 OSSD 1 MPCE 1 MPCE 2 Return TVS Machine control contacts 1 MPCE 2 OSSD 2 Return NPN Aux. 1 1 Notes: Suppression devices should be installed across the coils of the machine control relays. Two diode type devices are supplied in the documentation kit. 2 No external power is to be applied to terminals on TB 7 and TB8. Aux. +24V 5 PNP Aux. 2 3 The relay contacts on the MPCE1and MPCE2 must be force-guided contacts. To activate this function pos. 3 on SWA & SWB must be active. A jumper is needed when MPCE is inactive. See figure 3-5, item 14 and 16. 4 A N.C. or N.O. Remote Start input is selectable, a momentary N.O contact is shown. The selection jumper, Jumper 1, is located on the User control board. See figure 3-5, Item 19. 5 Aux. Outputs may also connect to PLC. Return Terminals on Main Board TB7 1 MCS 2 Sel 1 Sel 2 Must be accessible only by key. 1 Program 2 1 4 START 2 2 MPCE 1 MPCE 1 3 MPCE 2 Figure 10-6 Connecting with Two Force Guided Relay Outputs R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 43 10 10.2.4 C ONNECTING V IA A S AFETY M ONITORING D EVICE See Figure 10-7 for preferred connection diagram when connecting via a safety monitoring device. Note that all safety devices are inputs to the Safety Monitoring Device, which performs the MPCE monitoring function. NOTE: Normally PLCs are not control reliable, however Safety rated PLCs and monitoring devices are now available. Preferred Connection Diagram when Connecting Via a Safety Monitoring Device Terminals on Main Board TB1 +24 VDC 24VDC Supply Voltage 0 VDC SAFETY MONITORING DEVICE Suppressor 4 TB4 Output 1 OSSD 1 OSSD 1 MPCE1 Suppressor Return 4 Output 2 MPCE2 OSSD 2 OSSD 2 Return Safety Interlocks input NPN Aux. 1 MPCE 1 MPCE MONITORING Safety Mats input Aux. +24V 1 Other Safety Devices PNP Aux. 2 3 MPCE 2 MPCE 1 MPCE 2 Return Terminals on Main Board TB7 1 MCS 2 1 Machine control contacts Sel 1 Sel 2 Notes: 1 Auxilary outputs may also connect to PLC (optional). 2 No external power is to be applied to terminals on TB 7 & 8. Must be accessible only by key. Program 2 3 The relay contacts on the MPCE1and MPCE2 must be forced guilded contacts. The Safety Monitoring Device Must Monitor the MPCE's Normally Closed Contacts. 4 Suppression devices should be installed across the coils of the machine control relays. Two diode type devices are supplied in the Documentation Kit. 1 5 START 2 MPCE 2 5 A N.C. or N.O. Remote Start input is selectable; a momentary N.O contact is shown. The Selection jumper, Jumper1, is located on the User control board. 6 When MPCE is Inactive, a jumper is needed. 6 Figure 10-7 Connecting with Safety Monitoring Device R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 44 ..... 11 C HECKOUT AND T EST P ROCEDURES 11 11.1 C H E C K O U T P R O C E D U R E Once the 4700 system has been configured, mounted, aligned and properly connected to the machine control system, the initial Checkout Procedure detailed in Appendix A must be performed by qualified personnel. A copy of the checkout results should be kept with the machine records. 11.2 T E S T P R O C E D U R E ! WARNING! The tests outlined in the Test Procedure in Appendix B must be performed at installation, according to the employer's regular inspection program and after any maintenance, tooling change, set up, adjustment, or modification to the 4700 system or the guarded machine. Where a guarded machine is used by multiple operators or shifts, it is suggested that the test procedure be performed at each shift or operation change. Testing ensures that the light curtain and the machine control system work properly to stop the machine. Failure to test properly could result in serious injury to personnel. The Test Procedure must be performed by qualified personnel. To test the 4700 system without Exact Channel Select and Floating Blanking disabled, use the STI-supplied test object. For applications where Exact Channel Select or Floating Blanking are enabled, see Table 5-5, Table 5-6, Table 5-7 and Table 5-8 to determine the proper size test object. When using a 4700 system for Automatic Start Mode operation, in conjunction with an RM-1 relay module, it is necessary to verify that the RM-1 outputs can properly change state by causing an intentional beam break at least every change of shift or 24 hours of operation. 11.3 U S I N G T H E T E S T O B J E C T ST AR T ST OP MicroSafe MC4700 MicroSafe MC4700 When using the test object, guide it through the detection zone as shown below. Pay particular attention to areas which may be affected by Exact Channel Select. If Floating Blanking is active, use a proper size test object. Figure 11-1 Test Object Pattern R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 45 12 11.4 T E S T C O N S I D E R A T I O N S W H E N U S I N G E X A C T C H A N N E L S E L E C T O R FLOATING BLANKING !! Warning! Use of Exact channel Select and/or Floating Blanking will make the 4700 system less sensitive to objects in the detection zone. Improper use of either can result in severe injury to personnel. Exact Channel Select may require a hard barrier guard (see section 5.8), Floating Blanking requires an increase in the safety distance. Read section 5 carefully. When Exact Channel Select and/or Floating Blanking are active the user must verify that the detection zone is being used as intended, including the size and location of the selected/blanked beams. Check for the following condition: 1. That unauthorized modification of the detection zone is not possible. The controller should be installed in an enclosure with supervisor-controlled access. 2. That the area selected by Exact Channel Select is: a. Completely blocked by an obstruction; or b. that those areas not blocked by an obstruction are protected by supplemental guarding. If neither of these conditions can be met, the safe mounting distance of the 4700 system should be modified in accordance with the safe mounting distance formulas presented in Section 8--Safe Mounting Distance. 3. Using a proper size test object and the method described in Section 11.3--Using the Test Object, check those areas which have not been programmed by Exact Channel Select. Be sure that they have not been accidientally selected as well. 12 12 T ROUBLESHOOTING The controller contains a two-digit diagnostic display, which presents numeric codes indicating both normal operation and system fault status. The operational codes are described in the table below. Table 12-1 Operational Codes R Code Displayed System Status Corrective Action 88 Power-up indication. None required. 00 Normal operation; no floating blanking or exact channel select. None required. 01 Normal operation; waiting for start signal. Press and release start switch. 02 Normal operation; floating blanking active. None required. 03 Normal operation; exact channel select active. None required. 04 Normal operation: floating blanking and exact channel select active. None required. SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 46 ..... Table 12-2 DIP Switch Fault Codes Code Displayed System Status Corrective Action 20 Incorrect operating mode or floating blanking switch setting. 1. Check setting of operating mode switches 1 and 2. 2. Check setting of floating blanking switches 5 and 6. 21 Invalid switch setting. 1. Check to see that settings of switch positions 1 through 7 are valid and identically set between switches A and B. 22 DIP switch settings changed during operation. 1. Press and release start switch or cycle power. 23 Invalid switch settings. 1. Check channel select and MPCE switches for valid settings. Table 12-3 Safety Output (OSSD) Faults Code Displayed System Status Possible Cause/Corrective Action 30 General safety output (OSSD) fault. 1. OSSD A shorted to OSSD B. Check wiring. Wiring according to manual. 2. OSSD A or OSSD B shorted to power. Check wiring. Wire according to manual. 3. OSSD A or OSSD B shorted to ground. Check wiring. Wire according to manual. Table 12-4 MPCE Faults R Code Displayed System Status Corrective Action 40 General MPCE fault. 1. Possible incorrectly wired MPCE circuit. Check and wire according to manual. 41 MPCE Open before safety output (OSSD) activation. 1. Check to confirm that MPCE circuit is closed before OSSD activation. 43 MPCE open when power is applied. 1. Check to confirm that MPCE circuit is closed when power is applied. SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 47 13 Table 12-5 Controller Faults Code Displayed System Status 50 Internal controller fault. Corrective Action 1. Return controller to STI for repair. 51 Receiver fault. 1. Check receiver to controller wiring connections. Correct errors. 2. Check receiver cable for cuts, and proper connection to quick-disconnect fitting. Replace or properly connect cable as required. 3. If none of the above, return receiver to STI for repair. 52 Transmitter fault. 1. Check transmitter to controller wiring connections. Correct errors. 2. Check transmitter cable for cuts, and proper connection to quick-disconnect fitting. Replace or properly connect cable as required. 3. If none of the above, return transmitter to STI for repair. 53 Transmitter and receiver length mismatch or transmitter and receiver not connected. 1. Check to determine that transmitter and receiver are identical in protected height. 2. Check to determine that transmitter and receiver are properly connected to controller and that their cables are not damaged. 59 24 VDC power supply fault. 1. Check voltage supplied to unit. Correct so that it is 24 VDC 20%. 70 Grounding/Shielding Fault 1. Check the controller is properly grounded. 2. Check to see that the transmitter and receiver shield is connected properly. 3. Check for cross-talk from other I.R. light source. 13 13 C LEANING Accumulation of oil, dirt and grease on the front filter of the 4700 transmitter and receiver can effect the system operation. Clean filters with a mild detergent or glass cleaner. Use a clean, soft, lint-free cloth. Painted 4700 surfaces may be cleaned with a mild de-greasing cleaner or detergent. R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev. D 48 ..... 14 S PECIFICATIONS AND A DDITIONAL I NFORMATION 14 14.1 S Y S T E M S P E C I F I C A T I O N S Protective Height: * 12 mm minimum object resolution: 100 to 1200 mm in 100 mm increments * 14 and 20 mm minimum object resolution: 150 to 1800 mm in 75 mm increments * 30 mm minimum object resolution: 150 to 1800 mm in 150 mm increments. Operating Range: MC4700 SR LR 12 mm 0.2 to 3 m (0.7 to 10 ft.) 0.2 to 5 m (0.7 to 16.5 ft.) 14 mm 0.3 to 5 m (1 to 16.5 ft.) Not Available 20 mm 0.3 to 7 m (1 to 23 ft.) 0.3 to 12 m (1 to 39 ft.) 30 mm 0.3 to 7 m (1 to 23 ft.) 0.3 to 12 m (1 to 39 ft.) SR LR 12 mm 0.2 to 3 m (0.7 to 10 ft.) Not Available 14 mm 0.3 to 3 m (1 to 10 ft.) Not Available 20 mm 0.3 to 7 m (1 to 23 ft.) Not Available 30 mm 0.3 to 7 m (1 to 23 ft.) Not Available SR LR 12 mm 0.2 to 3 m (0.7 to 10 ft.) Not Available 14 mm 0.3 to 5 m (1 to 16.5 ft.) Not Available 20 mm 0.3 to 7 m (1 to 23 ft.) Not Available 30 mm 0.3 to 7 m (1 to 23 ft.) Not Available SR LR 12 mm 0.2 to 3 m (0.7 to 10 ft.) 0.2 to 5 m (0.7 to 16.5 ft.) 14 mm 0.3 to 5 m (1 to 16.5 ft.) Not Available 20 mm 0.3 to 7 m (1 to 23 ft.) 0.3 to 12 m (1 to 39 ft.) 30 mm 0.3 to 7 m (1 to 23 ft.) 0.3 to 12 m (1 to 39 ft.) SR LR 12 mm 0.2 to 3 m (0.7 to 10 ft.) Not Available 14 mm 0.3 to 3 m (1 to 10 ft.) Not Available 20 mm 0.3 to 7 m (1 to 23 ft.) Not Available 30 mm 0.3 to 7 m (1 to 23 ft.) Not Available MCF4700 MCJ4700 MS4700 MSF4700 R SCIENTIFIC TECHNOLOGIES INC. Fremont CA USA Tel: 1/888/510-4357 in USA and Canada (c) STI 0806 PN99584-0050 Rev.D 49 14 Minimum Object Resolution: * 12 mm minimum object resolution systems: -- With no Floating Blanking: 12.0 mm (0.47 inches)1 -- With 1-beam Floating Blanking: 19 mm (0.75 inches)1 -- With 2-beam Floating Blanking: 26 mm (1.02 inches)1 * 14 mm minimum object resolution systems: -- With no Floating Blanking: 14.0 mm (0.55 inches)1 -- With 1-beam Floating Blanking: 25 mm (0.98 inches)1 -- With 2-beam Floating Blanking: 36 mm (1.42 inches)1 * 20 mm minimum object resolution systems: -- With no Floating Blanking: 20.0 mm (0.79 inches)1 -- With 1-beam Floating Blanking: 31 mm (1.22 inches)1 -- With 2-beam Floating Blanking: 42 mm (1.65 inches)1 * 30 mm minimum object resolution systems: -- With no Floating Blanking: 30.0 mm (1.18 inches)1 -- With 1-beam Floating Blanking: 52 mm (2.05 inches)1 -- With 2-beam Floating Blanking: 74 mm (2.91 inches)1 1 Use of Exact Channel will increase this value MCJ4700 Joint Resolution (Resolution at the corner) Floating Blanking Floating Blanking Floating Blanking OFF 1 Channel 2 Channels MCJ-12 25 mm 31 mm 37 mm MCJ-20 29 mm 40 mm 50 mm MCJ-30 32 mm 52 mm 73 mm Safety Output: Din & Solid State Output version of Metal Chassis Controllers: Two PNP each output sourcing 625 mA @ 24 VDC. Relay version of metal chassis controller only: 1 N.O. and 1 N.C. /N.O. rated for 6A at 230 VAC. Auxiliary (non-safety) Output: Din & Solid State Output version of Metal Chassis Controllers: One NPN output sinking 100 mA @ 24 VDC. One PNP sourcing 250 mA @ 24 VDC. Relay version of metal chassis controller only: 1 N.O./N.C. rated at 3A @ 230 VAC. MPCE: 50mA @ 24 VDC Maximum Response Time: