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Shadow VI ® Safety Light Curtain 1107200 Rev. E July 2010 Tech Support Hotline 800-586-8324 8-5 EST www.wintriss.com ® ® Wintriss Controls Group, LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone (800) 586-8324 Fax (978) 263-2048 PRINTED IN USA DA46072

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Shadow VI®

Safety Light Curtain1107200Rev. E July 2010

Tech Support Hotline 800-586-8324 8-5 EST

www.wintriss.com

®

®

Wintriss Controls Group, LLC100 Discovery WayUnit 110Acton MA 01720 USAPhone (800) 586-8324Fax (978) 263-2048

PRINTED IN USA DA46072

Requirements You Must Meet When Installing and Using Shadow Safety Light Curtains

DANGER! FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID-

STROKE OR MID-CYCLE • DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped

at any point in its stroke or cycle. • Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle. Failure to comply with these instructions will result in death or serious injury.

DANGER! IMPROPER INSTALLATION, USE OR MAINTENANCE • Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-supplied

replacement parts. • Wire, install and maintain Shadow safety light curtain in accordance with OSHA lockout/tagout regulation 1910.147. • Ensure that Shadow safety light curtain is installed, tested and repaired by qualified personnel. • Ensure that all metal stamping presses on which Shadows are used meet the requirements and inspection procedures of

OSHA regulation 1910.217 and ANSI standard B11.1-2009, which govern the use of presence-sensing devices on metal stamping presses. Ensure that all other machinery, or other devices on which Shadows are used, meet the general machine guarding requirements in OSHA standard 1910.212 and any other regulations and standards that apply.

• Ensure that guarding is installed to prevent access to the machine over, under or around the light curtains. • Test the operation of your Shadow safety light curtain daily using the checkout sequence shown on the Shadow safety

light curtain units and also listed in this manual. If your Shadow safety light curtain is installed so the warning and test procedure labels are not clearly visible, call the factory for extra warning labels to affix to your machinery in a visible area.

• Perform the checkout sequence after any maintenance is done on the Shadow safety light curtain. • Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, or any others responsible for the

proper operation of the machinery have read and understood all instructions for use of the Shadow light curtain. Failure to comply with these instructions will result in death or serious injury.

DANGER! MACHINERY NOT CONFIGURED OR WORKING PROPERLY • Ensure that the machinery and devices on which Shadow safety light curtains are used meet the general machine

guarding requirements of OSHA standard 1910.212 and any other regulations and standards that apply. • Inspect all stopping mechanisms of the machinery regularly to be sure they work properly. • DO NOT operate a machine equipped with Shadow safety light curtains if the machine or any of its stopping mechanisms

is not in proper working order. Failure to comply with these instructions will result in death or serious injury.

DANGER! STOPPING MECHANISM FAILURE • Install and maintain stopping mechanisms of machinery or other devices according to the applicable regulations or

standards. • Regularly inspect all stopping mechanisms of the machinery to ensure proper functioning. Failure to comply with these instructions will result in death or serious injury.

DANGER! OTHER EQUIPMENT CONTINUING TO OPERATE • Equipment that operates with the machinery connected to Shadow safety light curtain may continue to operate after the

machinery has received a stop signal. • Ensure that all operators and other affected personnel know which equipment is connected to Shadow safety light curtain

and which is not. Failure to comply with these instructions will result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD

Turn off and disconnect power from Shadow safety light curtain and from the machinery it is connected to before making any wiring connections. This includes power to the machine control and motor.

Failure to comply with these instructions could result in death or serious injury.

Changes for Revision E of the Shadow VI User Manual

(1107200)

This revision of the Shadow VI Safety Light Curtain User Manual covers Shadow VI models with response times of 30 to 40 ms, maximum.

The changes include:

• The Remote Interrupt button has been removed from the Shadow VI Control board (see page 44) , and, as a result, all references to the button have been removed from the manual.

• AC power is now grounded to the set screw terminal on the Shadow VI enclosure rather than to pin #3 on TB 1 (see page 51).

• The procedure for replacing Shadow VI safety relays has been updated. Instead of replacing individual relays in the event of a relay failure, you now must replace the Shadow VI Control board. See page 91.

• References to and excerpts from ANSI standards B11.1 and B11.19 have been updated to their current versions, B11.1-2009 and B11.19-2003. See Appendix A.

Thank you for purchasing a Wintriss Product. We appreciate your business and want to do whatever we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are backed by an ironclad guarantee, international standards approvals, and unbeatable support. Whenever you need assistance or service, we back all our products with excellent spare parts inventories, training programs, and prompt repair service. We would like to share with you a list of service options–probably the largest number of service options offered in the industry.

• Technical Assistance

We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at 1-800-586-TECH (8324) should you have any questions about your equipment. Our technical staff is ready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our experienced technical staff can resolve your inquiry right over the phone.

• Return Authorization

Please call our “800” number for a return authorization (RMA) number to return a product for repair. Returned goods must arrive freight prepaid. In order to process your return quickly, we ask that you provide us with the following pertinent information when you call: purchase order number, shipping address, contact name and telephone number, and product type. The assigned RMA number should appear on all packages returned to Wintriss Controls Group to ensure prompt service.

At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you are returning. We ask that you either fax us a PO for that amount or enclose the PO with the returned item. This will enable us to ship the item back to you as soon as the repair has been completed. If the item cannot be repaired or there are additional charges, you will be contacted for approval.

Please be sure to carefully pack all returned items and ship to our Acton, MA location.

• Expedited Repair Program

Rush service providing 48 hour turnaround is available for most products upon request. An Expedite Fee will be applied to our standard repair rate.

• Board Exchange Program

If your needs are urgent, you can take advantage of out Board Exchange (EX) program. Call our “800” number between 8 a.m. to 5 p.m. EST and we will send a replacement to you overnight. A fee does apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details.

• Service Center

Our Service Center for product service is located at our headquarters in Acton, MA. If your equipment requires repair, please contact us at 800-586-8324 to obtain a return authorization number.

Nationwide field service is also available. Contact the Wintriss Technical Support group at 800-586-8324.

• Product Training

We also offer both product training and maintenance/troubleshooting courses at our Acton, MA and Chicago-area facilities. On-site training is available from the factory or through your local Wintriss representative.

• Restocking Charge

Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge is $50, not to exceed $250 per item.

Whatever the product, we are committed to satisfying you with innovative engineering, quality construction, reliable performance, and ongoing, helpful support. Call us whenever you need assistance.

Shadow VI User Manual 1107200 Table of Contents page i

Table of Contents

Chapter 1 – Introduction to Shadow® VI Safety Light Curtain ........................1

OSHA and ANSI Compliance....................................................................................................................2 About Shadow VI.......................................................................................................................................2 How Shadow Works...................................................................................................................................4 Shadow and Control Reliability .................................................................................................................6 Description of Shadow VI indicators .........................................................................................................7

At the Optic Heads.................................................................................................................................7 At the Control ........................................................................................................................................8 Inside the Control...................................................................................................................................8

Object Sensitivity .......................................................................................................................................8 Size and Scanning Distance........................................................................................................................8 Shadows Are Easy to Maintain ..................................................................................................................9 Shadow VI Features and Options .............................................................................................................10 Weld Shield Kit ........................................................................................................................................11

Chapter 2 – Installation and Checkout............................................................15

Installation overview ................................................................................................................................16 Calculating the safety distance........................................................................................................16 Mounting location for your Shadow transmitter and receiver ........................................................16 Wiring, aligning, mounting, and making proper settings................................................................16 Ensuring that the Shadow light curtains are working properly.......................................................16

Installation Procedure...............................................................................................................................17 Calculating the Safety Distance................................................................................................................18

OSHA and ANSI Requirements ..........................................................................................................19 The OSHA Safety Distance Formula ..............................................................................................20 The ANSI Safety Distance Formula................................................................................................21 Perimeter Guarding .........................................................................................................................24 Blanking Windows Affect Safety Distance ....................................................................................24 Pass-through Protection ..................................................................................................................25

Height Considerations..........................................................................................................................26 Designing and Mounting Brackets ...........................................................................................................26

Universal Mounts............................................................................................................................26 Mounting Location Requirements...................................................................................................27 How to Design and Mount Brackets or Floor Stands .....................................................................28 Alignment Considerations...............................................................................................................33 Maximum Openings for Side Guards .............................................................................................35 Using Mirrors with Shadows ..........................................................................................................36 Using Weld Shields.........................................................................................................................39 Mounting Shadow Light Curtains Upside Down............................................................................39 Avoiding Cross Talk When Mounting 2 Sets of Shadows .............................................................39

Loosely Mounting Shadow VI Transmitter and Receiver ........................................................................40 Mounting the Control ...............................................................................................................................42

1107200 Shadow VI User Manual

page ii Table of Contents

Connecting RF (Radio Frequency) Ground ....................................................................................42 Wiring the Transmitter and Receiver to the Control ................................................................................45

Terminating Shields of the Head Cables..............................................................................................46 Connecting the Head Cables to the Control .........................................................................................47 If You Have a Second Set of Shadow Optic Heads .............................................................................49

Connecting AC Wiring to the Control......................................................................................................50 Connecting Stop Circuits to the Control...................................................................................................52

8A. Wiring Shadow to the WPC (One or Two Control Boxes) ......................................................55 8B. Wiring Shadow to a PLC..........................................................................................................56

Optional Wiring........................................................................................................................................57 Indicator Outputs..................................................................................................................................57 MPCE Monitor Inputs..........................................................................................................................58

Making Settings Inside the Control ..........................................................................................................59 S1 settings ............................................................................................................................................60 S4 Settings ...........................................................................................................................................60 J12 Setting............................................................................................................................................61 Plug in Connector and Replace Cover .................................................................................................61

Aligning and Tightening Down Shadow VI Components........................................................................61 Alignment Procedure ...........................................................................................................................62 Diagnostic Steps to Perform Before Using Shadow.............................................................................63

No Power to Unit ............................................................................................................................63 The Light Curtain Is in a "Reset Required" Condition....................................................................63 If the Transmitter Has No Power or Is Not Functioning.................................................................63 Check Power and Indicator Lights ..................................................................................................63 Check Lens Window.......................................................................................................................64 Bring Shadow Heads Close Together .............................................................................................64 Green Light On ...............................................................................................................................64 No Green Light ...............................................................................................................................65 If You Have Two Sets of Shadow Heads........................................................................................65 Green Light On But Still Cannot Start Press...................................................................................65

Final Checkout Sequence .........................................................................................................................66

Chapter 3 – Fixed and Floating Blanking ........................................................69

Blanking Windows Affect Safety Distance ..............................................................................................70 Adding to Safety Distance for Fixed Blanking ....................................................................................71 Adding to Safety Distance for Floating Window.................................................................................71

Installing Blanking Windows ...................................................................................................................72 Installing the Master.............................................................................................................................72 Installing Slave Windows ....................................................................................................................75

Floating Window ......................................................................................................................................77 Adding to Safety Distance for Floating Window.................................................................................78 How to Enable the Floating Window...................................................................................................78

Chapter 4 – Troubleshooting Shadow VI ........................................................79

How to use this chapter ............................................................................................................................79 Description of Shadow VI Indicators .......................................................................................................80

Shadow VI User Manual 1107200

Table of Contents page iii

At the Optic Heads...............................................................................................................................80 At the Control ......................................................................................................................................80 Inside the Control.................................................................................................................................81 External MPCE Monitoring: Checking DS5 and DS6.........................................................................85

Shadow VI Optic Head Connector ...........................................................................................................86 Checking and Cleaning Lens Window(s).................................................................................................87 Checking Alignment.................................................................................................................................87

Alignment Problem or Bad Phototransistor .........................................................................................87 Checking and Replacing Fuses.................................................................................................................88 Checking and Replacing Control Relays..................................................................................................89

If the Relay Has Failed Completely .....................................................................................................89 Checking Relays with a Voltmeter ......................................................................................................90 Replacing Safety Relays ......................................................................................................................91

Checking and Correcting Cross Talk........................................................................................................92

Appendix A – Extracts from OSHA Regulations and ANSI Standards.........93

Extracts from OSHA Regulation 1910.217..............................................................................................93 Extracts from ANSI Standards for Presence-sensing Devices .................................................................97 Daily Tests in English ............................................................................................................................113 Tests Quotidiens du Rideau de Lumiere.................................................................................................114 Daily Tests in French..............................................................................................................................114

Appendix B – Shadow VI Panel Mount..........................................................115

Standard Enclosure Versus Optional Panel Mount ................................................................................115 Preparation for Mounting Shadow Using Your Enclosure.....................................................................115

About Shadow VI Panel Mount Labels .............................................................................................116

Appendix C – Installation of Shadow VI-WPC Control Board .....................119

Mounting Dimensions and Required Clearance .....................................................................................119 About Shadow VI-WPC Control Board Labels.................................................................................120

Wiring Shadow VI optic heads to the board ..........................................................................................124 Connecting AC wiring to WPC..............................................................................................................125 Connecting Stop Circuits to WPC..........................................................................................................126 Making settings on the control board .....................................................................................................127

Floating window setting.....................................................................................................................127 J12 Setting..........................................................................................................................................128

Reset button ............................................................................................................................................129

Appendix D – Replacement Parts..................................................................131

Index ................................................................................................................133

Wintriss Manuals ............................................................................................137

1107200 Shadow VI User Manual

page iv Table of Contents

List of Figures Figure 1-1. Illustration of Shadow Transmitter and Receiver ...............................................................................3 Figure 1-2. Illustration of Shadow Control ...........................................................................................................4 Figure 1-3. Showing Light Beams with Shadow Light Curtain ............................................................................5 Figure 2-1. Distance Between Pinch Point and Light Curtain.............................................................................19 Figure 2-2. Plan View Illustrating "Pass Through" Protection............................................................................25 Figure 2-3. Brackets for Shadow Light Curtains.................................................................................................29 Figure 2-4. Shadow VI Optic Heads Mounting Dimensions...............................................................................31 Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts) ............................................................32 Figure 2-6. Transmitter and Receiver Properly Aligned .....................................................................................34 Figure 2-7. Using Laser Alignment Tool to Properly Align Shadow..................................................................34 Figure 2-8. Aligning Brackets Using Mounting Holes So Shadow Light Beams Line Up Later

When Mounted .................................................................................................................................35 Figure 2-9. Shadow VI Mirror Dimensions.........................................................................................................37 Figure 2-10. Representation of Shadow with Mirrors for Three-sided Guarding ...............................................38 Figure 2-11. One Way to Avoid Cross Talk - Reversing Transmitters (TX) and Receivers (RX) .....................40 Figure 2-12. Mounting an Optic Head with Shock Mounts ................................................................................41 Figure 2-13. Shadow VI Control Enclosure Mounting Dimensions ...................................................................43 Figure 2-14. Location of Components, Shadow VI Control ...............................................................................44 Figure 2-15. Terminating Drain Wires to Set Screw Terminal ...........................................................................46 Figure 2-16. Terminal Block TB1 Connections ..................................................................................................50 Figure 2-17. Setting Voltage Selector Switch S2 ................................................................................................51 Figure 2-18. Connecting to Protective Earth Ground Set Screw Terminal .........................................................51 Figure 2-19. Relays Wired to Emergency Stop Circuit, Typical.........................................................................54 Figure 2-20. Wiring "Upper" TB4 Connector in Control....................................................................................55 Figure 2-21. Example of MPCE Usage ...............................................................................................................58 Figure 2-22. Setting MPCE Jumpers...................................................................................................................59 Figure 2-23. Factory Settings for Switch Blocks S1 and S4 ...............................................................................59 Figure 2-24. Jumper Position for "1 SET" and "2 SET" .....................................................................................61 Figure 3-1. Connecting Master Blanking Window .............................................................................................73 Figure 3-2. Close-up — Installing Blanking Window ........................................................................................74 Figure 3-3. Coil Stock Unwinding Using Floating Window...............................................................................77 Figure 4-1. Optic Head Connector Pinout Orientation and Chart .......................................................................86 Figure B-1. Daily Tests Label (left) and Operator instructions Label (right)....................................................117 Figure B-2. Shadow VI Panel Mount Control Dimensions...............................................................................118 Figure C-1. Shadow VI - WPC Labels ..............................................................................................................121 Figure C-2. Mounting Dimensions and Required Space for Control Board .....................................................122 Figure C-3. Important Components - Shadow VI-WPC Control board .............................................................123 Figure C-4. TB1 Power Terminal......................................................................................................................125 Figure C-5. Setting Voltage Selector Switch S2 ...............................................................................................126 Figure C-6. Floating Window Switch S1 ..........................................................................................................127 Figure C-7. Jumper Position for "1 SET" and "2 SETS"...................................................................................128 Figure C-8. Reset Button...................................................................................................................................129

Shadow VI User Manual 1107200

Table of Contents page v

List of Tables

Table 1-1. Shadow VI Specifications..................................................................................................................12 Table 1-2. Shadow options and functions ...........................................................................................................14 Table 2-1. Light Curtain Dimensions: inches (cm) .............................................................................................30 Table 2-2. OSHA Table 0-10 ..............................................................................................................................36 Table 2-3. Connecting Light Curtain Receiver Head to TB2 in Controller ........................................................48 Table 2-4. Connecting Light Curtain Receiver Head to TB3 in Controller .........................................................49 Table 4-1. Shadow troubleshooting guide for 1 or 2 sets....................................................................................82 Table 4-2. Shadow Troubleshooting Guide for 2 Sets ........................................................................................85 Table C-1. Connecting Light Curtain Receiver Head to TB2 in Controller......................................................124 Table C-2. Connecting Light Curtain Transmitter Head to TB3 in Controller ..................................................125 Table C-3. Shadow-WPC Board TB1 to WPC .................................................................................................126 Table C-4. Shadow-WPC Board TB4 to WPC .................................................................................................127 Table D-1. Replacement Parts List....................................................................................................................131

Wiring Diagrams at End of Manual

Figure 1. Dual Light Curtain Wiring Diagram

Figure 2. Simple Connection to N/O Machine ESTOP Circuit

Figure 3. Connection for Simple N/O ESTOP and Auxiliary Circuit

Figure 4. Wiring Diagram Showing External N/O and N/C Relays with Captive Contacts

Figure 5. External Indication Wiring Diagram

Figure 6. Wintriss Clutch/Brake Control Shadow VI Wiring

Figure 7. Wintriss Clutch/Brake Control Dual Shadow Wiring

Figure 8. Wintriss Clutch/Brake Control Integrated Shadow VI Wiring

Figure 9. Older Model Wintriss Clutch/Brake Control Shadow VI Wiring

Figure 10. WPC 1000 Shadow VI and Cam Output Wiring

1107200 Shadow VI User Manual

page vi Table of Contents

How to Use the Manual This is the installation and reference manual for the Shadow Safety Light Curtain. It has information about how to install, use and troubleshoot Shadow, as well as pertinent information about OSHA and ANSI requirements.

Chapter 1, Shadow Safety Light Curtain, introduces you to Shadow, tells how it works —specifically about control reliability—and explains how to use this product.

Chapter 2, Installation and Checkout, gives the instructions for installing Shadow. This chapter also includes installation of the mirrors, as well as installation information when installing for different applications. At the end of the chapter is a diagnostic and checkout section. Be sure to check out your Shadows prior to operating the machinery.

Chapter 3, Floating and Blanking Windows, tells what you need to know about using blanking and floating windows, including installation and safety distance.

Chapter 4, Troubleshooting, provides information to help diagnose and correct problems you may encounter when using a Shadow Light Curtain.

Appendix A, OSHA Regulations, ANSI Standards and Daily Tests gives excepts from documents related to presence-sensing safety devices, and instructions for tests that should be run every day.

Appendix B, Shadow VI Panel Mount explains how to install Shadow VI as a panel mount. Mounting and "cutout" dimensions are provided.

Appendix C, Installation of Shadow VI-WPC Control Board explains how to install, wire, and operate the optional Shadow VI-WPC control board assembly in conjunction with your Wintriss Clutch/Brake Control (WPC). This control board replaces the standard Shadow VI control box.

Appendix D, Replacement Parts lists the replacement parts available for the Shadow VI from the factory.

Shadow VI User Manual 1107200

Table of Contents page vii

Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows:

DANGER! A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will

result in death or serious injury.

WARNING! A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could

result in death or serious injury.

CAUTION A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may

result in property damage.

NOTICE A NOTICE symbol indicates important information that must be remembered and aids in job

performance.

1107200 Shadow VI User Manual

page viii Table of Contents

Warranty

Wintriss Controls warrants that Wintriss electronic controls are free from defects in material and workmanship under normal use and service for a period of one year (two years for Shadow light curtains) from date of shipment. All software products (LETS and SBR), electro-mechanical assemblies, and sensors are warranted to be free from defects in material and workmanship under normal use and service for a period of 90 days from date of shipment. Wintriss’s obligations under this warranty are limited to repairing or replacing, at its discretion and at its factory or facility, any products which shall, within the applicable period after shipment, be returned to Wintriss Controls freight prepaid, and which are, after examination, disclosed to the satisfaction of Wintriss to be defective. This warranty shall not apply to any equipment which has been subjected to improper installation, misuse, misapplication, negligence, accident, or unauthorized modification. The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by Wintriss Controls. No other warranty is expressed or implied. Wintriss accepts no liability for damages, including any anticipated or lost profits, incidental damages, consequential damages, costs, time charges, or other losses incurred in connection with the purchase, installation, repair or operation of our products, or any part thereof.

Please note:

It is solely the user’s responsibility to properly install and maintain Wintriss controls and equipment. Wintriss Controls manufactures its products to meet stringent specifications and cannot assume responsibility for consequences arising from their misuse.

U.S. patent numbers 4,266,124 and 3,805,061 apply

Wintriss Controls Group, LLC SHADOW® VI SAFETY LIGHT CURTAIN 100 Discovery Way USER MANUAL Unit 110 1107200 Acton, MA 01720 ©2010 Wintriss Controls Group, LLC Telephone: (800) 586-TECH (8324) (978) 268-2700 Fax: (978) 263-2048 Internet: http://www.wintriss.com

Shadow VI User Manual 1107200 Introduction to Shadow VI Chapter 1 page 1 Safety Light Curtain

Chapter 1 – Introduction to Shadow® VI Safety Light Curtain

Shadow VI is a compact, state-of-the-art, 3-box light curtain which contains transmitter and receiver optic heads plus a separate control.

Shadow protects personnel working around dangerous machinery. The system signals the press to stop if a person's hand (or any other part of the body) gets too close to the hazardous area. However, the invisible light screen does not interfere with normal operation. Unlike mechanical guards which physically block access to the hazardous area, Shadow safeguards personnel via this field of invisible infrared light.

DANGER! FULL REVOLUTION MECHANICAL POWER PRESSES CANNOT BE STOPPED IN MID-

STROKE

• DO NOT use Shadow safety light curtains on full-revolution clutched machinery.

• Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle.

Failure to comply with these instructions will result in death or serious injury.

WARNING! IMPROPER INSTALLATION

• Install and use Shadow safety light curtains according to applicable safety standards.

• Install presses used with Shadow safety light curtains according to the requirements and inspection procedures of OSHA regulation 1910.217 and ANSI standard B11.1-2009.

• Install other machinery or devices according to OSHA regulation 1910.212 for general machine guarding and any other regulations that apply.

Failure to comply with these instructions could result in death or serious injury.

NOTICE USE EXCERPTS FROM SAFETY STANDARDS FOR REFERENCE ONLY

Refer to the latest versions of the documents from which Wintriss has provided excerpts for your convenience. An excerpt from OSHA regulation 1910.217 appears in the appendix of this manual. Excerpts from the American National Standards Institute (ANSI) standards for safety devices are also included in Appendix A.

ANSI is a federation of trade and professional organizations which sets standards for the industry based on a national consensus of manufacturers, scientists, technical and professional groups.

1107200 Shadow VI User Manual

page 2 Chapter 1 Introduction to Shadow VI Safety Light Curtain

OSHA and ANSI Compliance

Shadow complies with OSHA CFR 1910.212 "General Machine Guarding" and 1910.217 "Mechanical Power Presses", ANSI B11.1-2009 "Mechanical Power Presses", ANSI B11.19 "Performance Criteria for Safeguarding"; ANSI B11.20 "Manufacturing Systems/Cells"; and ANSI/RIA 15.06 "Industrial Robots and Robot Systems".

These regulations require that a single component failure cannot jeopardize operator safety. Critical components are duplicated and continually cross-checked during operation to guarantee that a single component failure can never create an unsafe condition. Self-checking circuitry detects the presence of any faults and signals the press to stop.

About Shadow VI

DANGER! INCORRECT INSTALLATION

• Ensure that presses equipped with Shadow light curtains meet the requirements and inspection procedures of OSHA regulation 1910.217 and ANSI standard B11.1-2009.

• Ensure that other machinery or devices meet OSHA regulation 1910.212 for general machine guarding and any other regulations that apply.

Failure to comply with these instructions will result in death or serious injury.

NOTICE EXCERPTS FROM OSHA REGULATIONS AND ANSI STANDARDS

Excerpts from OSHA regulation 1910.217 and from the American National Standards Insti-tute (ANSI) standards for safety devices are also included in Appendix A. ANSI is a fed-eration of trade and professional organizations which sets standards for the industry based upon a national consensus of manufacturers, scientists, technical and professional groups.

Shadow safety light curtains provide excellent protection. Once properly installed, Shadow VI does not require additional adjustment, and no maintenance is required. You do not have to worry about personnel forgetting to close gates or replace barriers.

The optic heads are constructed of rugged, heavy-gauge extruded aluminum (0.12-inch wall thickness). These compact heads (2" x 2.85" cross-section) come in sizes ranging from 6 inches to 5 feet in height. The transmitter and receiver (see Figure 1-1) are optionally available in explosion-proof enclosures.

Shadow also includes a control enclosure (Figure 1-2) to which any-sized receiver and transmitter can be wired. No special settings are required. The control contains a power supply, relay circuitry, and switch block assemblies where you can easily enable or disable Shadow's options.

For added security, the control comes standard with an enclosure keylock and a reset keyswitch. Simply turn the reset keyswitch to the right when resetting is required.

Shadow VI User Manual 1107200

Introduction to Shadow VI Chapter 1 page 3 Safety Light Curtain

The cables join the control with the transmitter and receiver and are interchangeable between each optic head. These cables have connectors that plug into the optic head end and screw terminations that connect at the control end. They come in various lengths.

Receiver

LEDs:Red

(curtain obstructed)Orange

(floating window enabled)Green

(curtain unobstructed)

universalmountingbrackets

LED:Amber(power on)

end caps

"quick-connect"cable connectors

mating connectorfor blanking

window cable

Transmitter

Figure 1-1. Illustration of Shadow Transmitter and Receiver

1107200 Shadow VI User Manual

page 4 Chapter 1 Introduction to Shadow VI Safety Light Curtain

reset keyswitch

LED Indicators for curtain clear,

floating window enabled,curtain blocked and

reset required

(key pointed toward "operate"

during normaloperation)

enclosure keylock

cover latches

LIGHT CURTAIN

RESETOPERATE

CURTAINCLEAR

STOPSIGNAL

RESETREQUIRED

FLOATINGWINDOW

Figure 1-2. Illustration of Shadow Control

How Shadow Works

WARNING! IMPROPER INSTALLATION

• Connect the Shadow safety light curtain stop relays to the machine’s stop circuit. If you do not use the stop relays, you will not have the maximum protection afforded by these light curtains.

• DO NOT attempt to connect Shadow safety light curtains to any control until you have carefully read the installation instructions.

Failure to comply with these instructions could result in death or serious injury.

WARNING! UNPROTECTED MACHINERY MAY CONTINUE TO OPERATE

Ensure that all operators know which device(s) your Shadow safety light curtain protects and which it does not. The press Shadow is wired to will stop when the light curtain is interrupted and sends a stop signal to the press. However, the associated feeds and conveyors, to which Shadow is not wired, will continue to operate after the press stops.

Failure to comply with these instructions could result in death or serious injury.

You cannot see the actual light curtain emitted by Shadow. However, the invisible curtain of light automatically prevents access to hazardous areas while the press is operating.

Shadow VI User Manual 1107200

Introduction to Shadow VI Chapter 1 page 5 Safety Light Curtain

receivertransmitter light beams

Figure 1-3. Showing Light Beams with Shadow Light Curtain

Shadow's transmitter and receiver are not "matched sets". In other words, a Shadow VI transmitter will work with any same-sized Shadow VI receiver. You mount the units on the machinery on either side of the hazardous area.

Shadow can be described as an optoelectronic presence-sensing device. Presence-sensing means the light curtain detects an object that penetrates its field and reacts to it by signaling a press to stop when an intrusion occurs. Optoelectronic means Shadow works using light and electric current.

The transmitter's LEDs (light emitting diodes) emit a harmless, invisible, infrared light pulse when an electrical pulse passes through them. These LEDs transmit light towards the receiver. The receiver's phototransistors detect each light pulse and produce an electrical signal whenever the light pulse hits them. An invisible light barrier is formed by infrared light beams sent from the transmitter to the receiver. Reacting to the loss of light, Shadow sends a stop command to the press when there is an obstruction, such as when you put your hand into the light field.

As the light curtain is operating, each transmitter LED pulses in succession from top to bottom, in the form of a conical beam. The phototransistors in the receiver detect these light pulses instantly and produce an electrical signal (turn on) when the light strikes them. Each phototransistor detects the one pulse of light designated to it. It is only enabled at the instant that the beam is anticipated. Shadow's electronics must "see" the phototransistor turn "on" then "off" as the beam hits it and disappears. Each phototransistor must turn on, then off in sequence, or Shadow will send a stop command to the machinery.

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Because the receiver only accepts infrared light pulses of a certain duration in proper sequence, Shadow cannot be affected or fooled by other light sources. All other continuous light sources and even pulsed light sources are "tuned out." Therefore, the light curtain is not affected by normal lighting near the light curtain. Also, changes in area lighting or even flashing strobe lights will not affect operation.

This pulsed sequence is so fast that, where we mark time in units no smaller than a second, the effect is a continuous light field across the guarded area. You would have to move the point of your finger across an LED in the transmitter in less than 5/1000th of a second (5 ms or milliseconds) to evade the light pulses coming from that LED. Therefore in our world of seconds and minutes, the light curtain is really always there even though only one light beam is actually produced at a time. The actual light pulse lasts for only 1/100,000th of a second (10 microseconds). Consequently it does not take long to create a whole series of pulses one after the other.

Shadow and Control Reliability

WARNING! IMPROPER INSTALLATION • Install Shadow safety light curtains in compliance with applicable safety regulations from the

Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI). See excerpts in the appendices.

• Refer to the latest revision of all applicable documents. • Ensure that your installation meets the control reliability requirements of the applicable

regulations. • Ensure that both Shadow control relays are used in any Shadow installation, including

connection directly to the press control's stop circuit, to a PLC, or to other type of machine control. Wiring is explained in Chapter 2.

• Read carefully and understand the installation instructions before attempting to install and wire Shadows to any control

• Ensure that installation is performed by qualified personnel. Failure to comply with these instructions could result in death or serious injury.

WARNING! UNPROTECTED MACHINERY MAY CONTINUE TO OPERATE

Ensure that all operators know which device(s) your Shadow safety light curtain protects and which it does not. The press Shadow is wired to will stop when the light curtain is interrupted and sends a stop signal to the press. However, the associated feeds and conveyors, to which Shadow is not wired, will continue to operate after the press stops.

Failure to comply with these instructions could result in death or serious injury.

Shadow is control reliable. Control reliability is a term used and defined in the same way by the Occupational Safety and Health Administration (OSHA) and the American National Standards Institute (ANSI).

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NOTICE The Occupational Safety and Health Administration (OSHA) and the American National

Standards Institute (ANSI) have issued regulations for the use of presence-sensing devices such as Shadows. Both of them require control reliability. See Appendix A for more information.

Control reliability means "the device shall be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent the initiation of a successive stroke until the failure is corrected."

Control reliability is another reason why Shadow is an excellent machine guard. All critical components in Shadow are duplicated so that if one fails, the other will still allow normal operation to stop the machinery. If a component failure does occur, Shadow will immediately detect the failure and send a stop signal to the machinery. The light curtain will not allow operation until the repairs are made.

Another example of control reliability are Shadow's control relays. The control contains captive-contact relays (2 stop and 1 status relay). The N/O outputs are connected in series to the press's emergency stop circuit and are always energized (contacts held closed) when the light field is not broken. When an obstruction enters the field, Shadow's control circuitry instantly de-energizes the relays, which results in opening the contacts and breaking the stop circuit of the press. Shadow's response time from loss of light to relay contacts open is 30 to 40 milliseconds (depending on the size of the optic heads). Even if one of Shadow's control relay contacts fails closed (contact welds shut), the second relay will still de-energize and a stop signal will be sent to the machinery. Shadow will also detect the failed relay. It will not allow further press operation until the relay is replaced. It is highly unlikely that the relay contacts will fail simultaneously.

Description of Shadow VI indicators

Shadow includes several indicators. Figure 1-1 shows the indicators on the transmitter and receiver, and Figure 1-2 illustrates the control.

These indicators communicate Shadow's operating status. Use them to troubleshoot your light curtain (see Chapter 4 troubleshooting guides). If any contradiction exists between the indicator lights at the receiver and those at the control, make sure you compare your findings with the information in these troubleshooting guides to solve the problem immediately.

At the Optic Heads

The transmitter has an amber-colored power indicator which remains illuminated when Shadow has power. There are three indicators on the front of the receiver. The red indicator means that the light curtain has been interrupted. The orange indicator flashes when the floating window option is turned "on" at the control (see Chapter 2). The green indicator means the light curtain is unobstructed.

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At the Control

Four indicators appear on the front cover of the control and are clearly labeled. The green "curtain clear" indicator means that the light curtain is unobstructed and the machinery will be allowed to operate (the control relay contacts are held closed or in the unobstructed/ energized state). The "floating window" indicator lights up amber when this blanking feature is enabled inside the control (see Chapter 2). The "stop signal" indicator goes red when the light curtain is obstructed, the control relay contacts are open (or in the de-energized state) and the press is disabled, if there is misalignment, or when Shadow has detected an internal malfunction. The yellow "reset required" signifies that a “reset required” or condition exists. This could occur during power-up if “power up reset” settings are enabled at the control (see Chapter 2), or if Shadow detects an internal malfunction with any of the components (transmitter, receiver, or control).

Inside the Control

There are four indicators inside the control (refer to Figure 2-14 in Chapter 2 for location of components). DS1 and DS2 are red indicators that are located just above the TB2 receiver connectors at the lower right-hand corner of the board. They light up red if you are using only 1 set of optic heads and there is an obstruction, misalignment, or internal problem. If you have 2 sets, DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and TB3) is interrupted, the optic heads are misaligned, or an internal problem exists. DS2 corresponds with Set 2, which are wired to the lower connectors. Refer to the troubleshooting guides in Chapter 4 for more details.

DS3 and DS4, located in the upper right-hand corner of the control near the power supply, light up green all the time to indicate that power is going to the receiver and transmitter respectively.

Chapter 4 provides troubleshooting guides which reference the indicators at the control and the optic heads. They suggest how to solve a problem with the light curtains when certain conditions exist.

Object Sensitivity

Object sensitivity is the minimum diameter object that Shadow can detect. Object sensitivity for Shadow is 11/4" (3.2 cm), which means that it will detect any object of this diameter or larger anywhere in the sensing field. Shadow light beams are on 3/4" (1.9 cm) centers. An object smaller than 11/4" diameter could pass undetected through the light field if it traveled in a path directly between the light beams.

Size and Scanning Distance

Shadow is available in a wide array of standard sizes from 6" to 60". Shadow's standard scanning distance is 25 feet (7.6 meters), and optionally 50 feet (15.3 meters). The "standard range" units cannot be modified for "extended range" capability.

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Shadows Are Easy to Maintain

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

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Shadow VI Features and Options

Shadow is designed for uncompromising safety and durability under real world conditions. The light curtain includes various features and options. Some of these are described next.

The floating window feature provides a means for the random bypass of only one beam of the light curtain. It is useful in those applications where material must travel through or within the sensing field in a random pattern. The floating window may only be used when material or parts take up a space no greater than 11/8" (2.9 cm) within the sensing field. Larger material would block more than one light beam at a time which would generate a stop command. This built-in feature is enabled by turning a switch "on" at the control. The amber indicators at the receiver and on the front cover of the control flash when floating window is "on". A floating window automatically alters the object sensitivity from 11/4" to 2". If you plan to use this feature even occasionally, the safety distance for mounting must be increased. Refer to "Calculating Safety Distance" in Chapter 2 of this manual.

Shadow has optional fixed blanking capability. External blanking windows (purchased separately) allow you to disable up to 5 contiguous beams in an area where a fixture penetrates the light field and permits stationery objects to protrude into Shadow's sensing field. For example, in a situation where a conveyor or work table extends into this field, moving the fixture may not be feasible. Therefore, you install a blanking window on the Shadow receiver where the fixture penetrates the field. This disables the light beam that would normally detect the fixture. However, if the light field is penetrated in any area above or below the fixture (or "blanked" light beam), the light curtain will send a stop signal to the machinery.

Floating window can be used in conjunction with fixed blanking. An example could be an application where part of the tool physically protrudes into the light field and an air blow-off is randomly ejecting parts. Floating window is covered in Chapters 2 and 3, and fixed blanking is discussed in Chapter 3. Safety distance is also affected by fixed blanking window if the fixed obstruction does not extend all the way from the transmitter to the receiver. See Chapter 2 for a comprehensive discussion of safety distance.

Shadow has passed stringent environmental stress tests for shock, vibration, impact, exposure to temperature extremes, dust, humidity, and electrical abnormalities.

Shadow comes with a built-in status relay which can be set to perform different functions (setup is covered in Chapter 2). When wired to the main motor, the relay opens at power-up if “reset on power up” has been enabled at the control (see "Making settings" in Chapter 2). The status relay can be set to "mimic" stop outputs which can activate an alarm or beacon whenever Shadow is in a "stop signal" (red) condition.

Shadow can also be used in perimeter guarding applications when there is a walk-in hazard inside the guarded area. In this case, a "stop signal" condition is generated when any of the light curtain beams has been obstructed. Shadow will not reset to "curtain clear" (green) automatically even when the obstruction has been removed. You must reset the system to resume operation. Activating this feature is discussed in Chapter 2.

Both Shadow optic heads include universal mounts. These mounts are used to properly align the Shadow heads during installation. They can be rotated ±30° to make installation and

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alignment easier. By rotating the brackets 90° with respect to the head, they provide additional flexibility when mounting. Installing the universal mounts is covered in Chapter 2.

Weld Shield Kit

Shadow's operation is not affected by smoke, dirt, or oil found in a typical industrial environment. If necessary, however, you can at any time install replaceable shields to provide protection from weld splatter and other hazards. Weld shields are clear plastic covers that fit on the face of the transmitter and/or receiver. They come in kits ready for installation, and can be easily replaced if they become so damaged or scratched that the light curtain no longer indicates “green” during normal operation. (See the Troubleshooting Guide in Chapter 4 of this manual).

Refer to Chapter 2 of this manual for more information about using weld shields.

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Table 1-1. Shadow VI Specifications

WARNING! INDICATOR OUTPUTS NOT SUITABLE FOR SAFETY USE

• DO NOT use the indicator outputs listed in the specifications table for personnel protection. They cannot be used to stop the machinery.

• Use the safety outputs for personnel protection.

Failure to comply with these instructions could result in death or serious injury.

Scanning heights 9 models: 6, 12, 18, 24, 30, 36, 42, 48 and 60 inches (15.2, 30.5, 45.7, 61.0, 76.2, 91.4, 106.7, 121.9, and 152.4 cm)

Scanning range Standard: up to 25 ft (7.6 m) Extended: up to 50 ft (15.3 m)

Transmitter and receiver not matched sets

Beam spacing 3/4" (1.9 cm) centers

Object sensitivity 11/4" (3.2 cm)

Response time 30 msec max. for 6" to 24"

35 msec max. for 30" to 48"

40 msec max. for 60"

Size Optic heads Control enclosure

See Figures 2-4, 2-5, and Table 2-1 in Chapter 2. 7" x 9" x 3.5" (17.8 x 22.9 x 8.9 cm). See Figure 2-13 in Chapter 2.

Weight 6" optic heads

Control

1.4 lbs (.64 kg) ; add 0.9 lbs (.4 kg) for every additional 6 inches in height

9 lbs. (4 kg)

Construction

Heads

Control

Cables

Extruded aluminum; 0.12" (3 mm) wall min

18-gauge welded steel with enclosure keylock.

5, 15, 25, 50, and 100 ft. with connector at the optic head.

Environmental

Heads

Control

Cables

Vibration

NEMA 4, IP65; Optional explosion-proof enclosures.

NEMA 2 / IP52; Optional NEMA 4/IP65; Optional with 4 connectors for 2 sets of optic heads; Optional explosion- proof enclosure.

NEMA 4 connector; Oil-resistant PVC cable standard; Optional SJOOW cable with 1 or 2 connectors.

10g, 0.03" displacement; freq. 10-150 Hz sine, per UL491 (applies to all three axes).

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Shock testing 50g, 11ms pulse per MIL-STD-810 C, Method 516, Procedure I (applies to all three axes).

Operating Temperature - 4° F to 122° F (-20° to 50° C).

Inputs

Power

Heads

MPCE

Remote Reset

115-230 VAC (DC available) 50-60 Hz; 30 VA max.

Two sets (any height) can be connected to same control.

Monitor input: For external dry contacts rated at 20 mA @ 20 VDC; 25 msec. response time max.

Closure to ground ON voltage 2V @ 2mA

Light Source Infrared light emitting diodes (LEDs). Approximately 850 nanometer wavelength

Optics Angle of Divergence and Acceptance: less than ± 3.5°.

Outputs

Stop Circuit/status

Indicator Outputs*

2 "captive contact" stop relays and one status relay, plus 4 solid state indicator outputs.

4A @ 120 VAC or DC resistive max; N/O and N/C contacts with all 3 relays.

4 open collector, NPN, opto-isolated outputs can switch 70 V load @ 2 mA maximum (see warning below).

Indicators

Transmitter

Receiver

Control

Amber (power).

Red "obstructed"; Amber "floating enabled"; Green "clear unobstructed".

Red "obstructed"; Amber "floating enabled"; Green "clear unobstructed"; Yellow "Reset required".

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Table 1-2. Shadow options and functions

OPTION FUNCTION

Mirrors Provide 2 or 3-sided protection; each mirror reduces effective scanning distance by 10%.

Blanking Windows Electronics for blanking standard; external blanking windows must be purchased separately; maximum number of blanked beams is 5.

Floating Window Allows objects smaller than 11/8" to move through light field without interrupting operation. One beam floating capability built-in; enabled at control.

Weld shield kits Specify the model size of your Shadow. See Chapter 2 for more information.

Laser Alignment Tool For optimum alignment; uses 3V Lithium battery.

Interchangeability Transmitter and receiver are not matched sets; Shadow VI transmitter can be used with Shadow VI receiver of same.

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Chapter 2 – Installation and Checkout

DANGER! IMPROPER INSTALLATION, USE OR MAINTENANCE

• Follow all procedures in this manual. This is required for proper operation of the light curtain.

• Ensure that the light curtain is installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the machine without being detected. Use the correct height light curtain, combined with ancillary physical guards.

• Install and maintain your machine guarding system according to OSHA standard 1910.212 and any other regulations and standards that apply.

• Wire and install Shadow safety light curtains in accordance with the requirements of OSHA lockout/tagout regulation 1910.147.

• Ensure that Shadow safety light curtains are installed, tested and repaired by qualified personnel.

• Perform only the tests and repairs listed in this manual.

• Test the operation of your Shadow safety light curtains daily using the checkout sequence shown on the Shadow safety light curtain units and also listed in this manual. If your Shadow safety light curtains are installed so the warning and test procedure labels are not clearly visible, call the factory for extra warning labels to attach to your machinery in a highly visible area.

• Perform the checkout sequence after any maintenance is done on the Shadow safety light curtains.

• Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, or any others responsible for the proper operation of the machinery have read and understood all instructions for use of the Shadow safety light curtains.

Failure to comply with these instructions will result in death or serious injury.

Installing Shadow is a straightforward procedure. You must proceed carefully, however, since the Shadow VI light curtain is a safety device which protects press operators and other personnel.

Check that you received everything. With Shadow, you should have received optic heads (transmitter and receiver), a control (the "third box"), and two interchangeable quick connect cables, one for each optic head (required cable lengths specified at time of order). If you are missing any of these, contact Wintriss Tech Support immediately before proceeding with the installation. Before you start the installation, read the instructions thoroughly. Then proceed carefully to be ensure proper installation and operation.

A brief general overview of the installation procedure is listed first in this chapter. After reading the overview, follow the more detailed installation instructions that come next. The actual instructions must be followed for proper installation of Shadow VI.

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Installation overview

Read this overview before beginning the installation procedures that follow. It will familiarize you with the steps required to complete the installation.

Calculating the safety distance

The proper distance that the Shadow heads must be mounted away from the pinch point (or hazardous area) is calculated. This is called the safety distance. This distance allows enough time for Shadow to react, and the press to stop, before an intrusion, like the operator's hand, reaches the pinch point. The pinch point is the area of the press where moving parts can cause injury. The safety distance can be calculated precisely using the formula explained in the section "Calculating the safety distance".

Mounting location for your Shadow transmitter and receiver

A mounting location is selected. Rigid mounting brackets are fabricated and attached to your press. Brackets are used to bring the Shadow heads out to the proper safety distance and to allow proper alignment.

Wiring, aligning, mounting, and making proper settings

The Shadow light curtain optic heads are mounted to the brackets using shock mounts, then aligned, and wired to the control, which is then wired into your press's control circuitry. Proper settings are made at the Shadow’s control to enable its features and options.

The standard control enclosure is rated NEMA 2/IP52. You must use conduit of the same rating and make proper connections to ensure proper protection with the enclosure. If you have an optional NEMA 4/IP65 enclosure, suitably rated conduit hubs must be used on all unused holes in the control enclosure to maintain proper NEMA 4/IP65 rating.

Ensuring that the Shadow light curtains are working properly

Perform the checkout sequence after installation to ensure that Shadow VI is working properly.

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Installation Procedure

DANGER! FAILURE TO PERFORM SAFETY SYSTEM TESTS

• Perform the final checkout sequence below when you have completed installation of your light curtain, before operating the equipment it is connected to.

• Operate your machinery only after your safety system meets all the requirements of the checkout sequence.

• Perform the final checkout sequence whenever repair, maintenance or modification is performed on your light curtain or the machinery it is connected to.

• Perform the “daily test” safety system checkout sequence on page 93 (in French, en Français, page 114) every day before operating any machinery connected to Shadow safety light curtains.

Failure to comply with these instructions will result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD

• Turn off and disconnect power from the Shadow safety light curtain and from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/Tagout).

• Ensure that installation is performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

The installation procedure is divided into these steps:

• Calculating the safety distance

• Designing and mounting brackets

• Loosely mounting Shadow VI heads

• Mounting the control

• Wiring the transmitter and receiver to the control

• Connecting AC wiring to the control

• Connecting stop circuits to the control

• Making settings inside the control

• Aligning and tightening down Shadow VI components

• Diagnostic steps to perform before Shadow operation

• Final checkout sequence

It is a good idea to read over the complete installation procedure before starting. This will guide you about the materials and techniques required for making and positioning mounting brackets and aligning Shadow VI heads.

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Calculating the Safety Distance

DANGER! INCORRECT SAFETY DISTANCE

• Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area.

• Mount your light curtain heads at least 7.5” (191 mm) from the hazardous area, regardless of the calculated safety distance.

Failure to comply with these instructions will result in death or serious injury.

DANGER! INCORRECT SAFETY DISTANCE DUE TO BLANKING OR FLOATING WINDOWS

• Read “Chapter 3 – Fixed and Floating Blanking” before calculating the safety distance. This chapter tells how to modify the safety distance when you use windows.

• Modify the safety distance calculated with the instructions below, as required.

Failure to comply with these instructions will result in death or serious injury.

DANGER! INCREASED SAFETY DISTANCE DUE TO BLANKING OR FLOATING WINDOWS

Modify the safety distance between the light curtain and the hazardous area according to the instructions in this chapter and in Chapter 3, "Floating and Blanking Windows."

Failure to comply with these instructions will result in death or serious injury.

DANGER! INCORRECT SAFETY DISTANCE DUE TO LONGER RESPONSE TIME

Determine which model Shadow safety light curtains you have. Use the correct response time for your model light curtain in your safety distance calculations. Safety depends on your installing your light curtain at the correct safety distance from the hazardous area.

12” to 24” 30 ms response time 36” to 48” 50 ms response time

Failure to comply with these instructions will result in death or serious injury.

DANGER! STOPPING TIME TOO LONG

Use a brake monitor where a Shadow light curtain is used to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA 1910.217 (c) (3) (5). A brake monitor continually checks that the machine’s stopping time does not exceed a predetermined limit.

Failure to comply with these instructions will result in death or serious injury.

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Shadow light curtains must be mounted away from the pinch point (or hazardous area) of the press at a specific distance. This distance is based on the stopping time of your press. This distance is called the safety distance. It must be calculated using a precise formula. This ensures that Shadow VI can send the stop signal to the press, and the press will stop, before the operator's hand reaches the hazardous area.

This next illustration shows how you would measure the distance between the pinch point (or hazardous area) of your press and the light curtain.

pinch point

transmitter

Distance betweenlight curtain andpinch point

One of light curtain'sinvisible light beams

receiver

Figure 2-1. Distance Between Pinch Point and Light Curtain

This distance must be greater than the calculated safety distance or Shadow may not be able to stop the press before an operator's hand reaches the hazardous area.

OSHA and ANSI Requirements

All machine safeguarding devices, including Shadow VI, must be located at the correct safety distance from the pinch point or hazardous area. OSHA regulations govern the mounting of infrared light curtains when used with mechanical power presses (OSHA 1910.217). The OSHA formula has been used as a guide in other applications since there has not been a well-known formula for safety distance which governs general machine guarding.

When calculating safety distance, Wintriss, on the other hand, recommends that you use the formula from ANSI B11.1-2009. This formula represents a new consensus on the proper installation of light curtains. ANSI B11.1 has been developed specifically for guarding of mechanical power presses. However, it should be used as a guide in other applications as

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well. For complete information on OSHA regulation 1910.217 and ANSI standard B11.1-2009, see the Appendix, found at the end of this manual.

Both the ANSI and OSHA formulas are explained below. If you need assistance in calculating the safety distance, call Wintriss Tech Support.

The OSHA Safety Distance Formula

DANGER! INCORRECT SAFETY DISTANCE

• Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area.

• Mount your light curtain heads at least 7.5” (191 mm) from the hazardous area, regardless of the calculated safety distance.

• Be sure your value for Ts includes the response times of all devices that react to stop the press. If your measurement of stop time does not include response time of the press control, light curtain, and any other devices that react to stop the press, the safety distance will be too short.

Failure to comply with these instructions will result in death or serious injury.

DANGER! STOPPING TIME TOO LONG

Use a brake monitor where a Shadow light curtain is used to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA 1910.217 (c) (3) (5). A brake monitor continually checks that the machine’s stopping time does not exceed a predetermined limit.

Failure to comply with these instructions will result in death or serious injury.

The OSHA safety distance formula as specified in OSHA regulation 1910.217 is explained below. As noted earlier, Wintriss recommends you use the American National Standards Institute formula for calculating safety distance because it contains more factors that allow you to calculate the safety distance more precisely. The ANSI formula is explained in the next section.

Here is the OSHA safety distance formula as specified in OSHA 1910.217:

Ds = 63 inches/second x Ts

63 inches-per-second is the OSHA-recommended hand-speed constant.

Ds is OSHA safety distance in inches

Ds = 63 x Ts

Ts is the stopping time of the press (or other machine) in seconds, measured at approximately 90° of crankshaft rotation (or at maximum velocity). Ts must include: all components that are involved in stopping the press; response time of the press control that activates the brake and response time of the light curtain (30 ms for 6" through 24" models; 35 ms for 30" through 48" models; 40 ms for the 60" model); plus response time of other devices if also involved in stopping the press.

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Since some increase in stop time can invariably be anticipated due to clutch/brake system deterioration, a percentage factor must also be added to the actual measured stop time of your press when determining your safety distance.

A percentage factor of 20 percent is recommended for presses with new brakes or brakes in good condition; a percentage factor of 10 percent is recommended for presses with older brakes. This is because the stopping time for older brakes will be longer due to wear. Therefore, you add less time for older brakes.

An example of calculating the safety distance using the OSHA formula

The OSHA formula for finding safety distance is: Ds = 63 inches/sec. x Ts

We will use a stop time of .190 seconds for this example. This includes reaction time of all devices noted above in signaling the press to stop except the response time of the light curtain. Next we will add in Shadow VI response time and the braking percentage factor. Let's say our brakes are new. Then we will add 20% additional time to the stop time measurement (.20 x .190 = .038). We also add response time of the 60” Shadow VI (.040 seconds). Then:

Ts = .190 sec. + .038 sec + .040 sec.

(braking factor) (Shadow VI response time)

Ts = .268

Now, we will calculate safety distance:

Ds = 63 in/sec x Ts

Ds = 63 x .268

Ds = 16.88 in.

Shadow VI heads must be mounted more than 16.88 inches from the hazardous area using the OSHA formula.

The ANSI Safety Distance Formula

DANGER! INCORRECT SAFETY DISTANCE

• Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area.

• Mount your light curtain heads at least 7.5” (191 mm) from the hazardous area, regardless of the calculated safety distance.

• Be sure your value for Ts includes the response times of all devices that react to stop the press. If your measurement of stop time does not include response time of the press control, light curtain, and any other devices that react to stop the press, the safety distance will be too short.

Failure to comply with these instructions will result in death or serious injury.

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DANGER! STOPPING TIME TOO LONG

Use a brake monitor where a Shadow light curtain is used to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA 1910.217 (c) (3) (5). A brake monitor continually checks that the machine’s stopping time does not exceed a predetermined limit.

Failure to comply with these instructions will result in death or serious injury.

This is the ANSI B11.1 safety distance formula that Wintriss recommends:

Ds = 63 x (Ts + Tc + Tr + Tbm) + Dpf

Ds is the ANSI safety distance in inches.

K is the OSHA-recommended hand-speed constant. This constant is 63 inches-per-second. The hand-speed constant indicates how far you could theoretically move your hand and arm in one second.

It is very similar to OSHA's formula, except that it takes more details (such as response times, brake monitoring setting, and depth penetration factor) into account. Ts, Tc, and Tr are the worst case response times of the press (or other machine) Ts, the control Tc, and the light curtain Tr.

Ts is the stopping time of a press (or other machine) in seconds. It is measured at approximately 90° of crankshaft rotation (or at maximum closing velocity). Tc is the response time of the press control or other machine control. This is the time it takes for the control to activate the press's brake.

Tr is the response time of the light curtain. Response time for the Shadow VI is 30 to 40 ms (30 ms for 6" to 24” models, 35 for 30” to 48” models and 40 ms for the 60” model).

Tbm is the additional stopping time of the press (or other machine) allowed by the brake monitor. The brake monitor you use with your press control (or other control) stops the press when the preset stop time is exceeded. This means excessive brake wear has occurred. It is time for repair. The brake gradually wears until the limit is reached.

Tbm allows you to account for brake wear. You add the extra time allowed by the brake

monitor to Tc and Ts. In other words:

Tbm = brake monitor setting — (Tc + Ts)

Now the gradual increase in stopping time as the brake wear is accounted for up to the limit.

What if you did not account for brake wear? The safety distance would be right at the time you measured stop time. But as the brake gradually wore, safety distance would be too short for proper operator protection.

See instructions for your brake monitor to determine the proper brake monitor setting. Generally, the setting is 120% of the measured stopping time (Tc + Ts) when your brakes are new. It is 110% of stopping time (Ts + Tc) for older brakes.

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(The stopping time for older brakes will be longer due to wear. Therefore, you add less time for older brakes. This way, the brake monitor setting comes out approximately the same whether the brakes are new or old).

Dpf is the depth penetration factor, and equals 3.3" (8.4 cm). This is a measure of how far an object, like an operator's hand, can move through the light curtain before the light curtain reacts. Dpf is related to the object sensitivity.

Object sensitivity is the smallest diameter object that Shadow VI will detect anywhere in its field. Object sensitivity (S) for Shadow VI is 1.25" (3.2 cm), with beam centers of 3/4" (1.9 cm). An object smaller than 11/4" diameter could pass through the light field if it traveled in a path directly between the light beams. European standards discuss object sensitivity as it relates to the type of detection provided. For example, object sensitivity of less than 0.6” (1.5 cm) provides finger detection. Object sensitivities greater than 0.6” and up to 1.3” (~3.3 cm) offer hand detection. Object sensitivities within the hand detection range are equally effective.

For Shadow VI with one beam blanked, refer to the section "Blanking windows affect safety distance" further on in this chapter.

An example of calculating the safety distance using ANSI formula

Here is an example of how to use the formula to calculate safety distance (Ds): First take a look again at the formula we must use:

Ds = K x (Ts + Tc + Tr + Tbm) + Dpf

Let's use these numbers for our variables in the formula:

K (hand speed constant) = 63 inches per second (set by OSHA)

Ts + Tc = 0.190 sec.

We include Ts and Tc together because many stop time measuring devices measure stopping time of the press control as well as the stopping time of the clutch/brake mechanism.

Tr = .040 sec. (response time of Shadow VI)

Tbm = 0.228 sec. (brake monitor setting) – 0.190 sec = .038 sec.

Dpf = 3.3

Now let's put our numbers into the formula:

Ds = K x (Ts + Tc + Tr + Tbm) + Dpf

Ds = 63 x (0.190 + .040 + .038) + 3.3

Ds = (63 x .268) + 3.3

Ds = 16.88 + 3.30

Ds = 20.18"

The distance the light curtain must be mounted from the pinch point in our example is 20.18". When using the formula, be sure to do all calculations in this order:

(1) Add Ts + Tc + Tr + Tbm first.

(2) Multiply the result by 63.

(3) Add this result to Dpf. This is Ds.

If you do not follow this order, your safety distance calculation will be incorrect.

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Perimeter Guarding

DANGER! CONTROL INSIDE THE GUARDED AREA FOR PERIMETER GUARDING

Install the light curtain control outside the guarded area for perimeter guarding applications.

Failure to comply with these instructions will result in death or serious injury.

For perimeter safeguarding, there is another consideration: walking speed combined with the hand speed. This is because personnel might be walking while simultaneously reaching into a safeguarded area. Although there is no commonly accepted “walking speed constant” like the “hand constant,” you might use ergonomic tables or possibly even 100 inches per second, which is a conservative European “speed constant.” For perimeter guarding, the formula would be:

Ds = (100) x (Ts + Tc + Tr + Tbm) + Dpf

Blanking Windows Affect Safety Distance

If you use a blanking window or floating blanking window, safety distance is affected, because you are changing the sensitivity of the light curtain. Remember, the minimum size that Shadow VI can sense is an object 1.25" (3.17 cm) in diameter. Anything smaller might fit between two light beams. This diameter (1.25") is called the object sensitivity of the light curtain.

A blanking window or floating blanking window blocks one light beam, creating an additional 3/4" (1.9 cm) passageway through the light field where no object will be detected. Now the object sensitivity equals 2" (5.08 cm) wide (11/4"+ 3/4") and the Dpf = 5.9" (15 cm).

The ANSI safety distance formula states that if object sensitivity increases, the safety distance must also increase. This means that use of blanking windows will require moving the light curtain farther back from the hazardous area. The rule of thumb for increasing safety distance is this: Add 2.6" (6.6 cm) to the calculated safety distance for every blanking window used up to 2 beams maximum.

However, if the area blanked is entirely blocked by a fixture such that operator intrusion into this area is impossible, then you do not have to change the safety distance. For instance, you might have a work table that juts out into the light field but takes up the whole space between the transmitter and receiver which is unprotected by the light curtain.

You can blank more than one beam of the light curtain by adding slave windows to the master blanking window. Always remove blanking windows when they are no longer required.

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Pass-through Protection

DANGER! OPERATOR CAN BE BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA

Ensure that the operator cannot position him- or herself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee-to-waist height to prevent the operator or a passerby from being “trapped” between the light curtain and the hazard.

Failure to comply with these instructions will result in death or serious injury.

Another important impact on safety distance is “pass-through protection”. To illustrate, consider that you have determined your safety distance to be 12 inches from the hazardous point of operation — “pinch point”. There is a danger that a person could become trapped between the light curtain and the pinch point.

A recommendation would be to install a second set of light curtains at waist height mounted horizontally between the vertical light curtain and the hazard. See the illustration below. With Shadow VI, two sets of optic heads can be wired to the same control box.

Press pinch point

horizontal set

vertical set

safety distance

Figure 2-2. Plan View Illustrating “Pass Through” Protection

The size of the horizontal light curtain should be the minimum length necessary to detect the thinnest operator standing between the vertical light curtain and pinch point. For example, a 6" light curtain located in the center of a 12" safety distance at waist height may be reasonable.

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Height Considerations

DANGER! IMPROPER INSTALLATION

Ensure that the light curtain is installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the machine without being detected. Use the correct height light curtain, combined with ancillary physical guards.

Failure to comply with these instructions will result in death or serious injury.

DANGER! OPERATOR CAN BE BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA

Ensure that the operator cannot position him- or herself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee-to-waist height to prevent the operator or a passerby from being “trapped” between the light curtain and the hazard.

Failure to comply with these instructions will result in death or serious injury.

Once you have determined the correct safety distance, you must select the proper curtain height. Shadow VI comes in sizes ranging from 6" to 60". Shadow must be installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the press without being detected. This is accomplished with the proper height light curtain, combined with ancillary physical guards.

Designing and Mounting Brackets

Once you have calculated the correct safety distance, you can mount your Shadow transmitter and receiver at this distance from the nearest pinch point (or other hazardous area of the press). This set of steps lists all the information and dimensions you need to know to do a good job in designing and mounting brackets. It covers:

1. What requirements you must meet when choosing your mounting location.

2. How to design and mount the brackets so that the Shadow heads can be easily aligned.

3. Maximum openings for side guards used with Shadow light curtains for three-sided guarding.

4. Mounting Shadow light curtains with mirrors.

5. Mounting Shadow light curtains upside down.

A careful reading of this material will ensure that you will not have trouble mounting and aligning your Shadow light curtains. After you read this material, design and mount your brackets.

Universal Mounts

The Shadow VI transmitter and receiver come with universal mounts. These universal mounts are located at the top and bottom of each head and are held into place by mounting

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screws. They can be rotated ±30° to facilitate installation and alignment. If you need to pivot a bracket more than 30°, remove the screws, move the bracket 90°, and reattach the bracket to the head.

Mounting Location Requirements

DANGER! IMPROPER INSTALLATION

Ensure that the light curtain is installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the machine without being detected. Use the correct height light curtain, combined with ancillary physical guards.

Failure to comply with these instructions will result in death or serious injury.

DANGER! OPERATOR CAN BE BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA

Ensure that the operator cannot position him- or herself between the light curtain and the hazardous area. Use another pair of light curtains or a mechanical barrier at knee-to-waist height to prevent the operator or a passerby from being “trapped” between the light curtain and the hazard.

Failure to comply with these instructions will result in death or serious injury.

There are two ways to mount the Shadow universal mounts. You can either mount them parallel to the light beam. Or mount them perpendicular to the light beam, as might be done on a gap frame press. When choosing the mounting location, you must make sure the location meets these requirements:

1. Shadow VI heads must always be installed so that it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the press without being detected.

2. The units must be protected from pathways used by forklifts, die carts, and other material-handling equipment.

3. The mounting location must allow unobstructed access to the point-of-operation.

4. Shadow light curtains must be located at an adequate safety distance from the point of operation (pinch point) to allow time for the press to stop once the light curtain has been interrupted. This is explained in the section "Calculating the safety distance" earlier in this chapter.

5. Every route to the press's pinch point or hazardous area must be guarded. Shadow VI transmitter and receiver by themselves provide guarding on one side of the press. Mirrors used with Shadow VI can provide 3-sided protection by "bending" the light curtain around the hazardous point-of-operation. When Shadow mirrors are not used in conjunction with the light curtain, however, other guarding means (such as mechanical side-guards) must be substituted for them, in accordance with OSHA/ANSI guidelines.

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How to Design and Mount Brackets or Floor Stands

You mount the light curtains to floor stands or to brackets on your machinery using the Shadow flanges on the top and bottom of each unit. Wintriss does not supply brackets or stands with Shadows. You must supply your own.

This section lists the factors you must consider when designing and mounting brackets or stands. If you need more specific information about designing and mounting brackets for your particular machinery, do not hesitate to call our technical services department.

If you cannot make your own brackets, we can also give you information on where you can buy various types of brackets. Brackets must meet these four conditions:

1. They must provide a rigid mounting surface for the Shadow heads. With stands, they must be rigidly attached to the floor.

2. They must bring the Shadow heads out far enough away from the point of operation to exceed the calculated safety distance.

3. They must allow the light curtain to be easily aligned.

4. They must allow you to use shock mounts to mount the optic heads. Four shock mounts are shipped for each head.

It does not matter what type of brackets you design as long as they meet these four conditions.

The illustrations (Figure 2-3) on the following page show several types of brackets you can make. It gives you an idea of just some of the types used. See Figure 2-4 and Figure 2-5 for layout and hole dimensions of the light curtain.

Brackets have to be configured to fit the shape of your particular press. For instance, on some machinery like straight side presses you can mount angle iron (L-shaped) brackets directly to a sidewall of the press (see Figure 2-8).

On other machinery, like gap frame presses or bending rolls, you may have to mount the Shadow light curtains from the bed or platform of the press.

On gap frame presses, do not attach the top Shadow VI bracket to the press frame and the bottom bracket to the bolster. The upper portion of the press will deflect (pull away) from the bolster during the work portion of the stroke.

When mounting brackets on the bolster of presses, choose your location carefully. Make sure the brackets do not prevent dies from being removed from the press. Brackets used must be made of strong, thick steel so mounting is rigid. These are only a few of the designs you can make or use. They are shown only to give you an idea of what brackets are. Many different designs are possible as long as all mounting requirements are met.

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Long angle iron type ofbracket. Here one unitmounts right on onelarge bracket.

Wedge-shaped bracket good for mountingunits to bed or wall of machinery

Box type brackets

L-shaped brackets withside supports for rigidity

Figure 2-3. Brackets for Shadow Light Curtains

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Table 2-1. Light Curtain Dimensions: inches (cm) * see Figure 2-4

Size A B C

6 (15) 7.75 (19.7) 9.5 (24.1) 11 (27.9)

12 (30) 13.75 (34.9) 15.5 (39.4) 17 (43.2)

18 (45) 19.75 (50.2) 21.5 (54.6) 23 (58.4)

24 (61) 25.75 (65.4) 27.5 (69.9) 29 (73.7)

30 (76) 31.75 (80.6) 33.5 (85.1) 35 (88.9)

36 (91) 37.75 (95.9) 39.5 (100.3) 41 (104.1)

42 (106) 43.75 (111.1) 45.5 (115.6) 47 (119.4)

48 (122) 49.75 (126.4) 51.5 (130.8) 53 (134.6)

60 (152) 61.75 (156.8) 63.5 (161.3) 65 (165.1)

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1.2(3)

.12(.3).5 (1.3)

.75(1.9)

2.1 (5.3)2.75 (7)

BC

A

.28 (.7)

.75 (1.9)1.63(4.1)

seeTable2-1

2.34(5.9)

2.55 (6.5)2.1 (5.3)

1.5(3.8)

1.5(3.8)

locationof1stbeam

2.5 (6.4)(min. req'dblk. wind. cableallowance)

3 (7.6)(min. req'dheads cableallowance)

blankingwindow

** Use 1/4-20 bolts for mounting

Figure 2-4. Shadow VI Optic Heads Mounting Dimensions

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3.25(82,6)

30°

1.5(38,1)

30°

1.5(38,1)

2.55(64,8)

1.05(26,7)

2.10 (53,3)2.75 (69,9)

Dimensions:inches(mm)

Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts)

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Shadow optic heads must be attached at both ends so that vibration does not cause the units to go out of alignment. It is all right to mount Shadow VI brackets to your press at one end only (to the bolster of a press, for instance). However, the bracket must be designed so that the shock mounts supplied with your heads can be placed between the head and the bracket.

You can mount your Shadows directly to a vertical wall or column of your press if the location meets all mounting requirements, including safety distance.

Installing Brackets with Alignment in Mind

The bracket design must allow adjustment of the Shadow VI heads once they are mounted. Shadow light curtains may have to be moved slightly up or down or rocked slightly to one side or the other to align them once they are mounted (you will see why when we discuss alignment).

As we mentioned earlier the Shadow universal mounts allow subtle adjustments of the heads. These mounts can be rotated ±30° to facilitate installation and alignment. If you need to pivot a bracket more than 30°, remove the mounting screws, move the bracket 90°, and reattach the bracket to the head.

Alignment Considerations

Although Shadow is easy to align and tolerant of vibration and shock, optic life is improved by alignment optimization.

Optimum alignment can easily be accomplished using the optional Laser Alignment Tool (see "Using the Laser Alignment Tool" later in this section), which slides along the groove on either optic head.

As long as the phototransistor's field is anywhere within the funnel-shaped path of the light beam, Shadow will align. The optic heads don't have to be perfectly aimed (see Figure 2-6).

What alignment means

The alignment procedure is explained in the section "Aligning and tightening down Shadow VI components". For Shadows to operate properly, each infrared LED emitted horizontally from the Shadow transmitter must be detected by each PT in the receiver.

The PTs as well as the LEDs are located on the front of each unit. You cannot see them but their location can be determined using the alignment indicator guides on the Shadow receiver. To find the mating beam on the transmitter, use the same measurement from the base of the receiver to the lowest indicator guide. Each LED must match up with its opposite phototransistor when the Shadow light curtains are mounted as shown in the next illustration. Therefore, Shadow optic heads must be mounted in the same plane.

You should always try to mount the brackets as precisely as possible. Then, the alignment procedure in the section "Aligning and tightening down Shadow VI components" will be easy. Also note that the optic heads don't have to be mounted vertically (although this is certainly a common approach). They can be mounted at any angle as long as they are in the same plane.

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receiver

phototransistor(PT)

transmitter

funnel-shaped

light path

If PT is in funnel-shapedlight path, Shadow is inalignment, even if optic

heads are notperfectly aligned.

light beams

plane ofalignment

Figure 2-6. Transmitter and Receiver Properly Aligned

receivertransmitter

LaserAlignment

Tool

laser'salignment path

Laser Alignment Tool is usedto achieve optimum alignment.

Installing it at the very top andvery bottom of optic head will

not block any beams.

Figure 2-7. Using Laser Alignment Tool to Properly Align Shadow

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Aligning brackets

When mounting your brackets you can draw a leveling line using the center of the bracket holes as the end points (see the next illustration). When you mount the Shadow VI flanges onto the bracket holes, the Shadow light curtains will be aligned (or at least very close).

Use a plumb or leveling line and square to properly align the brackets. Use the bed of your press (if applicable) or the floor as a leveling reference point. Make sure that the brackets are placed in the same plane.

levelling lines through center of bracket holes

bracket

top mounting holes

Figure 2-8. Aligning Brackets Using Mounting Holes So Shadow Light Beams Line Up Later When Mounted

Maximum Openings for Side Guards

When mechanical side guards are used in addition to the Shadow light curtains for three sided-guarding, you must ensure that the openings between or around the guards meet OSHA requirements. You must also make sure that the openings in the guard material itself (wire, extruded mesh, rods, etc.) or openings between the guards and working surface meet OSHA requirements.

OSHA requirements for the maximum openings allowed in guards or between the guards and the top and bottom of the working surface are listed in OSHA Table 0-10. See Table 2–2.

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Table 2-2. OSHA Table 0-10

Distance of opening from pinch point

Maximum Dimension of Opening

1/2" to 1 1/2" 1/4"

1 1/2" to 2 1/2" 3/8"

2 1/2" to 3 1/2" 1/2"

3 1/2" to 5 1/2" 5/8"

5 1/2" to 6 1/2" 3/4"

6 1/2 to 7 1/2" 7/8"

7 1/2" to 12 1/2" 1 1/4"

12 1/2" to 15 1/2" 1 1/2"

15 1/2" to 17 1/2" 1 7/8"

17 1/2" to 31 1/2" 2 1/8"

Using Mirrors with Shadows

NOTICE MIRRORS DECREASE SCANNING DISTANCE AND ANGLE OF DIVERGENCE

• Allow for a reduction in scanning range of 10% for each mirror you use. For example, if your extended range unit normally scans 50’ and you use two mirrors, it will now scan 40’ (50’ minus 10’).

• Allow for a reduction in angle of divergence if you use mirrors. This greatly reduces the light curtain’s tolerance of vibration and makes alignment more critical.

You can use mirrors with Shadow VI for two- or three-sided guarding. Wintriss offers front-reflective mirrors that provide optimal light transmission or reflection. Mirrors can be optionally purchased from Wintriss. Dimensions for mirrors are shown in Figure 2-9.

Wintriss does not recommend the use of other mirrors or other reflective surfaces as they may severely reduce vibration tolerance or scanning distance. The Shadow transmitter and receiver are aimed at the mirrors. The light beam is reflected from the transmitter to the receiver by way of the mirrors. This method could be used on any type of machinery where three-sided guarding is needed. When using mirrors, your setup will look similar to the drawing in Figure 2-10. You do not have to arrange the Shadow light curtains and mirrors in a rectangle as shown, however.

You can adjust the mirrors to reflect light from the Shadow VI transmitter at other angles besides right angles. Shadow VI aligns in the same way using mirrors as without them. Even though the transmitter and receiver will not be pointed at each other, the units and the mirrors

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must be mounted in line with each other so each phototransistor in the receiver can detect the light beam coming from its opposite light emitter. The Laser Alignment Tool (illustrated in Figure 2-6 and Figure 2-7) is a useful tool when installing mirrors.

.19(.48)

1.75(4.45)

1(2.54)

.75 (1.91)

See table

50°MAX

1(2.54)

Top view

3.89(9.88)

2.25(5.72)

4.62 (11.73)3.75 (9.53)3.25 (8.26)

2(5.08)

A B C D

Model A B C D

6” 8 9.38 11.88 12.64

12” 14 15.38 17.88 18.64

18” 20 21.38 23.88 24.64

24” 26 27.38 29.88 30.64

30” 32 33.38 35.88 36.64

36” 38 39.38 41.88 42.64

42” 44 45.38 47.88 48.64

48” 50 51.38 53.88 54.64

60” 62 63.38 65.88 66.64

Figure 2-9. Shadow VI Mirror Dimensions

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receivercornermirror

light beams

transmittercornermirror

Figure 2-10. Representation of Shadow with Mirrors for Three-sided Guarding

Use of Laser Alignment Tool Is Useful During Mirror Installation

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Using Weld Shields

The operation of Shadow VI is not affected by smoke, dirt, or oil found in a typical industrial environment. In a more severe environment, you may need to install clear plastic shields that provide protection from weld splatter and other hazards.

Weld shields are clear plastic covers that fit on the face of the transmitter and/or receiver. They come in kits ready for installation and can be easily replaced if they become so damaged or scratched that the light curtain no longer indicates “green” during normal operation. (see the Troubleshooting Guide in Chapter 4 of this manual).

If you want to install a weld shield, you must order a separate kit (weld shield #42873xx, where “xx” is the height of the optic head in inches) for each optic head. Detailed instructions for installation are included in each kit, along with the necessary screw and clip(s). Each optic head has a screw hole for mounting a shield.

Mounting Shadow Light Curtains Upside Down

There is nothing inherent in the design of Shadow VI heads that prevents them from being mounted upside down. If you are mounting Shadow VI this way for any reason, both heads must be inverted. Shadow heads can also be mounted at any angle as long as they are in the same plane. Vertical mounting is the easiest.

Avoiding Cross Talk When Mounting 2 Sets of Shadows

Because the receiver only accepts infrared light pulses of a certain duration in proper sequence, Shadow cannot be affected or fooled by other light sources. All other continuous light sources and even pulsed light sources are "tuned out", and Shadow continues to work. Also, changes in area lighting or even flashing strobe lights will not affect operation. Even if the Shadow receiver were flooded with infrared light of the same intensity, the receiver would not be fooled because it only accepts light pulses of the right frequency in proper sequence. Instead it would send a stop command to the press.

In some cases, however, using two sets of Shadows in close proximity of each other may cause "cross talk". Cross talk occurs when the LEDs from the first set's transmitter are detected by the phototransistors from the second set's receiver.

If your application requires that you mount a set of Shadows horizontally next to a vertical set to detect an operator between the vertical set and the pinch point, you may need to alternate these sets to avoid any incidence of cross talk between sets. To do this, you may need to mount the horizontal transmitter next to the vertical receiver and vice versa.

Another scenario where cross talk may occur involves machines that are close together. Use caution if the guarded machines are too close together, such that the light from one transmitter may be detected by the other press's receiver.

To avoid any incidence of cross talking, you can select from several solutions. One is to insert a barrier of some type, such as a blind, between the two sets of Shadow heads. Make sure that the barrier runs all the way from the transmitter to the receiver. A second approach is to reverse the position of the transmitter and receiver on the second press. Another option is a combination of the above. The next illustration shows reversing the position of the optic heads on the second press.

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Press #1

TXRX

Press #2

TX RX

Figure 2-11. One Way to Avoid Cross Talk - Reversing Transmitters (TX) and Receivers (RX)

Loosely Mounting Shadow VI Transmitter and Receiver

CAUTION FAULTY SHOCK MOUNT INSTALLATION

Install the shock mounts between the mounting surface and the universal mounting brackets that hold the optic heads in order to protect the heads from damage.

Failure to comply with these instructions could result in property damage.

Leave the Shadow VI heads loose on their mounting brackets so that you can properly determine wiring length and conduit required. You will align and tighten the heads later.

Shock mounts are provided to help protect the optic heads of your Shadow VI from damage due to shock or vibration.

Follow the steps below to loosely mount the optic heads (transmitter and receiver).

1. Locate four mounting holes for each head, in either your brackets or on a solid surface as described above. The shock mount studs have 1/4-20 threads. For installation into a solid surface, use a No. 7 drill and 1/4-20 tap. For through-installation onto a metal bracket, drill clearance holes.

2. Before mounting the optic heads, install four shock mounts for each head. Thread a shock mount into each of the four tapped holes in the mounting surface (Figure 2-12, next page), or use a lock washer and nut to secure each shock mount to a metal bracket.

3. Using lock washers and nuts, loosely mount the optic heads onto the shock mounts, as indicated in Figure 1.

4. Follow the instructions below to complete the installation. You will align and adjust the heads (page 61) after you mount and wire the control.

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Universalmounting bracket

Shock mount(4 places)

Lock washer(4 places)

Nut(4 places)

Optic head(transmitter or receiver)

Mounting surface

Figure 2-12. Mounting an Optic Head with Shock Mounts

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Mounting the Control

DANGER! CONTROL AFFECTS LIGHT CURTAIN OPERATION

Install the light curtain control in a location where access to it will not affect the operation of the light curtain.

Failure to comply with these instructions will result in death or serious injury.

DANGER! CONTROL INSIDE THE GUARDED AREA FOR PERIMETER GUARDING

Install the light curtain control outside the guarded area for perimeter guarding applications.

Failure to comply with these instructions will result in death or serious injury.

1. Determine an appropriate location to mount the control. It should be mounted in an area where personnel can easily see the warning indicators and also have access to the circuitry, without interfering with the operation of the light curtains. The control must never be installed inside the protected area in perimeter guarding applications. The enclosure can be mounted to the press, on a free-standing pedestal, on a pendant, or at the entrance of a location used for area guarding.

2. Drill four holes for mounting, and tap, if necessary. Shock mount studs are 1/4-20. Mount the enclosure using the enclosed shock mounts and mounting flanges. Use a No. 7 drill and 1/4-20 tap. Refer to Figure 2-13 for mounting dimensions.

Connecting RF (Radio Frequency) Ground

To reduce electromagnetic interference, connect the RF ground terminal on the top of the control enclosure (Figure 2-13) to a clean ground using a low-impedance ground strap. If your installation does not experience electromagnetic interference, you may not need to use this additional grounding.

NOTICE A clean ground is a connection to the earth separate from the electrical service (green wire)

ground.

A low-impedance ground strap is made from braid at least 1/2” (1.25 cm) wide.

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0.31(0.79)

4 places

9.00(22.86)

CURTAINCLEAR

FLOATINGWINDOW

STOPSIGNAL

RESETREQUIRED

RESETOPERATE

LIGHT CURTAIN

9.75(24.76)

Connect this terminal to a clean groundusing a low impedance ground strap.See “Connecting to RF ground.”

8-32 thread

7.00(17.78)

inches(cm)

5.00(12.7)

typical, 2 places

3.50(8.89)

Figure 2-13. Shadow VI Control Enclosure Mounting Dimensions

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TB21

1

TB1

TB4

FSD1 FSD2 STAT

MPCE1 MPCE2 RESET XMTR INT

J15J14INT

DS8

GND

DS6ON OFF PWR UP

RESETDISABLE

RESET ONINTERRUPT

S4

S1FLOATINGWINDOW

STAT=GRN

OPTIONS

TRANSMITTER 2VCR VCC GND SHUTDOWN SYNC SHIELD

VCR VCC GND SHUTDOWN SYNC SHIELD

TRANSMITTER 1

TB31

FWIN VCC GND 2A SYNC SHIELD2B

FWIN VCC GND 1A SYNC SHIELD1B

RECEIVER 2

RECEIVER 11 SET

J12

DS5

TB51

GRN AMB RED YEL V-OUTJ13

F2

F3

K1 K2

F1S2

115 V

DS1 DS2

K3

F4

CAUTION

POWERTRANSFORMER

POWER TB1

VOLTAGESWITCH

J11DISPLAYCONNECTOR

OPTIC HEADSPOWER LED

DS4

OPTIC HEADSPOWER LED

DS3

OBSTRUCTIONLEDS

SS INDICATOROUTPUTS 1 SET/2 SETS

JUMPERS

UPPER 1 - 10 (#1)UPPER 1-10 UPPER 1 - 10 (#1)

STOP CIRCUITS TRANSMITTERRECEIVER

LOWER 11 - 20 (#2)LOWER 11 - 20 LOWER 11 - 20 (#2)

STATUSRELAY

KEYLOCKSWITCH

CONNECTOR

FUSES

MPCE1JUMPER

MPCE1 LED

MPCE2 LED

MPCE2JUMPER

TRANSMITTERACTIVE

LED

RESET ONLED

Figure 2-14. Location of Components, Shadow VI Control

(Important components shown and labeled)

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Wiring the Transmitter and Receiver to the Control

DANGER! FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES

CANNOT BE STOPPED IN MID-STROKE OR MID-CYCLE

• DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped at any point in its stroke or cycle.

• Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle.

Failure to comply with these instructions will result in death or serious injury.

DANGER! PRESS MAY CONTINUE TO MOVE AFTER INTRUSION

• Ensure that Shadow is wired to the emergency stop circuitry of the press.

• Ensure that any stop initiated by the light curtain is an immediate stop, one that occurs immediately after the stop signal is sent to the machinery. (If the light curtain is wired by mistake to the top-stop circuitry, the press continues its stroke until it reaches the top of the stroke, even after an intrusion or obstruction is detected.)

Failure to comply with these instructions will result in death or serious injury.

DANGER! STOP CIRCUITS NON-OPERATIVE IN SOME MODES

Wire the light curtain to your press control circuit so the stop signal from the light curtain stops the machine immediately in all modes of operation, including inch.

Failure to comply with these instructions will result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD

• Ensure that the power source is off before you make any wiring connections.

• Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Ensure that all procedures are performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

NOTICE LOCKOUT MAY NOT BE REQUIRED

If light curtains are installed so they are active in all press operating modes, it may not be necessary to lock out the press during routine die changes. Refer to the relevant safety standards for more details.

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The instructions below describe how to wire the Shadow transmitter and receiver to the control.

Terminating Shields of the Head Cables, next section

Connecting the Head Cables to the Control, page 47

If You Have a Second Set of Shadow Optic Heads, page 49

Terminating Shields of the Head Cables

The shields of the head cables must be terminated close to their entry into the control box. Follow the instructions in this document for terminating these cable shields.

Follow the steps below to terminate the shields of the cables that connect to your light curtain heads. Refer to the figure above, the tables on the next page and the figure at the end of this document.

1. Strip the cable jackets back as far as the end of the conduit fittings.

2. Cut the drain wires to a length that they can reach and be inserted into the set screw terminal.

3. Loosen the set screw in the set screw terminal. Twist together the ends of the drain wires and insert in the hole in the set screw terminal under the end of the set screw.

4. Tighten the set screw and check that all drain wires are firmly connected.

5. Connect the rest of the wires in the cables to the terminal blocks as instructed in the next section.

Set screw terminal Drain wires

Figure 2-15. Terminating Drain Wires to Set Screw Terminal

Showing Connection for Two Pairs of Heads

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Connecting the Head Cables to the Control

NOTICE Terminate the shields of the head cables as instructed in the previous section.

1. Find the two interchangeable quick connect cables, and plug them into the bottom of the transmitter and receiver. The connection is keyed. Twist the locknut so the connection is tight.

2. Run the cables through separate 1/2" flexible, liquid-tight conduits from the Shadow VI transmitter and receiver to the knockouts at the bottom of the control (receiver should go into right front knockout and transmitter into the center). Because the control enclosure is rated NEMA 2/IP52, you must use conduit of the same rating and make proper connections to ensure suitable protection with the enclosure.

NOTICE If you have a second set of Shadow heads, wire them through the remaining knockouts.

3. Next you need to properly terminate the conduits at the transmitter and receiver. You can use either of these approaches or one of your own. In either case, you must supply your own parts.

a. Use cord grips to secure the cables in the liquid-tight conduits and 1/2" hose clamps to support the conduits in place close to the transmitter and receiver.

b. Use 2 junction boxes located near the transmitter and receiver to secure the cables and the liquid-tight conduits.

4. Open the control by loosening the locking screw. Terminate the cable shield for each cable as described in the next section.

5. Locate terminal blocks TB2 and TB3. Refer to the location of components pictured in Figure 2-14 earlier in this chapter. Notice that there are actually two connectors at TB2 and two at TB3. If you have only one set of Shadow heads, the receiver will be wired into the upper level TB2 connector, and the transmitter into the upper level TB3 connector. If you have a second set, they are wired into the lower levels of TB2 (receiver 2) and TB3 (transmitter 2).

NOTICE LABEL CABLES CAREFULLY

Carefully label the transmitter and receiver cables inside the control. This will help troubleshoot the light curtains after installation, if necessary.

If you connect two sets of heads, be sure to separately label the cables for set #1 and set #2.

5. Measure the wires to fit and cut the wires as necessary.

6. Start by wiring the receiver. Remove the L-shaped connector from TB2 (upper level). Attach the wires to this connector as shown in Table 2-3 at the end of this section. You can also refer to Figure 1 at the end of this manual.

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To connect a wire, find the correct terminal and loosen the screw over it by turning it counterclockwise. Strip the correct wire for this terminal 1/4" (6.4 mm) from end. Insert bare wire into the terminal 90% of the way. Tighten the screw. The metal tooth inside the terminal will clamp down on the bare wire for a tight connection. Make sure that the metal tooth is clamped down on the bare part of the wire, not on the insulation.

7. Once you have completed the wiring for the receiver, plug the L-shaped connector firmly back into its base. It only can go in one way.

8. Now wire the transmitter. Remove the L-shaped connector from TB3 (upper level). Attach the wires to this connector as shown in Table 2-4 at the end of this section. You can also refer to Figure 1 at the end of this manual.

9. Once you have completed the wiring, plug the L-shaped connector firmly back into its base. It only can go in one way.

10. Make sure you have properly connected all wires and have double checked all connections when done.

Table 2-3. Connecting Light Curtain Receiver Head to TB2 in Controller

Set #1 Heads to Upper Level; Set #2 Heads to Lower Level

RCVR TB2 Wire color Terminal signal

Pin #1 orange FWIN

Pin #2 red VCC

Pin #3

blue and

black

GND

Pin #4 brown 1B

Pin #5 green 1A

Pin #6 yellow SYNC

Terminate shield to set screw terminal near entry point. (See “Terminating Shields of the Head Cables,” page 46.)

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Table 2-4. Connecting Light Curtain Receiver Head to TB3 in Controller

Set #1 Heads to Upper Level; Set #2 Heads to Lower Level

XMTR TB3 Wire color Terminal signal

Pin #1 orange VCR

Pin #2 red VCC

Pin #3

blue and

black

GND

Pin #4 brown SHTD

Pin #5 green SHTD

Pin #6 yellow SYNC

Terminate shield to set screw terminal near entry point. (See “Terminating Shields of the Head Cables,” page 46.)

If You Have a Second Set of Shadow Optic Heads

NOTICE W HEN USING TWO SETS OF HEADS

• Carefully label the transmitter and receiver cables for set #1 and set #2. This will help with troubleshooting your Shadow installation, if necessary.

• Run the cables for set #2 in a separate conduit from set #1’s cables.

• Set Jumper J12 to “2 SETS.” See page 61.

If you have a second set of optic heads, follow the steps in the previous section to connect the head cables of the second set of heads to the lower level of TB2 (receiver 2) and TB3 (transmitter 2) in the control. Run the cables in separate conduits. Refer to Tables 2-3 (for receiver) and 2-4 (for transmitter).

Set Jumper J12 to “2 SETS.” This enables operation of the second set of heads. See page 61.

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Connecting AC Wiring to the Control

WARNING! ELECTRIC SHOCK HAZARD

• Ensure that the power source is off before you make any wiring connections.

• Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Ensure that all procedures are performed by qualified personnel.

• Complete all installation procedures before connecting wires to the AC power source.

Failure to comply with these instructions could result in death or serious injury.

Wiring is a straightforward and simple procedure. The control is wired to a 115 VAC 50-60 Hz single phase power source. (Note: Shadow VI can also be used with 230 VAC, 50 Hz. Step 4 below explains how to switch to 230 VAC.)

Follow these wiring guidelines:

• All wires can be run through a flexible liquid-tight conduit to the control as long as all circuits are the same voltage. If your emergency stop circuits are low voltage circuits (such as 24V), run two conduits— for instance, one for 115V wires and one for 24V wires.

• Bring the wiring connections for AC power to a convenient point so that you can tie them to the appropriate connector. No. 16 wire is recommended for these circuits (No. 14, if local codes require it).

Follow the steps below to connect AC wiring to your control.

1. Open the control. Near the top left of the control board, you will see the connector for AC power (terminal block TB1) and the power supply (to the right of TB1).

TB1

Figure 2-16. Terminal Block TB1 Connections

2. Determine how you will bring wiring from your 115 VAC power source (or 230V source if applicable) to the knockout hole at the top of the unit. These wires should be connected directly to the press control transformer. For 115 VAC, you need three wires—high (red), neutral (white) and ground (green).

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3. Locate the 115V-230V voltage selector switch (S2) on the control board. It is located just below TB1. If your AC power is 115V, check to see that "115V" is displayed in the switch cavity. If your AC power is 230V, push the handle down.

115V

Handle.Pushdownfor 230V

Figure 2-17. Setting Voltage Selector Switch S2

4. Run the power wires to the control enclosure. If your stop circuits are 115V, the AC wiring and stop circuits will enter the enclosure through the same flexible, liquid-tight conduit (ideally, top). If the stop circuits are 24V, then 115V goes through the top knockout and 24V goes through the bottom left (refer to the next section for specific instructions). To maintain the control enclosure's NEMA 2/IP52 rating, you must use conduit of the same rating and make proper connections to the control.

5. Make proper AC wiring connections as shown in wiring diagram Figure 6 at the end of this manual.

6. Connect the electric service ground (green) wire to the set screw terminal on the inside left side of the enclosure, as shown below.

Connect AC ground wire(green) to set screwterminal

Ground wire pre-wiredto stud on case

TB11 2 3 4

Figure 2-18. Connecting to Protective Earth Ground Set Screw Terminal

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7. Leave a service loop at the control to allow for later adjustment of the conduit. Cut the wires as necessary. Proceed to the next section "Connecting Stop Circuits to the Control". Do not connect wires to AC power source until you are done with all other installation procedures.

Connecting Stop Circuits to the Control

DANGER! FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES

CANNOT BE STOPPED IN MID-STROKE OR MID-CYCLE

• DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped at any point in its stroke or cycle.

• Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle.

Failure to comply with these instructions will result in death or serious injury.

DANGER! PRESS MAY CONTINUE TO MOVE AFTER INTRUSION

• Ensure that Shadow is wired to the emergency stop circuitry of the press.

• Ensure that any stop initiated by the light curtain is an immediate stop, one that occurs immediately after the stop signal is sent to the machinery. If the light curtain is not correctly wired in this way, the press may continue its stroke after an intrusion is detected.(

Failure to comply with these instructions will result in death or serious injury.

DANGER! STOP CIRCUITS NON-OPERATIVE IN SOME MODES

Wire the light curtain in series with your press control circuit so the stop signal from the light curtain stops the machine immediately in all modes of operation, including inch.

Failure to comply with these instructions will result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD

• Ensure that the power source is off before you make any wiring connections.

• Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Ensure that all procedures are performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

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NOTICE LOCKOUT MAY NOT BE REQUIRED

If light curtains are installed so they are active in all press operating modes, it may not be necessary to lock out the press during routine die changes. Refer to the relevant safety standards for more details.

Wiring the control into your press's emergency stop or equivalent circuitry (e.g. emergency stop circuitry) ensures that whenever an obstruction or intrusion is detected, the press will stop as quickly as its clutch/brake system (or other system) will permit.

Follow these instructions to connect to a traditional relay control. If you are connecting to a PLC, refer to the instructions at the end of this section. Bring the wiring connections for the emergency stop circuits to a convenient point so that you can tie them to the appropriate connector. No. 16 wire is recommended for these circuits (No. 14, if local codes require it).

1. Determine how you will connect the wires from the control to your press control emergency stop circuit. You wire the circuit at your press control. Refer to Figure 2 or Figure 3 at the end of this manual and your press control manual or other electrical prints. You need two wires for the emergency stop circuit.

2. As we mentioned in the previous section, if your stop circuits are 115V, the AC wiring and stop circuits will enter the control through the same conduit (ideally, top). If the stop circuits are 24V, then 115V goes through the top knockout and 24V goes through the bottom left.

3. If entering from the top, make sure that you carefully dress the two wires neatly to the left inside the control.

CAUTION TERMINAL BLOCK TB4 WIRED INCORRECTLY

Wire stop circuits to the upper level of terminal block TB4, not the lower level. If you wire to the lower level, this could damage components on the circuit board.

Failure to comply with these instructions could result in property damage.

4. Now locate terminal block TB4 on the control circuit board to wire the emergency stop circuits. Notice that there are two levels at TB4 - "upper" and "lower". The stop circuits must be wired into the upper (higher) level connector. There is also a "lower" TB4 connector on the control circuit board.

5. There is one factory-installed jumper in place on the upper TB4 connector between pins 3 and 5 (see Figure 2 or Figure 3 at the end of this manual). Make sure this jumper is firmly installed. Do not remove this connector or the jumpers!

There is one factory-installed jumper (XMT INT) in place on the lower TB4 connector between pins 19 and 20 (see Figure 2 or Figure 3 at the end of this manual). Make sure this jumper is firmly installed. Do not remove this connector! Remove this jumper only if you use an external transmitter interrupt.

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If you plan to perform optional wiring (for instance — MPCE monitor inputs or external interrupt), refer to the section "Optional Wiring", found later in this chapter for additional information.

immediate stop

FSD1(1-3)

FSD2(4-6)

STATUS(7-9)

TB4

Figure 2-19. Relays Wired to Emergency Stop Circuit, Typical

active in all modes of operation

When wiring Shadow VI into the press circuit, you should ensure that it is active in all modes of operation. This would include inch, single stroke, and continuous. Following this practice will provide safety for setup personnel as well as the operator. In some cases, having Shadow VI active in all modes may even eliminate the need for lockout during a die change. See OSHA 1910.147 "Lockout/Tagout" for details. (Note: For PLC connections, see step 8B.)

The next set of instructions explains how to continue to wire the relays in series. Refer to the instructions below. The corresponding wiring schematics (Figure 2) can be found at the end of the manual.

6. Connecting in series with Machine Emergency Stop (Figure 2):

CAUTION TERMINAL BLOCK TB4 WIRED INCORRECTLY

Wire stop circuits to the upper level of terminal block TB4, not the lower level. If you wire to the lower level, this could damage components on the circuit board.

Failure to comply with these instructions could result in property damage.

Refer to Figure 2 to connect the two stop relays in series with the press's emergency stop circuit. The relays, which are labeled "FSD1" and "FSD2," are located on the upper level of the TB4 connector on the control circuit board. The descriptions of these terminal locations are as follows:

FSD1: Final switching device #1 (stop output relay #1) FSD2: Final switching device #2 (stop output relay #2)

At the upper level of TB4, connect pins #2 and #6 in series with the press's stop circuits.

Do not remove the factory-installed jumper across #3 and #5.

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FSD1(1-3)

FSD2(4-6) (7-9)

TB4

GND

N/C N/OCom. N/C Com. N/O

factory-installed jumperacross #3 and #5

N/C Com. N/O

Status outputStop output

Figure 2-20. Wiring "Upper" TB4 Connector in Control

7. Once you have completed the wiring of the relays (according to step 6), remember to leave a service loop at the control to allow for later adjustment of the conduit. Cut the wires as necessary.

Keep going in this section to connect to WPC or a PLC. If you do not need to perform either if these installation procedures, skip to the next section "Making settings inside the control".

NOTICE Guidelines for making these connections are covered in these steps:

8A. Wiring Shadow to the WPC

8B. Wiring Shadow to a programmable logic controller (PLC)

8A. Wiring Shadow to the WPC (One or Two Control Boxes)

If you are connecting the control to WPC, see Figure 6 at the end of this manual. To connect 2 control boxes, refer to Figure 7 also found at the end of the manual. It shows how Shadow must be connected to the resolver-based WPC. If you have a WPC 1000 see Figure 10 at the end of the manual. If you have an older-model WPC, refer to Figure 9 at the end of the manual.

Once you make connections, proceed to the next section "Making settings inside the control". If you have the optional Shadow VI-WPC control board, refer to Appendix C and Figure 8 for specific instructions.

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8B. Wiring Shadow to a PLC

DANGER! INCORRECT WIRING TO A PLC

• Ensure that the light curtain control is properly wired to your PLC.

• Follow the guidelines in the applicable ANSI standard, ANSI B11.1. The guidelines below serve as a reminder of the importance of connecting your light curtain correctly when using a PLC. Do not wire the outputs in series when connecting Shadow to a PLC.

• Be aware that the details of wiring and programming the PLC are solely your responsibility, and not Wintriss’s.

• Use a single safety PLC or multiple non-safety PLCs.

Failure to comply with these instructions will result in death or serious injury.

CAUTION TERMINAL BLOCK TB4 WIRED INCORRECTLY

Wire stop circuits to the upper level of terminal block TB4, not the lower level. If you wire to the lower level, this could damage components on the circuit board.

Failure to comply with these instructions could result in property damage.

When wiring the control to a Programmable Logic Controller (PLC) or other type of microprocessor-based control, two (or more) independent logic systems should be used to control the press's stop circuit. Wintriss does not provide specific step-by-step instructions for connecting Shadows to PLCs. This is because of the variety of PLCs and the various programming techniques used. Only general guidelines are supplied in this section. Refer to Figure 4 at the end of the manual for suggested wiring.

We recommend you carefully study the ANSI guidelines in Appendix C of the ANSI B11.1 standards before connecting Shadow to a PLC. Appendix C gives detailed guidelines for using PLCs to control the clutch and brake on metal stamping presses. Appendix C is entitled "Some Considerations for Design of Microprocessor-Based Clutch/Brake Controls."

To ensure maximum safety, you must wire and program the PLC so it can detect an internal component failure and immediately stop the press. Both outputs from Shadow's control relays must be connected separately to a PLC. These outputs are marked "FSD1" and "FSD2" (see Figure 2-20). You must remove the factory-installed jumper (as shown in Figure 4 at the end of the manual) when connecting to a PLC.

Next, you must create a program that will check each input signal from the Shadow relays independently. The program should stop the press immediately if the input signals ever differ. That way, a component failure within the PLC will be immediately detected. Also, with Shadow relays wired to the PLC separately, if one of Shadow's control relay contacts were to weld shut preventing the stop signal to the PLC, the other relay contact would still open to send the stop signal.

If you do not connect the control to the PLC properly, here is what could happen. A component in the PLC fails. This causes the PLC to incorrectly read the input signals. Even

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though Shadow signals a stop, the PLC does not stop the press. This situation must not be allowed to occur.

If the control is connected to a PLC instead of directly to the machinery, then the PLC must be able to transfer Shadow's control reliability capability to the press stop circuit. If this capability is overridden or if the PLC cannot detect a failure of its own components, much of Shadow's protection features are lost even though Shadow is working properly. This is why it is essential that you do not override Shadow's control reliability features when using Shadow with a PLC. After completing this step, proceed to the next section.

Shadow allows you to test your PLC's input modules, adding another level of safety to your operation. Wire the PLC to the transmitter interrupt at pins #19 and #20 on TB4 auxiliary connector. (Be sure to remove the factory-installed jumper at pins #19 and #20.) The PLC can momentarily interrupt the transmitter's function (#19, #20 at TB4), watch the redundant output relays open, and then resume the transmitter's operation and watch the relays close. If the input modules do not respond properly and simultaneously, the PLC can inhibit the press from further operation until the PLC inputs have been checked out.

Optional Wiring

This section provides instructions to wire various optional Shadow VI features, including remote reset, indicator outputs, and MPCE monitor input.

Indicator Outputs

DANGER! INDICATOR OUTPUTS NOT SUITABLE FOR SAFETY USE

• DO NOT use the indicator outputs listed in the specifications table for personnel protection. They cannot be used to stop the machinery.

• Use only the safety outputs for personnel protection.

Failure to comply with these instructions will result in death or serious injury.

You can wire up to 4 indicator outputs to customer-supplied solid-state relays.

These outputs, which are open collectors to ground, allow you to view Shadow's operating status at a remote location by mimicking the indicators at the Shadow control. Connect the positive input wire from your 12VDC solid-state relay to pin #5 ("V out") at TB5 connector inside the control. Wire pins #1 (Green), #2 (Amber), #3 (Red), and #4 (Yellow) as needed according to Figure 5 at the end of the manual.

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MPCE Monitor Inputs

DANGER! MPCE INSTALLATION NOT SUITABLE FOR SAFETY USE

• Install MPCE relays in pairs as instructed in this manual.

• Use only relays with forced guided type contacts for MPCE monitoring.

• Ensure that the response time of the MPCE circuitry is less than 25 ms.

• Use only the safety outputs for personnel protection.

Failure to comply with these instructions will result in death or serious injury.

To monitor the performance of your relays with the Machine Primary Control Element (MPCE) monitor inputs, connect the Shadow stop circuits to the interfacing relays, instead of connecting them in series with the machine’s immediate stop circuit or with control reliable safety relay modules.

See the figure below for an example of how to wire the MPCE inputs. Use normally closed contacts only. To monitor external MPCEs, place jumpers J14 and J15 in the EXT (external) position. See Figure 2-23. Call Wintriss Tech Support for further information.

Machine PrimaryControl Element(MPCE) Relays

2 3

11

5

4

6

3

8 1

7

2

K1

5

4

6

3

8 1

7

2

K2

FSD1 FSD2Light CurtainControl

65

USER POWER

MPCE1 MPCE2

UPPERTB4

UPPERTB4

LOWERTB4

12 13 14

Figure 2-21. Example of MPCE Usage

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Set MPCE2 at JP15

Set MPCE1 at JP14

TB21

1

TB1

TB4

FSD1 FSD2 STAT

MPCE1 MPCE2 RESET XMTR INT

J15J14INT

DS8

GND

DS6ON OFF PWR UP

RESETDISABLE

RESET ONINTERRUPT

S4

S1FLOATINGWINDOW

STAT=GRN

OPTIONS

TRANSMITTER 2VCR VCC GND SHUTDOWN SYNC SHIELD

VCR VCC GND SHUTDOWN SYNC SHIELD

TRANSMITTER 1

TB31

FWIN VCC GND 2A SYNC SHIELD2B

FWIN VCC GND 1A SYNC SHIELD1B

RECEIVER 2

RECEIVER 11 SET

J12

DS5

TB51

GRN AMB RED YEL V-OUTJ13

F2

F3

K1 K2

F1S2

115 V

DS1 DS2

K3

F4

DS3

DS4

J11

Note:Factory setting is “Internal” (INT).

For “Internal” place jumperon left-hand two pins.

For “External” placejumper on right-hand two pins.

J15J14INT J15

J14INT

J15J14INT

Figure 2-22. Setting MPCE Jumpers

Making Settings Inside the Control

Follow these steps to make the proper switch settings inside the control. Refer to the location of components found at Figure 2-14. Also look at the illustrations that follow, which show the factory settings for the switch blocks S1 and S4 and jumper block J12.

factory settings: OFF

S1

floating windowstatus relay follows

stop outputsON OFF

S4

power upreset disable

reset oninterrupt

ON OFF

Figure 2-23. Factory Settings for Switch Blocks S1 and S4

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S1 settings

1. Floating window: The "off" factory setting disables this feature. Set the switch to "on" when you want to enable this built-in floating window option. The feature provides a means for the random bypass of only one beam of the light curtain (refer to Chapter 1 of this manual for more detail). Notice that when this feature is enabled, the "floating window" indicators on the control and receiver will flash on and off.

DANGER! STATUS OUTPUT NOT SUITABLE FOR SAFETY USE

• DO NOT use the status output for personnel protection. It cannot be used to stop the machinery. It is intended only as a convenience to interface automation.

• Use only the safety outputs for personnel protection.

Failure to comply with these instructions will result in death or serious injury.

2. Status relay follows stop outputs: The factory setting is "off" which disables this feature. When the switch is "on", the status relay "mimics" the output relays. This feature can be used to turn on an alarm or beacon whenever the light curtain goes "red". No matter how this feature is set, the status function is always active.

S4 Settings

1. Power up reset disable: The "off" setting means that when Shadow is powered up, you must reset the system before proceeding. The "on" position disables the feature.

It is useful to keep the setting at "off". This is a reminder for you to ensure that the daily tests on Shadow are performed as soon as the “reset required” condition has been cleared. If your the Shadow is wired to the resolver-based Wintriss Clutch/Brake Control (WPC), disable this functionality because WPC already has this feature.

2. Reset on interrupt: The factory setting is set to "off" which disables this feature. When the switch is set to "on", if one or more of the light curtain beams have been obstructed, then a “reset required” condition will occur. When the obstruction is removed, the light curtain does not reset to "green" automatically. You must clear the condition by resetting Shadow to resume operation. This is a useful feature for perimeter guarding applications when there is a walk-in hazard inside the guarded area.

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J12 Setting

These instructions explain how to set Shadow for a second set of light curtains. The factory setting is "1 SET". If you are installing a second set of heads, follow these steps.

1. Locate jumper location J12 in the control (refer to Figure 2-14 for location of components). It is situated just above terminal block TB2 on the lower right-hand side of the board. Notice that the jumper is set on pins 2 and 3 for "1 SET."

2. Move the jumper so that it will be on pins 1 and 2 for "2 SET."

"1 SET" setting(Jumpers on bottom 2 pins)

J12J12

"2 SET" setting(Jumpers on top 2 pins)

** notice thatthere are 2jumpers sideby side at J12

Figure 2-24. Jumper Position for "1 SET" and "2 SET"

3. You will also have to perform some diagnostics to verify this setting. To do this, refer to the section, "Aligning and tightening down Shadow VI components."

Plug in Connector and Replace Cover

Now that you have completed the wiring of the control and made the proper switch settings, make sure all connections are properly plugged into position and that all conduits are in place. Close the cover and tighten the locking screw on the control. Leave the transmitter and receiver loose.

Connect 115 VAC wires from the control to the 115 VAC source. Make sure power is off before making connections.

Now go on to the next step—aligning and tightening down your Shadow VI heads.

Aligning and Tightening Down Shadow VI Components

DANGER!

HAZARDOUS EQUIPMENT OPERATING

Remove power from the press and other hazardous machinery while you are aligning the light curtain transmitter and receiver.

Failure to comply with these instructions will result in death or serious injury.

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You have wired and loosely mounted your Shadow transmitter and receiver as directed in the section "Loosely mounting Shadow VI transmitter and receiver". Now you need to test and align them. Once that is done you can tighten them using the appropriate adjustment method to keep them in alignment (such as rotating the universal mounts discussed at the beginning of this chapter).

If you suspect a problem with Shadow, verify that the heads are properly aligned. If there is still a problem, be sure to perform the diagnostic tests at the end of this chapter.

Alignment Procedure

If you have read the material in this chapter, you already know a lot about alignment. If the Shadow light curtains are out of alignment, one or more light beams from the transmitter are not being detected by the receiver. Shadow will react as if a part of the light curtain is blocked. Its relays will be open and stay open, and your press will not operate.

Proper alignment means each beam of light from the transmitter is detected by the appropriate phototransistor in the receiver. As long as you installed your brackets level and in the same plane (as described in Step 2), alignment will be very easy. Here is how to align your Shadow light curtains.

1. Make sure you have the Shadow light curtains mounted so the lenses are pointed at each another.

2. Turn on power to the Shadow light curtains. Do not start the press. You do not need to operate the press for this procedure.

3. Check the amber power light near the top of the transmitter cover. It should be on. If not re-check wiring. If you cannot find the problem, contact Wintriss Tech Support.

4. Make sure the light curtain is unobstructed. Then check the lights on the receiver. A green light means the Shadow light curtains are in alignment. A red light means they are not aligned.

5. Whether the light is green or red, experiment a little to get a feel for how precisely aligned you have to be. Your Shadow light curtains should be only loosely mounted. Tighten one unit so it will not move. Using the Shadow universal mounts mentioned at the beginning of this chapter, swivel the other one a little to see what happens. Move it a little vertically as far as the brackets will allow. Watch the lights. Note when the Shadow light curtains are aligned (green light on receiver on) and when they are not (red light on).

6. Now that you have a feel for what it takes to properly align the units, get them back in line.

7. Keep the units in alignment using the Shadow universal mounts or another method you designed. Tighten down the transmitter to take up slack, then work on the receiver. If the units go out of alignment, make adjustments, then start tightening again. When everything is right, tighten down each unit firmly.

8. Check the lights on the receiver again. The light must be green. If not, make sure the light beam is not obstructed. If the light is not green, you will have to loosen your mounting bolts, re-align, then re-tighten.

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Once your Shadow light curtains are tightened to their brackets and the light is green, you are done aligning and mounting your Shadow light curtains. Go on to the checkout procedure. Do not begin press operation until you have completed the checkout sequence.

Diagnostic Steps to Perform Before Using Shadow

DANGER! FAILURE TO PERFORM SAFETY SYSTEM TESTS

• Perform the final checkout sequence below when you have completed installation of your light curtain, before operating the equipment it is connected to.

• Operate your machinery only after your safety system meets all the requirements of the checkout sequence.

• Perform the final checkout sequence whenever repair, maintenance or modification is performed on your light curtain or the machinery it is connected to.

• Perform the “daily test” safety system checkout sequence on page 93 (in French, en Français, page 114) every day before operating any machinery connected to Shadow safety light curtains.

Failure to comply with these instructions will result in death or serious injury.

If your Shadow light curtain does not operate correctly, use the following diagnostic steps to troubleshoot and correct problems. If you need help, call Wintriss Tech Support.

No Power to Unit

If your light curtain has no power, check the power fuse F1. Also check that power connections have been done correctly. These procedures are discussed in detail in the section "Connecting AC wiring to the control" earlier in this chapter.

The Light Curtain Is in a "Reset Required" Condition

Use the reset keyswitch to clear the “reset required” condition. If this is not successful, power the system down, then up. Again, reset the system using the reset keyswitch.

If the “reset required” condition remains, check that you have correctly set the jumper settings for "1 set/2 sets". This is covered in "Making settings inside the control" in this chapter.

If the Transmitter Has No Power or Is Not Functioning

Verify your transmitter wiring and that the transmitter and receiver wiring is not reversed. Add labeling to the transmitter and receiver cables in the control if you have not already done so. Refer to "Wiring the transmitter and receiver to the control" in this chapter.

Check Power and Indicator Lights

Make sure the transmitter's amber light and red or green lights on the receiver and at the control are both on. Also check indicators — DS3 and DS4, located in the upper right-hand corner of the control near the power supply. DS3 and DS4 light up green to indicate that the optic heads are receiving power. They should be on all the time. If they are not lit, this

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means that either transmitter, receiver, or both may not be receiving power. If this is the case, run a few tests. First check that the power connections at the control have been performed correctly. (See location of components at Figure 2-14.)

If DS4 is off, test the transmitter. Unplug the quick-connect connector at the transmitter. If DS4 turns on, this means the transmitter is defective. If the indicator stays off, reconnect the transmitter. Next unplug the transmitter connector TB3 inside the control. If DS4 turns on, this means the transmitter cable is shorted and needs replacement.

If DS3 is off, test the transmitter as described above. Then test the receiver. Unplug the quick-connect connector at the receiver. If DS3 turns on, this indicates that the receiver is defective. If the indicator stays off, reconnect the receiver. Next unplug the receiver connector TB2 inside the control. If DS3 turns on, then the receiver cable is shorted and needs replacement.

Continue by checking indicators DS1 and DS2, which are red indicators that are located just above the TB2 receiver connectors at the lower right-hand corner of the board. They light up red if you are using only 1 set of curtains and there is an obstruction, misalignment, or indication of an internal problem. If you have two sets, refer to the section further down in this chapter — "If you have two sets of light curtains."

Check Lens Window

If both the amber and red lights and the indicators in the control are all on, your Shadow light curtains have power. You still need to get a green light (indicating Shadows are aligned). Make sure there is no object in the light field which you have overlooked. Then wipe off the lens window on each unit. It is possible that you got some substance on the lens window that is blocking a light beam. See "Checking lens window" in Chapter 4. If the green light comes on after you have cleaned the lens window, you are all set.

Bring Shadow Heads Close Together

If Shadow still is not working, the next step is to bring the optic heads closer. To do this, unbolt either the receiver or transmitter (whichever is more convenient). You will take the unbolted unit off its mounting and hold it right in front of the other. You may need to dis-connect wiring so the heads will reach. Power down the control before connecting or disconnecting the wires to the heads.

Once you have unbolted it and have wires connected, bring the unit within 6 to 11 inches of the other. Make sure the lenses are pointed directly at one another and you have the Shadow heads in the same plane (see Figure 2-8).

Green Light On

Shadow heads should align easily when placed very close together. If the green light is on now, you know there is a problem with your installation. Go over the mounting instructions in this chapter again to be sure you understand how Shadow heads should be mounted. Then adjust your brackets. The Shadow transmitter and receiver will then align.

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No Green Light

If you did not get a green light even after bringing the Shadows close together, your Shadows probably have an internal problem. Call Wintriss Tech Support to discuss the problem.

If You Have Two Sets of Shadow Heads

If you have two sets of Shadow heads, you should already have completed the necessary wiring explained in "Wiring Shadow heads to the control." You also made jumper settings at J12 in the control, page 61.

Next, check how the indicators — DS1 and DS2 — are lit up in the control when either of the two sets has been interrupted (see Figure 2-14 for location of components). DS1 and DS2 are located just above the TB2 receiver connector at the lower right-hand corner of the board. DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and TB3) is interrupted. DS2 corresponds with Set 2, which are wired to the lower connectors.

Green Light On But Still Cannot Start Press

WARNING! ELECTRIC SHOCK HAZARD

• Ensure that the power source is off before checking or replacing fuses.

• Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Ensure that all procedures are performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

If everything seems to be all right, but you still cannot start the press, perform the following checks. Shut off power before checking relays so that you do not get a shock! Check if one or more of the 3 output fuses (F2, F3, and F4) have failed. Replace if necessary. See "Checking and Replacing Fuses" in Chapter 4. If the press still will not start, check the control relays located above the TB4 connector inside the control. Relays have ty wraps around them to hold them tight in their sockets. Check to make sure the ty wraps are attached and relays are tight in their sockets. Also check to see if a relay has contacts that are welded shut. See “Checking and Replacing Control Relays” in Chapter 4 for relay location and procedure.

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Final Checkout Sequence

DANGER! FAILURE TO PERFORM SAFETY SYSTEM TESTS

• Perform the final checkout sequence below when you have completed installation of your light curtain, before operating the equipment it is connected to.

• Operate your machinery only after your safety system meets all the requirements of the checkout sequence.

• Perform the final checkout sequence whenever repair, maintenance or modification is performed on your light curtain or the machinery it is connected to.

• Perform the “daily test” safety system checkout sequence on page 93 (in French, en Français, page 114) every day before operating any machinery connected to Shadow safety light curtains.

Failure to comply with these instructions will result in death or serious injury.

DANGER! CHANGE IN STOPPING TIME REQUIRES SAFETY DISTANCE ADJUSTMENT

• Repair your machinery stopping mechanism if its stopping time increases beyond the acceptable limit.

• Re-calculate the light curtain safety distance, using the new stopping time.

• Adjust the location of the light curtain(s) accordingly.

• Perform the checkout sequence before operating the equipment.

Failure to comply with these instructions will result in death or serious injury.

You have followed the installation steps in this chapter to correctly install your Shadow safety light curtains. Now perform the checkout sequence to make sure your safety system is working properly.

You must perform a checkout sequence after mounting and wiring are complete and before you use Shadow safety light curtains with your machine.

It is also imperative to perform the checkout sequence every time any maintenance, repair or other modification is performed on a Shadow safety light curtain unit or on the machinery connected to the light curtain.

NOTICE Use opaque test bars of 1 1/4" (32 mm) and 1/8” (3.2 mm) diameter for performing the

checkout sequence. If you are using the Floating Window option, also use a 2" diameter test bar as instructed below.

Perform the daily test in Appendix A every day before operating the press. Follow the checkout sequence below every time you repair, maintain or modify the press.

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1. Have ready 1-1/4" (32 mm) and 1/8” (3.2 mm) opaque test bars. If your light curtain has floating window, also have ready a 2” (50.8 mm) opaque test bar. Turn on power to Shadow safety light curtain and to the machine.

2. Make sure the floating window option has been disabled, if your light curtain has it, by setting the "floating window" switch at switch block S1 (in the control) to the “OFF” position (see “Making Settings Inside the Control,” page 59).

NOTICE LIGHT CURTAINS EQUIPPED WITH FLOATING WINDOW OPTION

Indicators on the receiver and on the control blink to indicate that floating window has been enabled. This indicator should be off when you perform this checkout procedure with the 1 ¼” test bar. Later you will enable floating window and repeat the test with the 2” bar .

3. Using the 1-1/4" (32 mm) diameter test bar, interrupt the sensing field on the receiver side by passing the test bar from the top to the bottom of the receiver's lens cover. The red light should come on while the test bar is in the sensing field.

4. Repeat step 3, passing the 1-1/4" (32 mm) diameter test bar from the top to the bottom of the transmitter's lens cover. The red light should stay on while the test bar is in the sensing field.

5. Block the light curtain so that the red light is on; verify that the machine will not start while the light curtain is obstructed.

6. Using the 1/8” (3.2 mm) diameter test bar, interrupt the sensing field on the receiver side by passing from the top to the bottom of the receiver’s lens cover. The green light should remain on. If the red light comes on, realign the heads to prevent nuisance stops.

7. Repeat step 6, passing the 1/8” diameter test bar from the top to the bottom of the transmitter’s lens cover. The green light should remain on. If the red light comes on, realign the heads to prevent nuisance stops.

NOTICE If muting is used, interrupting the light curtain during the non-hazardous portion of the stroke

(upstroke) will not stop the machine. To test, you must interrupt the stroke on the downstroke, which is the hazardous portion of the stroke.

8. Start the machine and interrupt the light field with the 1-1/4" (32 mm) diameter test bar. The red indicator light on the receiver should come on and the machine should stop immediately.

NOTICE Step 9 applies specifically to presses with single cycle and cycle stop capability. If you

cannot single stroke or top stop your press, carry out all steps except Step 9. You must ensure that your Shadow meets the requirements of the other steps before using the Shadow-equipped equipment. Remember, your press must be able to stop when the light beam is broken.

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9. Single stroke the machine and make sure it stops at top dead center. Make sure the machine's braking system is working properly. If the machine does not stop fast enough, adjust the braking system or increase the light curtain's safety distance.

10. Test the floating window option if you have it:

• If the light curtain does not have the floating window option, go to the next step.

• If your light curtains have floating window, enable it and repeat the steps above with the 2” (50.8 mm) test bar instead of the 1 ¼” test bar.

11. You have completed the Checkout Sequence.

• If your Shadow safety light curtain performed as described in the checkout sequence, you can now begin to operate your machinery.

• If your light curtain did not perform as indicated, and you are still experiencing problems, refer to the complete Troubleshooting guides in Chapter 4. For further technical assistance, call Wintriss Tech Support.

If your Shadow safety light curtain did not work exactly as described in this chapter, there is a problem with your mounting or with the Shadow itself. DO NOT operate the machinery until all conditions of the checkout sequence are met.

See "Chapter 4. Troubleshooting Shadow Safety Light Curtains" to see if you can solve the problem by making some simple checks described in that chapter. If the safety system still does not work properly, contact Wintriss Tech Support for assistance.

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Chapter 3 – Fixed and Floating Blanking

DANGER! INCORRECT SAFETY DISTANCE

Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

Failure to comply with these instructions will result in death or serious injury.

External fixed blanking is an option available with Shadow. With fixed blanking, you can disable light beams in an area where a fixture penetrates the light field, and you can permit stationery objects to protrude into Shadow's sensing field.

As an example, in a situation where a conveyor or work table extends into the light field, it would not be feasible to move the fixture. Therefore, by installing a blanking window on the Shadow receiver where the fixture penetrates the field, you disable the light beam that would normally have detected the fixture. However, if penetration occurs anywhere above or below the blanked beam, the light curtain will send a stop signal to the machinery.

The built-in floating window feature provides a means for the random bypass of only one beam of the light curtain. It is useful in those applications where material or air ejected parts randomly travel through or within the sensing field. The floating window may only be used when material or parts take up a space no greater than 11/8" (2.9 cm) within the sensing field. Larger material would block more than one light beam at a time. As a result, the light curtain would generate a stop command.

You can enable the floating window feature by turning a switch "on" inside the control. The orange indicators at the receiver and on the cover of the control flash to let you know floating window has been enabled. Floating window automatically alters the object sensitivity from 11/4" to 2". If you use this feature, even occasionally, the safety distance for mounting must be increased. Refer to "Calculating Safety Distance" in Chapter 2 of this manual.

Floating window can also be used in conjunction with fixed blanking. For example, you can use both in an application where part of the tool protrudes into the light field and an air-blow-off is ejecting parts. Instructions for installing and/or enabling both of these features are covered in this chapter.

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Blanking Windows Affect Safety Distance

DANGER! INCORRECT SAFETY DISTANCE

Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

Failure to comply with these instructions will result in death or serious injury.

DANGER! UNPROTECTED ZONE DUE TO EXTRA BLANKING WINDOWS

• DO NOT blank more than two beams of the light curtain unless a conveyor or other object completely fills the blanked area, or if you use barrier guards to block any unfilled areas.

• Remove blanking windows when they are no longer needed.

• Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

IMPORTANT

Refer to Chapter 2 in this manual for more information on safety distance, object sensitivity, and depth penetration factor.

If you use a blanking window or floating blanking window, safety distance is affected, because the sensitivity of the light curtain is altered. The minimum size that Shadow can sense is an object 11/4" (3.2 cm) in diameter. This diameter, called the object sensitivity of the light curtain, is the smallest diameter object that Shadow will detect anywhere in its field. Anything smaller might fit between two light beams.

You must also consider the depth penetration factor (Dpf) which is 3.3" (8.4 cm) for an unblanked Shadow. This factor represents how far an object, such as an operator's hand, can move through the light path before the light curtain reacts. Depth penetration factor and object sensitivity are interrelated.

A blanking window blocks one light beam, creating an additional 3/4" (1.9 cm) passageway through the light field where no object will be detected. Now the object sensitivity equals 2" (5.08 cm) wide (11/4"+ 3/4") and the depth penetration factor is 5.9" (15 cm).

The ANSI safety distance formula stipulates that if object sensitivity increases, the safety distance must also be increased. This means that using fixed or floating blanking will require moving the light curtain farther back from the hazardous area.

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Adding to Safety Distance for Fixed Blanking

DANGER! INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS

• Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

• When more than one beam is blanked, but the blanked area is not completely obstructed, the depth protection factor is at least 36” (914.4 mm).

• Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage.

• Remove blanking windows when they are no longer needed.

Failure to comply with these instructions will result in death or serious injury.

Use this rule of thumb for increasing safety distance. Add 2.6" (6.6 cm) to the calculated safety distance for every blanking window used.

On the other hand, if the blanked area is entirely blocked by a fixture from the transmitter to the receiver such that operator intrusion into this area is impossible, then you do not have to change the safety distance. For instance, you might have a work table that extends into the light field but takes up the whole space between the transmitter and receiver which is unprotected by the light curtain.

Adding to Safety Distance for Floating Window

DANGER! INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW

• Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

• Add 2.6” (6.6 cm) to the calculated safety distance when you use floating window. This compensates for the change in object sensitivity to 2” from 1 ¼”.

Failure to comply with these instructions will result in death or serious injury.

As with fixed blanking, using the floating blanking window feature affects safety distance because the sensitivity of the light curtain is altered. If you enable the floating window option in the control, add 2.6" (6.6 cm) to your calculated safety distance. By doing this, you compensate for the increased object sensitivity when floating window is enabled (from 11/4" to 2").

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Installing Blanking Windows

Blanking windows are easy to install. If you are blanking more than one beam, you attach the master blanking window first and connect "slave" blanking windows above it. This increases the blanked area. The maximum number of beams that can be blanked is 5.

Because blanking windows attach to the receiver, they are clearly visible to personnel. As a result, it is obvious when a beam is blanked.

Installing the Master

DANGER! INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS

• Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

• When more than one beam is blanked, but the blanked area is not completely obstructed, the depth protection factor is at least 36” (914.4 mm).

• Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

DANGER! UNPROTECTED ZONE DUE TO EXTRA BLANKING WINDOWS

• DO NOT blank more than two beams of the light curtain unless a conveyor or other object completely fills the blanked area, or if you use barrier guards to block any unfilled areas.

• Remove blanking windows when they are no longer needed.

• Maintain access to blanking master or slave windows under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

NOTICE Install the master blanking window at the lowest blanked beam. Install slaves above the

master.

Here are steps to install the master blanking window. If you are blanking more than one beam, you attach the master blanking window first and connect slave blanking windows above it (installing slaves is discussed in the next section).

1. Locate the master blanking window. Notice a cable is attached at one end. The other end of the cable has a connector that screws into the mating connector at the top of the receiver. See the illustration in Figure 3-1 to locate each component.

2. The master blanking window attaches to the receiver by sliding it down from the top (it can also be slid up from the bottom). Determine which light beam to blank. If you

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intend to blank more than 1 beam, install the master blanking window on the lowest blanked beam at this time. (The next section explains how to install the slave.)

3. Position the master blanking window over the front of the receiver. Loosen the thumbscrew on the right side. This will allow it to slide down easily.

receiver

masterblankingwindow

cable attachesat top

thumbscrew

matinghole

remove protectivecap to attach cable

(must notinterfere withlight beams)

alignmentindicators

blanking window connector

Figure 3-1. Connecting Master Blanking Window

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slide blankingwindow up or

down the grooveon receiver

cut-away representing top of receiver

plastic coverings havebeen removed to allow

stacked windows

part ofmaster cable

shownthumbscrew

grooves on window helps fitone on top of the other

(no cable with slave)

alignmentindicators

Figure 3-2. Close-up — Installing Blanking Window

4. Press down firmly on the blanking window, and line it up between the alignment indicators on the receiver. If you need to adjust the blanking window back up, press down on the top of the receiver end cap as you push the master upward.

5. Once the blanking window is in the desired location, retighten the thumbscrew so it fits firmly into the mating hole.

6. Next, guide the master blanking cable to the top of the receiver.

NOTICE Be careful that the cable does not interfere in any way with the light path. If the cable is

routed in front of the receiver, you may inadvertently be blocking other light beams.

7. Locate the plastic cap attached to the mating connector at the top of the receiver. If it is difficult to remove, carefully unfasten it from the threads by twisting and turning back and forth. Once the cap is removed, the cable connector goes into that location.

8. Position the blanking window connector directly over the keyed connector at the top of the receiver. The keyed connector has three pins which must fit into holes in the cable connector. Twist the connector slightly until you feel the pins fit into the base. Then screw the nut on the connector to tighten the cable connector in place.

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9. Notice the 2 tiny plastic coverings on the top of the master blanking window. These should remain in place unless you plan to add more slave blanking windows (next section).

10. You are done connecting the master blanking window. The beam you selected has been physically disabled. It will not detect any object penetrating the light path.

Installing Slave Windows

DANGER! INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS

• Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

• When more than one beam is blanked, but the blanked area is not completely obstructed, the depth protection factor is at least 36” (914.4 mm).

• Maintain access to blanking master and slave windows under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

DANGER! UNPROTECTED ZONE DUE TO EXTRA BLANKING WINDOWS

• DO NOT blank more than two beams of the light curtain unless a conveyor or other object completely fills the blanked area, or if you use barrier guards to block any unfilled areas.

• Remove blanking windows when they are no longer needed.

• Maintain access to blanking master or slave windows under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

You can add up to 4 slave blanking windows to the master. Follow these steps.

1. Locate the slave blanking window. If you have more than 1 slave, repeat these steps for each.

2. Just as with the master, the slave blanking window attaches to the receiver by sliding it down from the top (must be above the master or another slave). See Figures 3-1 and 3-2 from the previous section.

NOTICE The master blanking window must always be installed at the lowest blanked beam. Install

slaves above the master.

3. Remove the 2 tiny plastic coverings on the top of the master blanking window. Remember these should only be removed when you plan to add slave blanking windows.

4. Position the slave window over the front of the receiver. Loosen the thumbscrew on the right side of the slave window. This will allow it to slide down easily.

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5. Press down firmly on the slave blanking window so that it lines up between the alignment indicators on either side of the receiver. Make sure that the pins in the slave blanking window fit properly into the mating connector holes on the top of the master. If you need to adjust the blanking window back up, press down on the top of the receiver end cap as you push the slave upward.

6. Retighten the thumbscrew on the slave window so it fits firmly into the mating hole. Notice that there is no cable or cable connection that needs to be made for the slave.

7. If you need a larger blanked area, you can add another slave window (up to 4 slaves). Repeat the previous steps. Remember to remove the 2 tiny plastic coverings at the top of the lower slave window. Then carefully fit the pins at the upper slave window into the mating holes at the lower one.

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Floating Window

DANGER! INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW

• Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

• Maintain access to blanking windows and floating window under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

The built-in floating window feature provides a means for the random bypass of only one beam of the light curtain. It is useful in those applications where material or air ejected parts must pass through, or move within the sensing field in a random pattern.

The next illustration shows how coil stock cuts different light beams as the coil unwinds. As long as only one beam is cut at a time (no matter which one it is), Shadow continues to allow machinery to operate.

coil stockstraightener

light beams

Figure 3-3. Coil Stock Unwinding Using Floating Window

The floating window may only be used when material or parts take up a space no greater than 11/8" (2.9 cm) within the sensing field. Larger material would block more than one light beam at a time and send a stop command.

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Adding to Safety Distance for Floating Window

DANGER! INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW

• Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance. If you purchased Shadows with a floating window, you must add 2.6" (6.6 cm) to the safety distance. This 2.6" (6.6 cm) addition compensates for the change in object sensitivity of Shadows with floating windows (from 1 1/4" to 2").

• Maintain access to blanking windows and floating window under supervisory control to avoid unauthorized usage.

Failure to comply with these instructions will result in death or serious injury.

As with fixed blanking, using the floating blanking window feature affects safety distance because the sensitivity of the light curtain is altered. If you enable the floating window option, add 2.6" (6.6 cm) to your calculated safety distance. By doing this, you compensate for the change in object sensitivity when floating window is enabled (from 11/4" to 2").

How to Enable the Floating Window

The floating window feature is enabled by turning a switch "on" at switch block S1 inside the control. This procedure is explained in detail in the section "Making switch settings" in Chapter 2. The indicators both on the receiver and on the front of the control will flash, reminding you that floating window has been enabled.

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Chapter 4 – Troubleshooting Shadow VI

DANGER! UNAUTHORIZED REPAIRS

• Replace only the control relays, fuses and indicator lamps.

• Obtain replacement control relays, fuses and indicator lamps from Wintriss Controls.

• DO NOT replace any other components. If you do, this will violate the warranty.

• Ensure that repairs are made by qualified personnel. Improper repair by unqualified personnel may put operators at risk of injury.

Failure to comply with these instructions will result in death or serious injury.

CAUTION MAKING OR BREAKING CONNECTIONS WITH POWER ON

Power down Shadow before connection or disconnecting any connections at the control, transmitter or receiver.

Failure to comply with these instructions could result in property damage.

Shadow VI has complex electronics. You should not attempt to test or repair components on the Shadow circuit boards unless authorized to do so. That level of troubleshooting and repair must be left to technicians trained in Shadow operation.

However, there are some tests and repairs you can perform yourself, and they are included in this chapter. In many cases, you will be able to get an inoperative Shadow working again just by changing a blown fuse, replacing control relays, or re-aligning.

How to use this chapter

This chapter covers how to make some Shadow repairs and adjustments and includes several troubleshooting procedures. Two charts found at the beginning can be used as quick troubleshooting reference guides.

Start with Table 4-1. This chart is useful if your Shadow VI comes with either 1 or 2 sets of optic heads. The first column provides common symptoms. The next columns identify how the indicators will or will not light up when the symptoms occur. The "Action" column briefly recommends steps to take to correct the problem. The last column "Chapter Reference" tells you where to go in the manual (if applicable) for complete, detailed instructions. Table 4-2 refers to those systems with 2 sets of optic heads. In this chart there is an extra column (first one) which identifies which set of optic heads is affected and how it corresponds with the "indicator" columns. Following the charts there are checks that you can make yourself, if your Shadow stops working or gives you trouble.

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• Checking and Cleaning Lens Window(s), page 87

• Checking Alignment, page 87

• Checking and Replacing Fuses, page 88

• Checking and Replacing Control Relays, page 89

• Checking and Correcting Cross Talk, page 91

For many of the procedures provided, you can correct the problem yourself. However, if you find serious problems, the defective component (optic head or control circuit board) must be factory-repaired. However, once you know which unit is bad, you may be able to substitute another unit for the faulty one until the repairs are made.

Description of Shadow VI Indicators

Shadow includes several indicators. Figure 1-1 in Chapter 1 shows the indicators on the transmitter and receiver, and Figure 1-2 illustrates the control.

These indicators communicate Shadow's operating status. Use them to troubleshoot your light curtain (refer to the Troubleshooting guides that follow). If a contradiction exists between the indicator lights at the receiver and those at the control, make sure you compare your findings with the information in these troubleshooting guides to solve the problem immediately.

At the Optic Heads

The transmitter has an amber-colored power indicator which remains illuminated when Shadow has power. There are three indicators on the front of the receiver. The red indicator means that the light curtain has been interrupted. The orange indicator flashes when the floating window option is turned "on" at the control (see Chapter 2). The green indicator means the light curtain is unobstructed.

At the Control

Four indicators appear on the front cover of the control and are clearly labeled. The green "curtain clear" indicator means that the light curtain is unobstructed and the machinery will be allowed to operate (the control relay contacts are held closed or in the unobstructed/ energized state). The "floating window" indicator lights up amber when this blanking feature is enabled inside the control (see Chapter 2). The "stop signal" indicator goes red when the light curtain is obstructed, the control relay contacts are open (or in the de-energized state) and the press is disabled, or when Shadow has detected an internal malfunction. The yellow "reset required" indicator signifies that a reset-required condition exists. This could occur during power-up, when certain settings are enabled at the control (see Chapter 2), or if Shadow detects an internal malfunction with the components (transmitter, receiver, or control).

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Inside the Control

There are eight LED indicators on the circuit board inside the control (refer to Figure 2-14 in Chapter 2 for location of components).

DS1 and DS2 are located just above the TB2 receiver connectors at the lower right-hand corner of the board, and do not light up under normal conditions. However, they light up red if you are using only 1 set of curtains and there is an obstruction. If you have 2 sets, DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and TB3) is interrupted. DS2 corresponds with Set 2, which are wired to the lower connectors.

DS3 and DS4, located in the upper right-hand corner of the control near the power supply, normally light up green all the time, indicating that the optic heads are receiving power.

DS5 and DS6 are located in the lower left corner of the board below TB4. They light up orange when you are using external MPCE monitoring and there is an obstruction in the light field. See “External MPCE Monitoring: Checking DS5 and DS6” on page 85.

DS7 is located in the lower left corner of the board below TB4. It is off under normal conditions, but lights up yellow when “Reset” is on.

DS8 is located in the lower left corner of the board. Under normal conditions, it lights up green, indicating that the transmitter is active.

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Table 4-1. Shadow troubleshooting guide for 1 or 2 sets

Control

Des

crip

tio

n

Tra

nsm

itte

r

Rec

eive

r

Ind

icat

ors

*

Action

.

Ch

apte

r re

f.

No power to unit. Off Off All Off

Off Off 7 Off 8 Off

1. Check power fuse F1. 2. Check power connection.

4 2

Optic heads are blocked.

Amb Red Red Red 3 Grn4 Grn

7 Off 8 Grn

1. Make sure a part of the machinery or other object is not inadvertently protruding into the light field.

2. Clean lens cover(s) if necessary.

3. Check alignment. Realign if necessary.

- 4 2, 4

Machine will not start. (Scenario 1)

Amb Grn Grn Off 3 Grn4 Grn

7 Off 8 Grn

1. Check if one or more of the 3 output fuses (F2, F3 or F4) has failed. Replace if necessary.

2. Check if one or more of the 3 output relays has failed OPEN (high resistance). Replace if necessary.

3. If you are not using the MPCE or transmitter interrupt inputs, make sure the appropriate jumpers are in place at TB4. See “Wiring Shadow 3 X Series Light Curtain.”

4. If you are using one or more of the inputs listed above, the user interfacing relay circuit(s) should be CLOSED. If any user interfacing relay circuit is OPEN, replace the relay or repair the circuit as necessary.

5. To further troubleshoot your MPCE monitoring circuit, see “External MPCE Monitoring: Checking DS5 and DS6” on page 85.

4 4 2 - 4

Machine will not start. (Scenario 2)

Amb Grn Red Red 3 Grn4 Grn

7 Off 8 Off

1. If you have an external Transmitter interrupt circuit, check to make sure it is operating properly. Repair if necessary.

2. If you do not have an external Transmitter Interrupt circuit, check the XT INT (transmitter interrupt) jumper on lower TB4, between pins 19 and 20, to make sure it is correctly installed and not loose.

3. Contact Wintriss Tech Support.

2

-

* “Red” = One or both of these LEDs light up red. “Off” = both are off.

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Troubleshooting Shadow VI Chapter 4 page 83

Table 4-1. Shadow troubleshooting guide for 1 or 2 sets (continued)

Control D

escr

ipti

on

Tra

nsm

itte

r

Rec

eive

r

Ind

icat

ors

DS

1 &

2

*

Action

.

Ch

apte

r re

f.

Unit is in “reset required” condition. (Note NOTICE message below.)

Amb Grn Red +

Yel

Off 3 Grn4 Grn

7 Off 8 Grn

1. Turn reset keyswitch to Reset. 2. Power down, then up. Turn reset keyswitch to

Reset. 3. Make sure that 115 V/230V switch inside control is

set correctly. 4. Check both jumpers at J12 (1 SET vs.

2 SET designation) are set correctly. 5. Check for loose output relays. If any

are loose, tighten ty-wraps. 6. Check that the factory-installed jumper at TB4 (stop

outputs terminal block) is intact and not loose.

7. Check relays for weld shut or stuck open.

-

2 2 4 2 2

Cannot reset (Scenario 1)

Amb Red Red +

Yel

Red 3 Grn4 Grn

7 Off 8 Grn

1. Remove any obstructions between the optic heads. Follow the instructions under “Optic heads are blocked” at beginning of this table.

Cannot reset (Scenario 2)

Amb Grn Red +

Yel

Off 3 Grn4 Grn

7 Yel 8 Grn

1. Check reset key to see if it is stuck in the “Reset” position. If it is, contact Wintriss Tech Support.

2. Check your external reset circuit to see if it is stuck “on.” If it is, repair it.

-

NOTICE You cannot clear a “reset required” condition unless the optic heads are properly aligned and the

indicator(s) on the receiver(s) light up green. If the receiver(s) indicate a red condition, you will not be able to reset the system by turning the reset keyswitch on the control. You first must properly align the optic heads and check that the indicator(s) light up green.

Transmitter has no power or is not functioning.

Off Red Red Red (1 or both)

3 Grn4 Grn

7 Off 8 Grn

1. Check transmitter wiring.

2. Check whether transmitter and receiver wiring is reversed. If you cannot trace the cables, go to the section that immediately follows Table 4-2 for further action.

2 2

Transmitter power supply is not functioning.

Off Red Red Red 3 Grn4 Off

7 Off 8 Grn

1. Unplug transmitter connector at transmitter. If DS4 turns ON, transmitter is defective.

2. If DS4 stays OFF, reconnect transmitter. Unplug transmitter connector at control. If DS4 Turns ON, transmitter cable is shorted and must be replaced.

2 2

* “Red” = One or both of these LEDs light up red. “Off” = both are off.

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Table 4-1. Shadow troubleshooting guide for 1 or 2 sets (cont.)

Control D

escr

ipti

on

Tra

nsm

itte

r

R

ecei

ver

Ind

icat

ors

DS

1 &

2

*

Action

.

Ch

apte

r re

f.

Receiver head is not getting power. OR Transmitter logic is not getting power.

Amb Off Red Red 3 Off4 Grn

7 Off 8 Grn

1. Unplug receiver connector at receiver. If DS3 turns ON, receiver is defective.

2. If DS3 stays OFF, reconnect receiver. Unplug receiver connector at control. If DS3 turns ON, receiver cable is shorted and must be replaced.

3. Unplug transmitter connector at transmitter. If DS4 turns ON, transmitter is defective.

4. If DS4 stays OFF, reconnect trans- mitter. Unplug transmitter connector at control. If DS4 Turns ON, transmitter cable is shorted and must be replaced.

2

2

2

2

Receiver “green”, but control box “red.” (Scenario 1)

Amb Grn Red Red 3 Grn4 Grn

7 Off 8 Grn

1. Check wiring at control box terminal block (TB2), which goes to receiver.

2. Using a digital voltmeter, measure the AC voltage between outputs and ground: Set #1: between pins 4 & 7 and 5 & 7. Set #2: between pins 11 & 14 and 12 & 14. Voltage in each case should read between 5.1 and 5.2 volts.

3. If voltage is 0, receiver connector might be cross-threaded. Unscrew receiver quick-connect cable and plug back in. Re-measure the voltage as in step 2.

4. If voltage is still 0, replace cable. 5. If none of the above works, receiver has a

hardware failure. Contact Wintriss Tech Support to replace receiver.

2

2

Receiver “green”, but control box “red.” (Scenario 2)

Amb Grn Red Off 3 Grn4 Grn

7 Off 8 Grn

1. This indicates a power supply failure. Contact the factory for assistance.

-

* “Red” = One or both of these LEDs light up red. “Off” = both are off.

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Troubleshooting Shadow VI Chapter 4 page 85

External MPCE Monitoring: Checking DS5 and DS6

These LEDs help diagnose problems relating to external MPCE monitoring. If you are using external MPCE monitoring do the following:

1. Block the light curtain and look at LEDs DS5 and DS6 (see Figure 2-14 for location). They should both light up orange.

2. If only one lights up, or if neither lights up, check the machine control circuit.

3. Verify that MPCE wiring is correct and check that MPCE jumpers J14 and J15 are both set for “external.” See Chapter 2.

Table 4-2. Shadow Troubleshooting Guide for 2 Sets

Control

Set #

Des

crip

tio

n

Tra

nsm

itte

r

Rec

eive

r

Ind

icat

ors

DS

1 &

2

Action

.

Ch

apte

r re

f.

#1 #2

Set #1 optic heads are blocked.

Amb

Amb

Red

Grn

Red

1 Red

2 Off

3 Grn

4 Grn

7 Off 8 Grn

1. Make sure a part of the machinery or

other object is not inadvertently protruding into the light field.

2. Check lens cover(s) for dirt buildup

- 4

#1 #2

Set #2 optic heads are blocked.

Amb

Amb

Grn

Red

Red

1 Off

2 Red

3 Grn

4 Grn

7 Off 8 Grn

and clean if necessary. 3. Check alignment. Realign if necessary.

2

#1 #2

Sets #1 and #2 optic heads are both blocked. OR Transmitter #1 is wired with receiver #2 and vice versa.

Amb

Amb

Red

Red

Red

1 Red

2 Red

3 Grn

4 Grn

7 Off 8 Grn

1. Complete steps 1, 2 and 3, above. 2. If this does not solve the problem, check

to see if transmitter and receiver connections are reversed. If you cannot trace the problem, go to the section that immediately follows this table for further instructions.

4, 2 2

#1 #2

Relays are chattering on and off.

Amb

Amb

Grn

Grn

Flicker betw/ Grn & Red

1 Off

2 Off

3 Grn

4 Grn

7 Off 8 Grn

1. Optic head jumper setting is incorrect (1 set vs. 2 sets). Check that both “1 set/2 sets” jumpers at J12 are set at “2 sets.”

2

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Shadow VI Optic Head Connector

CAUTION MAKING OR BREAKING CONNECTIONS WITH POWER ON

Power down Shadow before connection or disconnecting any connections at the control, transmitter or receiver.

Failure to comply with these instructions could result in property damage.

If you discovered in your troubleshooting that the transmitter had no power or was not functioning properly, we had suggested in the troubleshooting guides that you check the transmitter wiring to see if it was inadvertently reversed.

If you cannot trace the cables, we suggest that you unplug all the connectors at the optic head connection. Next, disconnect all the head connectors inside the control except one. Power up Shadow. Next check pin #4 at the optic head connectors for 12 VDC (see the illustration below) until you find the right connector.

Be sure that you carefully label the wiring in the control. For 1 set of light curtains, you need only perform this process once in order to differentiate between transmitter and receiver wiring. For 2 sets, you must repeat this procedure 3 times. Do this by disconnecting the connector inside the control that you just identified and plug in another unlabeled connector. Check which optic head connector pin #4 has 12 VDC. You will be repeating this process until you have carefully identified all the connectors.

Plug Pin # Cable Wire Color

1 Shield

2 Black

3 Brown

4 Red

5 Orange

6 Yellow

7 Green

8 Blue

Figure 4-1. Optic Head Connector Pinout Orientation and Chart

8

7

6

5 4

3

2

1

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Troubleshooting Shadow VI Chapter 4 page 87

Checking and Cleaning Lens Window(s)

Sometimes dirt, oil, or another substance can get on the plastic lens window on each optic head, which could block a light beam and prevent press operation. This might be the case when the red light is on at the control and receiver with no objects in the light field.

If your operation is particularly dusty, oily, or smoky, general build-up of dirt could also affect operation. Both problems are easily corrected by cleaning the lens window with a clean, particle-free cloth. Use a mild solution of detergent and water, a solvent (such as acetone), or an isopropyl-based cleanser. Make sure you avoid excessive rubbing.

Checking Alignment Shadows can go out of alignment if the universal mounting brackets have been bent, if a unit has been hit (by a die cart or forklift, for example), or if mounting bolts have loosened, allowing the units to move slightly. You may have an alignment problem if the red indicator light stays on even with the light field clear.

To check alignment, first loosen one optic head's universal mounting brackets at both ends. Then, rotate the head back and forth to see if this generates a green light. See "Aligning and tightening down your Shadows" in Chapter 2 for alignment procedures.

If that does not solve the problem, remove either the receiver or transmitter (whichever is easier) from its bracket, and move it right up to the other unit —within 6 to 11" (15.2 to 27.9 cm). Make sure that the connection to the control remains intact as you move it closer.

Aim that unit so it is pointing directly at the mating optic head exactly in a straight line. See the alignment information and diagrams in Chapter 2 if you are not sure what this means. Shadows will always align at this close range if working properly.

Alignment Problem or Bad Phototransistor

Observe the lights at the receiver and the control as you test Shadow. If the green light comes on at close range, alignment may be the problem. However, you have to make one more check to be sure. Place both units on a bench so that they are aligned and the green light is on. Now start moving one unit away from the other, making sure you keep the beams aligned.

If you find the red lights come on at further distances, but the green lights come on at close range, the problem may be a bad phototransistor or LED. Phototransistors are the devices inside the receiver that detect the light beams. When one becomes weak, it can detect a light beam close up, but not at greater distances. LEDs send the light from the transmitter to the phototransistors at the receiver. If they are weak, they cannot generate enough light at greater distances. If you suspect a bad LED or phototransistor, contact Wintriss Tech Support immediately to discuss return of the unit.

If the green lights stay on even as you move the units apart, then your mounting on the ma-chinery is the problem. A unit may have been hit and moved out of alignment or a bracket may have been bent, shifting the unit out of alignment. Check for the cause of misalignment and correct it. See Chapter 2 for proper alignment procedures.

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Checking and Replacing Fuses

WARNING! ELECTRIC SHOCK HAZARD

• Ensure that the power source is off before checking or replacing fuses.

• Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Ensure that all procedures are performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

Any time Shadow loses power or will not allow press operation, first check the fuses that are located in the control. They are easy to check and replace.

The fuses are common 3AG glass cartridge fuses (1/4" dia. x 11/4" length) listed in Appendix D. The rating, 1/4 amp and 4 amp, is marked next to the fuse on the circuit board. Here is how to check the fuses inside the control.

1. Turn off power to Shadow. Never check or change fuses with the power on.

2. Open the hinged cover of the control by loosening the locking screws.

3. Locate the fuses on the circuit board. Refer to the location of components illustration in Chapter 2. There are 4 fuses - 1 power (at F1), 2 stop (at location F2 and F3), and 1 status (at F4).

4. Remove the plastic cover over the fuse. Look to see if the metallic strip inside any of the fuses is broken. Test with an ohmmeter if available. Put the ohmmeter leads on each side of the fuse. No resistance (0 ohms) means the fuse is good.

5. If the fuse has blown, pop it out of the holder by prying it out at the ends. Snap in a new fuse.

6. Replace all plastic fuse covers.

WARNING! ELECTRIC SHOCK HAZARD

Replace plastic fuse covers after checking or replacing fuses. These covers help reduce the risk of electric shock.

Failure to comply with these instructions could result in death or serious injury.

7. Close the control. Insert and tighten the locking screws.

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Troubleshooting Shadow VI Chapter 4 page 89

Checking and Replacing Control Relays

DANGER! IMPROPER SAFETY RELAY REPAIR

• Replace the Shadow VI Control board before placing the safety product back into operation after the occurrence of a failed relay.

If a relay fuses

• DO NOT reset the Shadow to restart the machine.

• Remove the Shadow from operation immediately and replace the Shadow VI Control board before operating the press again.

Failure to comply with these instructions will result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON

• DO NOT touch electrical connections or circuit boards.

• Use test equipment only on the terminals specified in the instructions.

• Ensure that this test is performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD WHEN CHECKING OR REPLACING RELAYS

• Turn off and disconnect power from the Shadow safety light curtain and from the machinery it is connected to before checking relays or replacing the Shadow VI Control board unless the test requires power to be on. This includes disconnecting power to the machine control and motor.

• Ensure that all tests and repairs are performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

If the Relay Has Failed Completely

If a relay has failed completely (will not energize to close contacts or the contacts are welded shut), Shadow immediately stops the machinery and will not allow further press operation. The red light will always be on.

In this case, you cannot check relay contacts with a voltmeter (see next section). This is because Shadow will not allow relay operation if a relay failure occurs. Even the contacts of the good relay will be open and all voltages will be zero. You must replace the Shadow VI control board (see Replacing Safety Relays, page 91).

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Checking Relays with a Voltmeter

WARNING! ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON

• DO NOT touch electrical connections or circuit boards.

• Use test equipment only on the terminals specified in the instructions.

• Ensure that this test is performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

You can perform a test on the control relays in the control using a voltmeter. This test will tell you if a relay contact is pitted or burned. When this occurs, resistance at the contact may be so high that no current reaches the press control. Therefore, the press will not operate even though the Shadow relay contacts are closed and the indicator light is green.

If you find a bad control relay, replace the Shadow VI Control board (see next section). To obtain a new Control board, contact Wintriss Tech Support.

To check relays with a voltmeter, follow these steps.

1. Turn off power to Shadow.

2. Open the hinged cover of the control by loosening the locking screw. Locate the relays on the circuit board. Refer to the location of components illustration in Chapter 2. There are 3 relays - 2 stop relays (at location K1 and K2), and 1 status relay (at K3). Also find terminal block TB4 (upper level). (It is illustrated in the section "Connecting stop circuits to the control" in Chapter 2.)

3. Turn power on. Make sure the green light is on at the control. If it is not, the relays are bad (see the previous section for an explanation), and you must replace the Shadow VI Control board.

If the green light does go on, continue with the following steps.

4. Test the input voltage to the relays at FSD1 and FSD2 (see location of components in Figure 2-14 of Chapter 2). If you are also using the third relay, labeled "SSD", test that relay also. Make sure your meter is properly calibrated. The voltmeter should read 120 VAC. Verify your wiring.

NOTICE Your press control may use 24 VDC voltage or other voltage. If so, check for these voltages.

5. Now test the relay contacts. To test relay K1, place the voltmeter leads across the FSD1 terminals on the connector. Voltage should be 0. If it is not, replace the Shadow VI Control board. Check relay K2 by putting the leads across FSD2 terminals. If voltage is not 0, replace the Shadow VI Control board. If you are also using the third relay, labeled "SSD", test that relay also.

Shadow VI User Manual 1107200

Troubleshooting Shadow VI Chapter 4 page 91

Replacing Safety Relays

DANGER! IMPROPER SAFETY RELAY REPAIR

Replace the Shadow VI Control board before placing the safety product back into operation after the occurrence of a failed relay.

Failure to comply with these instructions will result in death or serious injury.

WARNING! ELECTRIC SHOCK HAZARD

• Ensure that the power source is off before you make any wiring connections.

• Disconnect power from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Ensure that all procedures are performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

1. Turn off power to the Shadow VI control.

CAUTION

DAMAGE TO BOARD FROM STATIC DISCHARGE

Ground yourself before touching circuit boards or chips by touching a large metal object such as the press. Static electricity can destroy electronic components.

Failure to comply with these instructions could result in property damage.

2. Making sure that you are grounded, open the Shadow VI enclosure (see Figure 2-13, page 43).

3. Identify all cables with inputs on the Shadow VI Control board by the terminal block to which they connect (see Figure 2-14, page 44) and attach identifying labels.

4. Remove cable connectors from terminal blocks.

5. Unscrew the old Shadow VI Control board from its mounting studs and remove it from the enclosure.

6. Maintaining the orientation of the old board, place the new Shadow VI Control board on the mounting studs and screw down.

CAUTION The cable connector can be inserted into the terminal block in only one direction. Do

not try to force the connector into the terminal block; otherwise, you may damage one or both components.

Failure to comply with these instructions could result in property damage.

7. Replace cable connectors in the appropriate terminal blocks, referring to the labels you created in step 3.

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8. Set switches S1, S2, and S4 and jumpers J12, J14, and J15 on the new Shadow VI Control board in the positions they were in on the old board. (Instructions for setting switches and jumpers are provided on page 51 (S2) and pages 57-61.)

9. Perform the steps in the Final Checkout Sequence, page 66.

Checking and Correcting Cross Talk

In some cases, using two sets of Shadow optic heads in close proximity of each other may cause "cross talk". Cross talk occurs when the LEDs from the first set's transmitter are detected by the phototransistors from the second set's receiver. Cross talk could be the problem if the green and red lights on the receivers from set #1 and set #2 flicker back and forth even though there is no visible obstruction causing the light curtains to repeatedly change state.

Diagnose the problem by performing this test. First, try to swap the transmitter with the receiver on one of the sets. If the symptoms go away, cross talk was the problem. You can also place an opaque barrier of some type (such as a wall or barrier) between the two sets. Make sure that the barrier runs all the way from the transmitter to the receiver. If the symptoms go away, cross talk was the problem.

Refer to the section "Avoiding cross talk when mounting 2 sets of Shadows" in Chapter 2 which provides alternate ways of mounting 2 sets of light curtains so that you can eliminate the incidence of cross talk.

Shadow VI User Manual 1107200 Excerpts from OSHA Regulations and Appendix A page 93 ANSI Standards Daily Tests in French and English

Appendix A – Extracts from OSHA Regulations and ANSI Standards

WARNING! REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS

The following extracts from OSHA and ANSI documents are provided for the user’s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information.

Failure to comply with these instructions could result in death or serious injury.

This appendix provides extracts from the Occupational Safety and Health Administration (OSHA) regulations and the American National Standards Institute (ANSI) standards covering presence-sensing devices.

Extracts from OSHA Regulation 1910.217

WARNING! REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS

The following extracts from OSHA and ANSI documents are provided for the user’s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information.

Failure to comply with these instructions could result in death or serious injury.

Reprinted below are extracts from OSHA regulation 1910.217 pertaining to the use of presence-sensing devices for point-of-operation guarding on mechanical power presses. Also reprinted here are interpretations of selected regulations provided by the Precision Metalforming Association (PMA). Extracts from the OSHA regulation are printed in the left-hand column; interpretations by PMA are shown in the right-hand column.

Wintriss makes no claim for the accuracy or effectiveness of the PMA interpretations, and persons making use of this material do so at their own risk. PMA interpretations should not be relied upon for use in any specific application. The material is provided, with PMA’s permission, for informational purposes only.

Refer to the most recent versions of OSHA documents. To obtain copies of OSHA regulations, write to: OSHA’s Office of Information and Consumer Affairs, 200 Constitution Avenue NW, Room N3647, Washington, DC 20210. Tel (202) 219-8151; fax (202) 219-5986.

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page 94 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

Extracts from OSHA Regulation 1910.217

OSHA Regulations PMA Interpretation

OSHA 1910.217 (c).

(c) Safeguarding the point of operation.

(1) General requirements.

(i) It shall be the responsibility of the employer to provide and insure the usage of “point of operation guards” or properly applied and adjusted point of operation devices on every operation performed on a mechanical power press. See Table 0-10.

TABLE 0-10

Distance of opening Maximum width of from point of operation opening (inches) hazard (inches)

1/2 to 1 1/2..................................... 1/4 1 1/2 to 2 1/2..................................... 3/8 2 1/2 to 3 1/2..................................... 1/2 3 1/2 to 5 1/2..................................... 5/8 5 1/2 to 6 1/2..................................... 3/4 6 1/2 to 7 1/2..................................... 7/8 7 1/2 to 12 1/2 ................................. 1 1/4 12 1/2 to 15 1/2 ................................. 1 1/2 15 1/2 to 17 1/2 ................................. 1 7/8 17 1/2 to 31 1/2 ................................. 2 1/8

OSHA 1910.217 (c) (3) (i) (a)

(3) Point of operation devices.

(i) Point of operation devices shall protect the operator by:

(a) Preventing and/or stopping normal stroking of the press if the operator’s hands are inadvertently placed in the point of operation.

Presence-sensing device

(c) (3) (i) (a) Refers to the functional requirement of a presence-sensing device which prevents and/or stops normal stroking of the press.

OSHA 1910.217 (c) (3) (iii)

(iii) A presence-sensing point of operation device shall protect the operator as provided in paragraph (c) (3) (i) (a) of this section, and shall be interlocked into the control circuit to prevent or stop slide motion if the operator’s hand or other part of his body is within the sensing field of the device during the downstroke of the press slide.

(a) The device may not be used on machines using full revolution clutches.

(b) The device may not be used as a tripping means to initiate slide motion.

European method (curtain of light) uses self trip safety system effectively. Variance applied for 11/17/73 by Interlake Stamping Company to use this fail safe system.

(c) The device shall be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required, but does prevent the initiation of a successive stroke until the failure is corrected. The failure shall be indicated by the system.

When failure occurs, the best indication is the press won’t run.

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Excerpts from OSHA Regulations and Appendix A page 95 ANSI Standards Daily Tests in French and English

Extracts from OSHA Regulation 1910.217

OSHA Regulations PMA Interpretation

(d) Muting (bypassing of the protective function) of such device, during the upstroke of the press slide, is permitted for the purpose of parts ejection, circuit checking and feeding.

Top of stroke is the point at which muting shall cease as it is not possible to set a point on the downstroke as the exact position where the hazard of die closing starts.

(e) The safety distance (Ds) from the sensing field to the point of operation shall be greater than the distance determined by the following formula:

Ds = 63 inches/second x Ts where

Ds = minimum safety distance (inches);

63 inches/second = hand speed constant and Ts = stopping time of the press measured at approximately 90° position of crankshaft rotation (seconds)

Safety distance represents the distance an operator can move his hand during the time it takes a press to stop. The internationally recognized hand reach speed is 63 inches/second.

To determine this safety distance, the stopping time of the press is measured with some appropriate measuring device. The measurement is taken such that the stop signal is given to the press at the 90 degree point of the crank position.

Since some stopping time increase must be accommodated due to braking system deterio-ration, a percentage factor must be added to the measured time to obtain the factor for use in the equation for determining safety distance. A percentage factor of 20% is recommended for presses with new brakes or brakes of good condition. For older brakes, a 10% factor is recommended.

Example: Measured stopping time = 0.190 seconds Time factor = 1.2 x 0.19 = 0.228 seconds Calculation = 63 x 0.228 Safety distance = 14.4 inches

(f) Guards shall be used to protect all areas of entry to the point of operation not protected by the presence-sensing device.

(3) (iii) (f) Great care must be taken to assure that no access to the die area exists unguarded.

OSHA 1910.217 (c) (3) (5)

(5) Additional requirements for safe-guarding. Where the operator feeds or removes parts by placing one or both hands in the point of operation, and a two hand control, presence-sensing device, Type B gate or movable barrier (on a part revolving clutch) is used for safeguarding:

This paragraph tells the condition under which a brake monitoring system is required after November 1, 1975.

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Extracts from OSHA Regulation 1910.217

OSHA Regulations PMA Interpretation

OSHA 1910.217 (c) (3) (5) (cont)

(i) The employer shall use a control system and brake monitor which comply with paragraphs (b) (13) and (14) of this section. This requirement should be complied with by November 1, 1975.

(b) (13) Control reliability

(b) (14) Construction requirements.

OSHA 1910.217 (c) (3) (vii) (c)

(c) The safety distance (Ds) between each two hand control device and the point of operation shall be greater than the distance determined by the following formula:

Ds = 63 inches/second x Ts, where:

Ds = minimum safety distance (inches); 63 inches/second = hand speed constant; and Ts = stopping time of the press measured

at approximately 90° position of crankshaft rotation (seconds).

Example:

Measured stopping Time = 0.190 seconds Time Factor = 1.2 x 0.19 = 0.228 seconds Calculation = 63 x 0.228 Safety Distance = 14.4 inches

OSHA 1910.217 (e) (1)

(e) INSPECTION, MAINTENANCE, AND MODIFICATION OF PRESSES

(i) It shall be the responsibility of the employer to establish and follow a program of periodic and regular inspections of his power presses to insure that all their parts, auxiliary equipment, and safeguards are in safe operating condition and adjustment. The employer shall maintain records of these inspections and the maintenance work performed.

Records of clutch and brake will be weekly. Other inspections are periodic subject to time factor determined by employer.

(ii) Each press shall be inspected and tested no less than weekly to determine the condition of the clutch/brake mechanism, anti-repeat feature and single stroke mechanism. Necessary maintenance or repair or both shall be performed and completed before the press is operated. The employer shall maintain records of these inspections and the maintenance work performed. These requirements do not apply to those presses which comply with paragraphs (b) (13) and (14) of this section.

If brake monitoring system is installed, weekly inspection and records are not required for clutch/brake mechanism. Other parts of the press will require periodic inspections and records.

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Excerpts from OSHA Regulations and Appendix A page 97 ANSI Standards Daily Tests in French and English

Extracts from ANSI Standards for Presence-sensing Devices

WARNING! REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS

The following extracts from OSHA and ANSI documents are provided for the user’s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information.

Failure to comply with these instructions could result in death or serious injury.

Reprinted below are the American National Standards Institute (ANSI) standards for presence-sensing devices (light curtains). ANSI, a national federation of trade associations, technical societies, professional groups, and consumer organizations, is the United States clearinghouse and coordinating body for voluntary standards activity. Approximately 1000 companies are affiliated with the Institute as company members.

ANSI creates voluntary standards to eliminate duplication and to weld conflicting standards into single, nationally accepted standards under the designation “American National Standards.” The standards reflect a national consensus of manufacturers; consumers; scientific, technical, and professional organizations; and governmental agencies.

Shown below are extracts of standards requirements and explanatory information from ANSI B11.1-2009 and ANSI B11.19-2003 for presence-sensing devices (light curtains). Complete versions of these documents can be obtained by writing to: ANSI, 1430 Broadway, New York, NY 10018.

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Extracts from ANSI B11.1-2009 8.6.2.1

Standards Requirements Explanatory Information

8.6.2.1.7 Each operator’s hand controls shall be located at a distance from the point-of-operation so that the operator(s) cannot release either hand actuating control and reach into the point-of-operation during the hazardous portion of the cycle.

E8.6.2.1.7 The total stopping time of the press should include the total response time of the control system and the time it takes hazardous motion to stop. The following formula should be used when calculating the safety distance (Ds):

Ds = K (Ts + Tc + Tbm)

Where:

K = 63 inches/second (hand speed constant). Ts = the stop time of the press measured fromthe final de-energized control element, usually the air valve. Tc = the response time of the control.

Tbm = the additional time allowed by the stopping-performance monitor (brake monitor) before it detects stop time deterioration.

NOTE - Ts + Tc are usually measured by a stop time measuring device.

When the press stopping-performance monitor setting is changed, the safety distance should be recalculated. See also Annex C.

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Excerpts from OSHA Regulations and Appendix A page 99 ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information

8.6.3 Presence-sensing safeguarding device

8.6.3.1 A presence-sensing device, when used for safeguarding, shall protect the operator as specified in E8.6.1 (a).

E8.6.3.1 Various presence-sensing devices employ different sensing and adjustment techniques. The point at which a device responds to an intrusion can vary.

Safety mats and area scanners may not be suitable (effective) safeguards when utilized as primary point-of-operation safeguarding. Factors which can affect this suitability include but are not limited to:

a) response time; b) minimum object sensitivity; c) measurement accuracy; d) breach ability; e) penetration before detection; f) single point of failure;

g) large safety distances.

These devices may be utilized as supplemental safeguarding.

8.6.3.2 The device shall interface with the control circuit to prevent or stop slide motion if any object is within the sensing field of the device during the hazardous portion of the cycle.

E8.6.3.2 The device should be located or adjusted so that the device always responds to the intrusion at or prior to the safety distance Ds.

Also, care should be taken when installing the device so that it does not detect false signals from other devices or equipment in the area.

The presence-sensing device cannot protect against a catastrophic failure of the press, which causes unintended cycling action. See Annex A, Figure A.3.

8.6.3.3 The device shall not be used for safeguarding the point-of-operation on presses using full-revolution clutches.

8.6.3.4 When the sensing field has been interrupted, use of the normal press cycle-actuating means shall be required after clearing the sensing field to resume press operation.

8.6.3.5 When the device is used in the PSDI mode, re-initiation of the press motion shall be in accordance with 6.4.3.8.1.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information

8.6.3.6 Muting of the device shall be permitted only during the non-hazardous portion of the press cycle.

E8.6.3.6 Muting is typically accomplished by interface circuits or auxiliary controls.

The die closing portion of the cycle is always considered hazardous. In some cases, feeding and transfer automation or die features can cause additional hazardous conditions even during the opening portion of the cycle (up-stroke). See also ANSI B11.19 for additional information.

8.6.3.7 Muting of the device shall be accomplished in a manner that conforms to the requirements of 6.11 and 8.8.

E8.6.3.7 Muting is typically accomplished by interface circuits or auxiliary controls. The muting element should incorporate a similar level of control reliability as the presence-sensing device itself. A simple cam-operated limit switch wired in parallel with the device’s output is inadequate as its failure can remain undetected.

8.6.3.8 The device shall have an identifiable minimum object sensitivity so that an obstruction of an equal or greater size will be detected anywhere within the sensing field regardless of the plane of intrusion.

E8.6.3.8 The device should have a minimum object sensitivity stated by the device supplier. For example, an electro-optical device may detect a 32 mm (1-1/4 inch) diameter opaque object anywhere in its sensing field but allow 25 mm (1 inch) obstructions to pass undetected at certain points in the field.

8.6.3.9 The device shall have a maximum response time, which shall not be affected by object sensitivity adjustments or environmental changes.

E8.6.3.9 The device supplier should state the maximum total response time, including output devices, of the presence-sensing device.

8.6.3.10 Devices which require adjustments to accommodate variations in operating conditions, or which incorporate fixed blanking or floating blanking features, shall be designed so that the adjustments or features are capable of supervisory control by the user.

E8.6.3.10 Typically, these adjustments or controls are key-operated or located under lockable covers.

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Excerpts from OSHA Regulations and Appendix A page 101 ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information

8.6.3.11 The device shall be provided with a means that visibly indicates when it is functioning properly.

E8.6.3.11 Red and green indicators or other means that can be easily seen by the operator and others should be provided to indicate that the device is functioning.

Indication that the sensing field is being blanked shall be provided. For fixed blanking, the blanked area shall be identified. Supplemental safeguarding shall be provided to prevent access to the hazard through the fixed blanked area.

The blanking function of a presence-sensing safeguarding device desensitizes a portion of the sensing field by disabling one or more channels such that a specific interruption is ignored. Presence-sensing devices can be provided with either fixed or floating blanking. For fixed blanking, the desensitized area does not move or change once configured. Floating blanking allows the blanked area to move within the sensing field.

Means to identify the desensitized area may include but are not limited to:

a) Indicators within the device; b) Signage or marking of the fixed blanked

area;

c) The physical location of the object in the blanked area if movement or removal of the object can be detected and it results in a stop command.

Means of supplemental safeguarding can include completely filling the fixed blanked area to restrict access to the hazard, installing the device at a distance that accounts for the worse case object sensitivity (see 8.6.3.16), or alternate safe-guarding may be provided to prevent access to the hazard.

If means are provided to bypass the device, visible indication that the device is bypassed shall be provided.

Means to provide visible indication may include but are not limited to:

a) colored indicator lights; b) signage; c) physical position; d) awareness barrier (i.e., safety tape);

e) other means.

8.6.3.12 The device shall not fail to respond to the presence of the individual’s hand or other body part due to the presence of a reflective object or workpiece.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information

8.6.3.13 The device shall conform to the requirements of 6.11 and 8.8. In the event of a power failure to the device, the device shall initiate a stop command to the press control system.

8.6.3.14 The interface of the presence-sensing device to the press control shall conform to the requirements of 6.11 and 8.8.

8.6.3.15 The sensitivity of the device to intrusion shall not be adversely affected by changing conditions around the press.

8.6.3.16 The effective sensing field of the device shall be located at distance from the nearest point-of-operation hazard so that individuals cannot reach into the point of operation with a hand or other body part before cessation of motion during the hazardous portion of the cycle.

E8.6.3.16 The total stopping time of the press should include the total response time of the presence-sensing device, as stated by the supplier, the response time of the interface, the response time of the control system, and the time it takes the press to cease slide motion.

The following formula should be used when calculating the safety distance:

Ds = K (Ts + Tc + Tr + Tbm) + Dpf

where

K = 63 inches/second (hand speed constant) Ts = the stop time of the press measured from the final de-energized control element, usually the air valve. Tc = the response time of the press control.

Tr = the response time of the presence-sensing device and its interface, if any, as stated by the supplier or measured by the user. Tbm = the additional stopping time allowed by the stopping-performance monitor before it detects stop time deterioration. Dpf = the added distance due to the penetrationfactor as recommended in ANSI B11.19, AnnexD, Figure D.2. The minimum object sensitivity is stated by the supplier. If beam blankouts or floating window features are used, these figures should be added to the object sensitivity figure before using the chart.

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Excerpts from OSHA Regulations and Appendix A page 103 ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information

8.6.3.16 (cont) NOTE - Ts + Tc is usually measured by a stop time measuring device. See also ANSI B11.19, Annex C and D.

Whenever the press-cycle STOP command or stopping-performance monitor time or angle setting is changed, the safety distance should be recalculated. See also “stopping-performance monitor” (6.12).

NOTE – No increase in safety distance is required for fixed blanking applications if the blanked area is entirely occupied by the material or fixtures.

In some instances, the use of blanking does not allow efficient production of certain piece parts. Horizontal placement of the sensing field, so that it detects the operator’s waist area, may present a solution. In this application, the operator may freely manipulate the workpiece and operate the press as long as the operator stands outside of the horizontal sensing field.

The sensing field should be located so that the operator cannot reach the point-of-operation prior to interrupting the sensing field and completion of the stopping action. Where possible, the sensing field should be of sufficient depth to prevent the operator from standing between the field and the point-of-operation. See also ANSI B11.19, Annex C and D.

8.6.3.17 If the position of the device will allow the operator or others to place themselves between the sensing field and the point-of-operation, additional means shall be provided in conjunction with the device to prevent the operator or others from exposure to the point-of-operation hazard.

E8.6.3.17 Additional means may include manual reset outside of the sensing field of the device or additional barrier guards, safety mats, light curtains or other devices.

Operator controls for each operator located outside of the sensing field of the presence-sensing device may be used.

As an alternative to the reset control and to prevent an individual from stepping behind the sensing field of a PSD, the maximum distance between the light curtain and the machine structure should not exceed 75mm (3 inches). Supplemental safeguarding may be utilized to eliminate a space greater than 75mm.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information

8.6.3.18 The device shall not be affected by ambient light or by light-source decay so that the increase in response time or object sensitivity is greater than the value used to calculate the safety distance.

E8.6.3.18 Examples of ambient light are associated with windows, light fixtures, skylights, bay doors, or die lights.

8.6.3.19 All areas of entry to the point-of-operation not protected by the presence-sensing device shall be otherwise safeguarded.

E8.6.3.19 Usually the electro-optical presence-sensing device is used in a manner that provides a protected zone in front of the primary work area with auxiliary devices or guards used to protect secondary access areas.

In some cases, mirrors may be used in conjunction with the device to provide two-, three- or four-sided protection.

8.6.3.20 Press production systems with a configuration that would allow an individual to enter, pass through, and become clear of the presence–sensing device sensing field shall not be operated in the PSDI mode of operation.

E8.6.3.20 For PSDI applications see Clause 10.

8.6.3.21 When a device is used on a press production system and the protection of the operator is dependent upon the stopping action of the press, a stopping-performance monitor shall be required in conformance with 6.12. See section 8.3.9 for exceptions.

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Excerpts from OSHA Regulations and Appendix A page 105 ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

8.3 Electro-Optical, RF, and area scanning presence-sensing safeguarding devices

8.3.1 Design and Construction

8.3.1.1 The presence-sensing device shall be designed and constructed to create a field that detects the presence of an individual(s).

The presence-sensing device shall not create a hazard in and of itself.

E8.3.1.1 The device should be designed and constructed such that it does not present hazards to individuals from:

sharp edge or pinch point hazards; radiated light or energy hazards; electromagnetic interference hazards; electrical shock hazards.

8.3.1.2 The electro-optical presence-sensing device shall have a minimum object sensitivity such that an obstruction of a same or greater size will always be detected anywhere within its sensing field, regardless of the plane of intrusion.

E8.3.1.2 The presence-sensing device should have a minimum object sensitivity stated by the supplier. For example, an electro-optical device may detect an opaque object with a diameter of 32 mm (1-1/4 inch) anywhere in its sensing field, but allow an obstruction with a diameter of 25 mm (1 inch) to pass undetected at certain points in the field.

8.3.1.3 The device shall not fail to change its output state, if not muted, when it detects the presence of an individual.

E8.3.1.3 Muting may be accomplished by the device, its interface, auxiliary controls, or the machine control system. When the device provides the muting, its output may or may not change state.

8.3.1.4 Adjustment or configuration of presence-sensing devices shall be capable of being supervised by the user.

E8.3.1.4 Methods of meeting this requirement include, but are not limited to, the use of key operated controls or controls located under lockable covers.

Adjustments or configuration can include, but are not limited to:

muting; blanking; power adjustments; sensing field configuration; reset functions.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

8.3.1.5 The presence-sensing device shall incorporate visual means to indicate that the device is detecting an individual within the effective sensing field of the device.

E8.3.1.5 Indicators (usually red and green), displays or meters should be provided to indicate the status of the device. The visual means may be integral to the device or part of the interface or machine control system.

Due to the prevalence of color blindness, methods such as unambiguous positioning, patterning, labeling or flashing of the indicators may be effective in providing the indication required.

8.3.1.6 The presence-sensing device shall have a maximum response time that shall not be affected by object sensitivity or environmental changes.

The safeguarding supplier shall provide the maximum response time of the presence-sensing device.

8.3.1.7 The RF (radio frequency) presence-sensing device shall provide means to adjust the sensitivity of the field. The field, once adjusted, shall not decrease in sensitivity below this established level.

8.3.1.8 The electro-optical device shall not be affected by ambient light conditions or by changes in the device light source characteristics, such that an increase in response time or object sensitivity occurs.

E8.3.1.8 When the electro-optical device is exposed to signals from other electro-optical devices or to changes in ambient light commonly associated with windows, light fixtures, skylights, bay doors or work area lights, the response time or object sensitivity should not be adversely affected.

8.3.1.9 Components, subassemblies or modules of electro-optical, RF, and area scanning presence-sensing safeguarding devices shall be designed and constructed to meet the requirements of 6.1.

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Excerpts from OSHA Regulations and Appendix A page 107 ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

8.3.1.10 The area scanning device shall provide a means or operating mode to verify the size, shape, and detection capabilities of the detection area or zone.

Information shall be provided by the area scanning device supplier to identify the:

a) maximum safeguarding range; b) minimum object sensitivity within the stated safeguarding range; c) maximum field of view in degrees; d) tolerance in the range measurement; and e) detection capabilities with respect to the reflectivity of an object versus the distance to the object.

E8.3.1.10 These devices typically operate on the principle of “diffuse reflectance," which is a principle of transmitting beam(s) of light to form a detection area or zone. When an object enters the detection area, it reflects the transmitted light back to the device, which then evaluates the object's position. The amount of reflected light (degree of reflectance in percent) that can be reliably detected typically ranges from 1.8% to over 90% and can be represented graphically by reflectivity versus distance. For more information, see IEC 61496, parts 1 and 3.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

8.3.2 Installation, operation, and maintenance

8.3.2.1 Exposure to the hazard(s) shall not be possible by reaching over, under or around the sensing field of the device. Additional guards or safeguarding devices shall be provided to protect those areas.

E8.3.2.1 The user should select a presence-sensing device adequate to prevent individuals from reaching over, under or around the sensing field during the hazardous portion of the machine cycle. Additional safeguarding may be required in conjunction with the device to meet this requirement.

The effective sensing field shall be of adequate height, width, and depth so that entry of the individual into the hazard area is detected.

If individuals can place themselves between the sensing field and the hazard area, additional safeguarding should be used in conjunction with the device to prevent the individual from exposure to the hazard.

When an individual can pass through the sensing field, see the requirements of 8.3.2.3.

The electro-optical presence-sensing device may fail to detect an individual's presence due to reflective workpieces or objects in the vicinity of the device. Care should be used to ensure that these reflections do not render the device ineffective.

Some examples of reflective objects include, but are not limited to:

machine surfaces; tooling; work pieces; hand tools; auxiliary equipment; workholding tables and fixtures.

Testing each set-up for minimum object sensitivity should be done with an appropriate test rod, following the supplier's recommendation.

Where objects are placed within the defined sensing field of an area optical laser scanner, care should be taken to ensure that:

a) No shadows exist behind the objects such that the device is rendered ineffective; b) Removal of the object will not allow undetected access to a hazard area.

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Excerpts from OSHA Regulations and Appendix A page 109 ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

The device shall be installed such that it does not create additional hazards.

Some installation hazards include, but are not limited to:

pinch point hazards created by interference between the device and moving members of the machine; tripping hazards; electrical shock hazards; overhead or other "strike against" hazards; thermal hazards.

Where such conditions can exist, additional safeguarding may be required.

8.3.2.2 The presence-sensing device shall be installed at a location so that the effective sensing field prevents individuals from reaching the hazard(s) during the hazardous portion of the machine cycle.

E8.3.2.2 The safety distance calculation is dependent upon the:

total response time of the device as stated by the safeguarding supplier; response time of the interface; response time of the control system; time it takes the machine to stop hazardous motion; and depth penetration factor of the device.

See Annex D for the formula(e) to calculate the safety distance.

Radio frequency devices have sensing fields that can vary due to:

antenna(e) design; effects of adjacent machinery and equipment; field sensitivity adjustments; and environmental factors (such as humidity or temperature).

Before the machine is used for production purposes, the RF device should be checked to ensure that the effective field protects individuals at the safety distance.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

8.3.2.3 The presence-sensing device shall protect individuals from hazards by initiating an immediate stop command to the machine control system when the sensing field of the device is interrupted during the hazardous portion of the machine cycle. It shall require reinitiation of the normal actuating means prior to the start or continuation of motion of the machine.

When an individual can pass through the sensing field of the presence-sensing device, the device shall initiate an immediate stop command to the machine control system and shall require that the device or machine control be manually reset before hazardous motion can occur.

The operator should ensure that no individual is in the safeguarded area before re-setting the device or machine control and initiating hazardous motion.

The reset device shall be located outside of the safeguarded area such that it cannot be reached from within the safeguarded area. Reset of the device or machine control shall not occur until verification that the safeguarded area is clear of individuals.

Key lock reset switches located at various positions around the safeguarded area may be one method of accomplishing this requirement.

8.3.2.4 Components, subassemblies or modules of the interface or machine control system shall meet the requirements of 6.1.

8.3.2.5 Muting of the device shall be permitted during the non-hazardous portion of the machine cycle. Muting of the device shall be accomplished such that a single failure of a component, a subassembly or a module of the system / device that affects the performance of the safety-related functions shall not prevent a normal stop command from being initiated, or shall cause an immediate stop command. In the event of a failure, re-initiation of the machine shall be prevented until the failure is corrected or the system or device is manually reset.

E8.3.2.5 Muting is typically accomplished by interface circuits or auxiliary controls. The muting element should incorporate a similar level of control reliability as the presence-sensing device itself. A simple cam-operated limit switch wired in parallel with the device's output is inadequate, as its failure can remain undetected.

In the presence of a failure, repetitive manual reset of the system or device shall not be used for production.

The intention of a manual reset is to encourage the diagnosis of a failed component, subassembly, device or module. A second failure may occur during the diagnostic or troubleshooting process, negating the safety function(s). Additional safeguarding should be used to protect individuals during this process.

See the definition for control reliability and

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

Annex C for further information.

If the machine has reversing capability where a muting hazard is possible, the control system shall include an automatic means so muting is only permitted in the forward direction.

If an individual can pass through a sensing field when the device is muted, means shall be provided to ensure that the individual is outside of the hazard area, or that the machine ceases hazardous motion when the muting is removed.

One method of meeting this requirement is by the use of a control circuit interlock on the drive motor starter (forward direction contact) to allow "muting" only in the forward direction when the starter is energized. See 8.3.2.1.

8.3.2.6 Bypassing of the device shall be capable of being supervised by the user. Indication that the device is active or bypassed shall be provided and shall be readily observable by individuals protected by the device.

E8.3.2.6 Care should be taken to ensure that the operators and other individuals are aware that the device has been bypassed so that individuals do not assume that the device is active and they are safeguarded when, in fact, the device is bypassed.

When bypassed, the device, interface or control system shall not indicate any state other than "bypass."

An amber indicator lamp or other means may be used to meet this requirement.

When the device is bypassed, other safeguarding must be provided and used.

When bypassed, the device's normal status indicators can be misleading if still active. One method that may be used to meet this requirement is to remove power to the device or to disable the normal status indicators when it is bypassed or not being used.

Due to the prevalence of color blindness, methods such as unambiguous positioning, patterning, labeling or flashing of the indicators may be effective in providing the indication required.

8.3.2.7 The radio frequency device shall not be adversely affected by changes around the machine that may alter the sensitivity of the device such that individuals are no longer detected in the sensing field at the proper safety distance.

E8.3.2.7 The radio frequency device may be affected by changes in the conditions around the machine such as ambient conditions, the placement of parts and tote boxes, grounding conditions of the operator, or the movement of industrial trucks. These changes should not adversely affect the performance of the device.

1107200 Shadow VI User Manual

page 112 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information

8.3.2.8 The total tolerance in the range measurement of an area scanning device shall be included in determining the distance from the nearest recognized hazard to the detection area or zone. This detection area shall be identified and tested to ensure that the device is able to detect individuals entering the detection area. The effective sensing field shall be verified for proper size and coverage upon installation, replacement, or changes of the detection area.

E8.3.2.8 When the device is horizontally mounted, the detection area or zone should be visibly marked on the floor. This verification can be accomplished by using a programming device or by physically identifying the perimeter of the detection area with an appropriate test rod, following the supplier's recommendation. This verification is to ensure that a preprogrammed device with a small or improper detection area is not used by mistake in an installation requiring a larger field.

Area scanners may not be suitable (effective) safeguards when used to protect an individual's hands or fingers from hazards.

Items which can affect this suitability are:

response time; minimum object sensitivity; measurement accuracy.

Shadow VI User Manual 1107200

Excerpts from OSHA Regulations and Appendix A page 113 ANSI Standards Daily Tests in French and English

Daily Tests in English

Perform these tests daily to make sure the light curtain and the machine's control systems work properly. Also perform these tests after any modification or maintenance to the light curtain or the machine.

NOTICE Use an opaque 1¼" diameter test bar for performing the daily tests on the Light Curtain. If

you are using the Floating Window option, enable it and use a 2" diameter test bar to perform the daily tests.

1. Turn on power to the light curtain and to the machine. Observe the LEDs at the receiver. If the red and green lights are on at the same time, clear the light curtain to the green state by momentarily interrupting the sensing field with a test bar.

2. Interrupt the sensing field on the receiver side by passing the test bar from the top to the bottom of the receiver lens cover. The red LED on the receiver should come on while the bar is in the sensing field.

3. Repeat step 2, passing the bar from the top to the bottom of the transmitter lens cover. Make sure the red LED comes on when the bar is anywhere in the sensing field.

4. Start the machine and interrupt the sensing field with the test bar. The red LED should come on and the machine should immediately stop.

NOTICE When muting is used, interrupting the Light Curtain during the MUTED (nonhazardous)

portion of the cycle will NOT stop the machine.

5. Single stroke the machine and make sure it stops at top dead center and that the machine's braking system is working properly. If the machine does not brake fast enough, adjust the braking system or increase the light curtain's safety distance.

6. If either the light curtain or the machine fails any of these tests, DO NOT RUN THE MACHINE. Notify the supervisor immediately.

7. When using the light curtain on mechanical power presses, all OSHA Safety and Health Standards (29 CFR 1910.217) must be met. DO NOT USE THE LIGHT CURTAIN ON FULL-REVOLUTION CLUTCH MACHINES.

1107200 Shadow VI User Manual

page 114 Appendix A Excerpts from OSHA Regulations and ANSI Standards Daily Tests in French and English

Tests Quotidiens du Rideau de Lumiere

Daily Tests in French

Effectuer ces tests quotidiennement pour s'assurer que le rideau de lumière et le système de commande de la machine fonctionnent comme if faut. Effectuer également ces tests après toute modification ou tout entretien du rideau de lumière ou de la machine.

REMARQUE

Utiliser une barre de test opaque de 3,15 cm de diamètre pour effectuer les tests quotidiens sur les appareils. Utiliser une barre de test de 5,08 cm de diamètre pour effectuer les tests quotidiens sur les appareils à plage élargie.

1. Mettre le rideau et la machine sous tension. Si les voyants rouge et vert s'allument en même temps, mettre le rideau dans son état vert en bloquant momentanément le champ de détection à l'aide d'une barre de test.

2. Si votre rideau est muni d'une fenêtre flottante, mettre ce système hors fonction. S'assurer que le voyant de la fenêtre flottante s'éteint.

3. Bloquer le champ de détection du côté du récepteur en faisant passer la barre de test de haut en bas le long du cache-lentille du récepteur. Le voyant rouge devrait s'allumer quand la barre traverse le champ de détection.

4. Recommencer l'étape No 3 en faisant passer la barre de haut en bas le long du cache–lentille de l'émetteur. S'assurer que le voyant rouge s'allume dès que la barre bloque une partie quelconque du champ de détection.

5. Mettre la machine en marche et bloquer le champ de détection au moyen de la barre de test. Le voyant rouge du récepteur devrait s'allumer et la machine devrait s'arrêter immédiatement.

REMARQUE

Quand la fonction d'assourdissement est en service, le blocage du rideau de lumière pendant la partie non dangereuse de la course (vers le haut) n'arrêtera pas la machine.

6. Faire marcher la machine pendant une seule course, et s'assurer qu'elle s'arrête au point mort supérieur et que le système de freinage de la machine fonctionne comme il faut. Si la machine ne freine pas assez vite, ajuster le système de freinage ou augmenter la distance de sécurité du rideau.

7. Si la machine ou le rideau de lumière ne passe pas avec succès l'un quelconque de ces tests, ne pas faire fonctionner la machine. Avertir le contremaître immédiatement.

8. Quand le rideau est utilisé sur des presses mécaniques, toutes les normes de sécurité et de santé d'OSHA (Etats-Unis) [29 CFR 1910.217] doivent être respectées. Ne pas utiliser le rideau sur les machines avec embrayage à rotation complète.

Shadow VI User Manual 1107200 Shadow VI Panel Mount Appendix B page 115

Appendix B – Shadow VI Panel Mount

This appendix explains how to install your Shadow VI panel mount. Refer to Chapter 2 for the remainder of the installation steps.

Standard Enclosure Versus Optional Panel Mount

Shadow VI is available either with an enclosure or as a panel mount. The panel mount can be mounted from the inside or outside. Be sure to allow at least 8" (20.3 cm) of clearance behind the panel mounting plane to allow enough room for the electronics.

Preparation for Mounting Shadow Using Your Enclosure

DANGER! ACCESSING CONTROL AFFECTS LIGHT CURTAIN OPERATION

Install the light curtain control in a location where access to it will not affect the operation of the light curtain.

Failure to comply with these instructions will result in death or serious injury.

DANGER! CONTROL INSIDE THE GUARDED AREA FOR PERIMETER GUARDING

Install the light curtain control outside the guarded area for perimeter guarding applications.

Failure to comply with these instructions will result in death or serious injury.

To prepare for mounting Shadow VI using your panel enclosure, follow these steps:

1. Determine an appropriate location to mount the control panel mount. It should be mounted in an area where personnel can easily see the warning indicators, important labels, and also have access to the circuitry, without interfering with the operation of the optic heads. The control must never be installed inside the protected area in perimeter guarding applications. The enclosure can be mounted to the press, on a free-standing pedestal, on a pendant, or at the entrance of a location used for area guarding.

2. Cut out a hole in your panel enclosure, and drill and tap ten holes for 1/4-20 screws. Refer to Figure B-2 for mounting dimensions.

3. Prop Shadow near the location where it will ultimately be mounted. Allow at least 12 inches of service loop when performing the wiring connections. Also make sure all cables will reach.

4. Refer to Chapter 2 of the Shadow VI user manual to complete the entire installation.

1107200 Shadow VI User Manual

page 116 Appendix B Shadow VI Panel Mount

About Shadow VI Panel Mount Labels

DANGER! DAILY TESTS LABEL INACCESSIBLE

Affix the Daily Tests label where operators can clearly read the instructions. The daily tests are critical to operator safety and must be run every day before operating the press.

Failure to comply with these instructions will result in death or serious injury.

NOTICE The information on the Operator Instructions label is used for maintenance purposes. Affix

the label where it can be easily read.

You should have received 2 labels with your panel mount assembly: "Daily tests" and "Operator instructions." See Figures B-1A and B-1B, below.

Shadow VI User Manual 1107200

Shadow VI Panel Mount Appendix B page 117

REMOTEINTERRUPT

S3

ORG RED BLK/BLU

BRN GRN YEL SHIELD

TRANSMITTER/RECEIVER CABLE COLOR CODE

D43087 Rev

DS1 DS2HEAD INTERRUPT INDICATORS

IN 1 SET MODE, BOTH ON, IN 2 SETS MODE,DS1 ON = SET 1 RED,DS2 ON = SET 2 RED

OFFON

S4

S1

RESET ONINTERRUPT

FLOATINGWINDOW

STATUS RELAY FOLLOWSSTOP OUTPUTS

POWER UPRESET

DISABLE

OPTIONS

GRN AMB RED YEL V-OUT

REMOTE INDICATORS

FSD1 FSD2 STAT GNDRELAY OUTPUTS

E-STOP E-STOP STATUSSHIPPED WITH FACTORY

INSTALLED JUMPERS

MPCE2AUX INPUTS

XMTR INTMPCE1 RESET

RECEIVER 1

RECEIVER 2TRANSMITTER 2

TRANSMITTER 1

1 SET

2 SETSHEAD SELECTIONJUMPERS

FUSE F1 1/4 A SLO-BLO, INPUT POWERFUSES F2, F3, F4 4 A SLO-BLO, RELAY OUTPUTS

FOR ASSISTANCE CALL 1-800-586-8324

®DATA INSTRUMENTS75 Discovery Way, Acton MA 01720 U.S.A.

DS8XMTRACTIVE

DS6

DS5INTERNAL

EXT MPCE2 CK(DE-ENERGISED)

EXT MPCE1 CK(DE-ENERGISED)DS

7

RESETON

INT/EXTMPCE CKSELECTIONJUMPERS

J12

J15

J14

1 10

2011

1 7

8 14

1 7

148

TB2TB3TB4

Figure B-1. Daily Tests Label (left) and Operator instructions Label (right)

ATTENTION

CAUTION

Perform these tests daily to make surethe Light Curtain and the machine'scontrol system work properly. Also,perform these tests after anymodification or maintenance to theLight Curtain or the machine.NOTE: Use an opaque 1 1/4" diametertest bar for performing the daily tests.1. Turn on power to the Light Curtainand the machine. If the red and greenlights are on at the same time, clear theLight Curtain to green state bymomentarily interrupting the sensingfield with a test bar.2. If your Light Curtain has a FloatingWindow, shut off the Floating Windowsystem. Make sure the FloatingWindow indicator light goes off.3. Interrupt the sensing field on thereceiver side by passing the test barfrom the top to the bottom of thereceiver lens cover. The red lightshould come on while the bar is in thesensing field.4. Repeat step 3, passing the bar fromthe top to the bottom of the transmitterlens cover. Make sure the red lightcomes on when the bar is in thesensing field.5. Start the machine and interrupt thesensing field with the test bar. The redindicator light on the receiver shouldcome on and the machine shouldimmediately stop. NOTE: When mutingis used, interrupting the Light Curtainduring the muted portion of the strokewill NOT stop the machine.6. Cycle the machine and make sure itstops at the proper position and that themachine's braking system is workingproperly. If the machine does not brakefast enough, adjust the braking systemor increase the Light Curtain's safetydistance.7. If the machine or Light Curtain failsany of these tests, DO NOT RUN THEMACHINE. Notify the supervisorimmediately.8. When using the Light Curtain withmechanical power presses, all OSHASafety and Health Standards(29 CFR 1910.217) must be met. DONOT USE THE LIGHT CURTAIN ONF U L L R E V O L U T I O N C L U T C HMACHINES.

LIGHT CURTAIN DAILY TESTS

Perform these tests daily to ensure theLight Curtain and the machine's controlsystem work properly. These testsshould also be performed after anymodification or maintenance to theLight Curtain or the machine.

Des essais doivent être effectuéschaque jour pour s'assurer que lerideau de lumière et le système decommande de la machine fonctionnentcomme il faut. Ces tests doiventégalement être effectués après toutemodification ou tout entretien du rideaude lumière ou de la machine.

C42254 Rev

1107200 Shadow VI User Manual

page 118 Appendix B Shadow VI Panel Mount

Final assembly Once the final checkout has been confirmed and Shadow is working satisfactorily while it has been sitting outside the enclosure, you are ready to completely install the Shadow VI panel mount into your enclosure.

Remember earlier you had cut out a hole in your panel enclosure. Mount the Shadow panel assembly into this cavity using the ten 1/4-20 screws. Refer to Figure B-2 for mounting and cutout dimensions for Shadow VI panel and your enclosure.

cutout size3" x 9"

(7.6 x 22.9 cm)

3.5 (8.9)

10(25.4)

0.218 dia.(0.55)

10 plcs.

9.5(24.1)

4(10.2)2 plcs.

8(20.3)

2.5 (6.4)

4 (10.2)

allow minimum8" clearancebehind panel

mounting plane

Figure B-2. Shadow VI Panel Mount Control Dimensions

Shadow VI User Manual 1107200 Installation of Shadow VI-WPC Control Board Appendix C page 119

Appendix C – Installation of Shadow VI-WPC Control Board

This appendix explains how to install, wire, and operate the optional Shadow VI-WPC control board assembly in conjunction with your Wintriss Clutch/Brake Control (WPC). This control board replaces the standard Shadow VI control box.

The Shadow VI-WPC control board can only be used with Shadow VI Light Curtains (all sizes) and Wintriss Clutch/Brake Control. It cannot be used with any other press control or any other model of light curtain.

NOTICE This appendix explains specific differences when installing the Shadow VI-WPC board.

Refer to Chapter 2 and related illustrations for complete installation information where noted.

If you ordered WPC with the Shadow VI-WPC control board factory-installed and pre-mounted, you can disregard most of the installation sections in this appendix. You need only to connect the optic heads to the control board and make appropriate settings.

Mounting Dimensions and Required Clearance

WARNING! ELECTRIC SHOCK HAZARD

• Turn off and disconnect power from the Shadow safety light curtain and from the machinery it is connected to before making any wiring connections. This includes disconnecting power to the machine control and motor.

• Remove all fuses and “tag out” per OSHA 1910.147 Control of Hazardous Energy (Lockout/Tagout).

• Ensure that installation is performed by qualified personnel.

Failure to comply with these instructions could result in death or serious injury.

Refer to Figure C-2 for mounting dimensions and required clearance information for the Shadow VI-WPC control board. The Shadow VI-WPC control board comes assembled with eight standoffs for each mounting hole. Each standoff is size 6-32 and 1/2" in length. Recommended screw size is 6-32 x 3/8". Be careful to protect existing electronics, PC boards, etc. in the enclosure while drilling and mounting components.

If you are installing this control board inside a standard resolver-based WPC enclosure, we recommend that you mount it on the right side of the enclosure. If your display is mounted on the right side, install this board on the door. When mounted on the door, dress the wires carefully across the hinge. Use a loom to protect the wires from getting caught in the hinge.

1107200 Shadow VI User Manual

page 120 Appendix C Installation of Shadow VI-WPC Control Board

Mount the control board assembly near the WPC assembly so that important components on the board are readily accessible to personnel during installation and maintenance. Make sure that there is enough room to access the board whenever necessary.

About Shadow VI-WPC Control Board Labels

DANGER! DAILY TESTS LABEL INACCESSIBLE

Affix the Daily Tests label where operators can clearly read the instructions. The daily tests are critical to operator safety and must be run every day before operating the press.

Failure to comply with these instructions will result in death or serious injury.

NOTICE The information on the Operator Instructions label is used for maintenance purposes. Affix

the label where it can be easily read.

With your panel mount assembly you should have received the three labels shown below: "Daily tests,” “Shadow VI” and “Warning.” Place these labels where they are clearly visible.

Shadow VI User Manual 1107200

Installation of Shadow VI-WPC Control Board Appendix C page 121

shadow VIWINTRISS LIGHT CURTAINMAX RESPONSE TIME <40mS

INPUT POWER115/230 VAC 1/4 A

50-60Hz MAX 20 VASOLID STATE OUTPUTS

MAX 20 mA/24VDC

SEE CONTROLLER BOARD FOR ITEM& SERIAL NUMBERS

1-800-586-8324

®

Substitution ofcomponents mayimpair operatorsafety.

La substitutiond’éléments constitutifspeut compromettre lasécurité d l’operateur.!

WARNING AVERTISSEMENT

Figure C-1. Shadow VI - WPC Labels

"Daily tests" label (left), "Shadow VI" label showing response time (upper right), “Warning” label (lower right)

ATTENTION

CAUTION

Perform these tests daily to make surethe Light Curtain and the machine'scontrol system work properly. Also,perform these tests after anymodification or maintenance to theLight Curtain or the machine.NOTE: Use an opaque 1 1/4" diametertest bar for performing the daily tests.1. Turn on power to the Light Curtainand the machine. If the red and greenlights are on at the same time, clear theLight Curtain to green state bymomentarily interrupting the sensingfield with a test bar.2. If your Light Curtain has a FloatingWindow, shut off the Floating Windowsystem. Make sure the FloatingWindow indicator light goes off.3. Interrupt the sensing field on thereceiver side by passing the test barfrom the top to the bottom of thereceiver lens cover. The red lightshould come on while the bar is in thesensing field.4. Repeat step 3, passing the bar fromthe top to the bottom of the transmitterlens cover. Make sure the red lightcomes on when the bar is in thesensing field.5. Start the machine and interrupt thesensing field with the test bar. The redindicator light on the receiver shouldcome on and the machine shouldimmediately stop. NOTE: When mutingis used, interrupting the Light Curtainduring the muted portion of the strokewill NOT stop the machine.6. Cycle the machine and make sure itstops at the proper position and that themachine's braking system is workingproperly. If the machine does not brakefast enough, adjust the braking systemor increase the Light Curtain's safetydistance.7. If the machine or Light Curtain failsany of these tests, DO NOT RUN THEMACHINE. Notify the supervisorimmediately.8. When using the Light Curtain withmechanical power presses, all OSHASafety and Health Standards(29 CFR 1910.217) must be met. DONOT USE THE LIGHT CURTAIN ONF U L L R E V O L U T I O N C L U T C HMACHINES.

LIGHT CURTAIN DAILY TESTS

Perform these tests daily to ensure theLight Curtain and the machine's controlsystem work properly. These testsshould also be performed after anymodification or maintenance to theLight Curtain or the machine.

Des essais doivent être effectuéschaque jour pour s'assurer que lerideau de lumière et le système decommande de la machine fonctionnentcomme il faut. Ces tests doiventégalement être effectués après toutemodification ou tout entretien du rideaude lumière ou de la machine.

C42254 Rev

1107200 Shadow VI User Manual

page 122 Appendix C Installation of Shadow VI-WPC Control Board

The LED indicators, switches, and terminal blocks listed below are on the control board (see Figure C-3 in this appendix) that should be readily accessible to personnel.

The indicators include: DS1: Set #1 optic heads blocked DS5: "Curtain clear"

DS2: Set #2 optic heads blocked DS6: "Floating"

DS3 & DS4: Power DS7: “Reset Required”

The switches include: S1: Floating window enable J2: 1 or 2 sets

S2: 115/230 voltage S3: Reset button

The terminal blocks include: TB2: Receiver(s) TB1: Power

TB3: Transmitter(s) TB4: Stop outputs

3.25(8.26)

2.75(6.99)

3.25(8.26)

6.00(15.24)

9.50(24.13)

10.00(25.40)

xx.x = inches(xx.x x) = cm

allow at least5" clearanceabove board

and 1"clearance

around

8 standoffs(size 6-32, 1/2" long)

are provided withprocessor board

Figure C-2. Mounting Dimensions and Required Space for Control Board

Shadow VI User Manual 1107200

Installation of Shadow VI-WPC Control Board Appendix C page 123

PowerTB1 Voltage

SelectorS2

CAUTIONPower

Transformer

DS5 DS6 DS1 DS2DS7

FLOATINGWINDOW

S1(shown set to "OFF")

RESETBUTTON

S3

STOP OUTPUTSTB4

FuseF1

Labelsshown here

do not appearsame on

on actual board.

LEDs

2SET / 1 SETJumpers

J12

RECEIVER(S)TB2

upper - Set 1lower - Set 2

TRANSMITTER(S)TB3

upper - Set 1lower - Set 2

mountingholes

(8 places)

DS4 DS3

PEformerly"CHAS"

X M T R

P W RR C V RP W R��

��

��

��

��

��

���

���

��

���

��

���

���

��

��

��

���

��

���

��

��� ��� ��� ��� ���

Figure C-3. Important Components - Shadow VI-WPC Control board

1107200 Shadow VI User Manual

page 124 Appendix C Installation of Shadow VI-WPC Control Board

Wiring Shadow VI optic heads to the board

You will be connecting the two interchangeable quick-connect cables, and plugging them into the bottom of the transmitter and receiver. Remember that the connection is keyed. Be sure to twist the locknut so the connection is tight.

To make proper wiring connections from the optic head(s) to the board, consult in the manual: • "Wiring the transmitter and receiver to the control" in Chapter 2 • Table C-1 Receiver & Table C-2 Transmitter wiring tables • Figure 8 (Shadow VI-WPC wiring schematic) at the end of the manual • Figure 10 (Shadow VI-WPC 1000 wiring schematic) at the end of the manual

Run the cables through separate 1/2" flexible, liquid-tight conduits from the Shadow VI transmitter and receiver to the knockouts at the bottom of the WPC enclosure. Because the enclosure is rated NEMA 4, you must use conduit of the same rating and make proper connections to ensure suitable protection with the enclosure.

The following are the wiring tables for receiver and transmitter.

NOTICE Remember to use the upper level TB2 for set #1, and the lower for set #2.

Table C-1. Connecting Light Curtain Receiver Head to TB2 in Controller

Set #1 Heads to Upper Level; Set #2 Heads to Lower Level

RCVR TB2 Wire color Terminal signal

Pin #1 orange FWIN

Pin #2 red VCC

Pin #3

blue and

black

GND

Pin #4 brown 1B

Pin #5 green 1A

Pin #6 yellow SYNC

Terminate shield to chassis near entry point

Shadow VI User Manual 1107200

Installation of Shadow VI-WPC Control Board Appendix C page 125

Table C-2. Connecting Light Curtain Transmitter Head to TB3 in Controller

Set #1 Heads to Upper Level; Set #2 Heads to Lower Level

XMTR TB3 Wire color Terminal signal

Pin #1 orange VCR

Pin #2 red VCC

Pin #3

blue and

black

GND

Pin #4 brown SHTD

Pin #5 green SHTD

Pin #6 yellow SYNC

Terminate shield to chassis near entry point

Connecting AC wiring to WPC

You will be connecting to terminal block TB1, located at the upper left corner of the board. See Figure C-3 for location of components. To make proper wiring connections to WPC (115 VAC 50-60 Hz single phase power source), consult in the manual: • Table C-3 TB1 Wiring table • Figure 8 (Shadow VI-WPC wiring diagram) at the end of the manual

The following is an illustration of this terminal.

#3 GND

#4 PE

#2 NEU

#1 HI

TB1

formerly"CHAS"

Figure C-4. TB1 Power Terminal

The following is the wiring table for power connections.

1107200 Shadow VI User Manual

page 126 Appendix C Installation of Shadow VI-WPC Control Board

Table C-3. Shadow-WPC Board TB1 to WPC

Shadow VI-WPC TB1 Pin # WPC Pin #

Pin #1 (L1) 125 (L1)

Pin #2 (L2) 126 (L2)

Pin #3 (GND) 127 (GND)

Pin #4 (PE) Shield

Next, locate the 115V-230V voltage selector switch (S2) on the control board. It is located at the upper right corner of the board. The setting on this board must match the voltage setting at WPC. The default setting is 115V ("115V" displays in the switch cavity). If the WPC is set for 230V AC power, push down on the handle for the Shadow VI control board to display "230V".

115V

Handle.Pushdownfor 230V

Figure C-5. Setting Voltage Selector Switch S2

Connecting Stop Circuits to WPC

Wiring the Shadow VI-WPC board to WPC's emergency stop circuitry ensures that whenever an obstruction or intrusion is detected, the press will stop as quickly as WPC will permit.

NOTICE Whenever Shadow VI stops the press, WPC will display a numeric error code on the LED

display. If SmartPAC is interfaced with WPC, an error message will appear on SmartPAC's LCD display.

To make proper wiring connections to WPC, consult in the manual: • Table C-4 TB4 Wiring table • Figure 8 (Shadow VI-WPC wiring schematic) at the end of the manual

Connect to terminal block TB4 located at the lower half of the Shadow VI-WPC board (see Figure C-3 for location of components).

The following is the wiring table for stop circuits.

Shadow VI User Manual 1107200

Installation of Shadow VI-WPC Control Board Appendix C page 127

Table C-4. Shadow-WPC Board TB4 to WPC

Shadow VI-WPC TB4 terminal #

WPC terminal #

Pin #1 (OUT 1) Pin #77 (LIGHT CURTAIN A 1 INPUT -)

Pin #2 (GND) Pin #44 (GND)

Pin #3 (OUT 2) Pin #87 (LIGHT CURTAIN A 2 INPUT -)

Pin #4 (RST) no connection

Pin #5 (INT) Pin #27 (LIGHT CURTAIN 1 ENABLE)

Making settings on the control board

These are the settings to make on the Shadow VI-WPC board.

Floating window setting

The floating window feature provides a means for the random bypass of only one beam of the light curtain (refer to Chapters 1 and 3 of this manual for more detail).

To set, locate switch block S1 (illustrated below). This switch is situated at the lower half of the board to the left of the black reset button (see Figure C-3 for location of components). The "off" setting (default) disables the floating window option. When this feature is enabled ("on"), the floating window indicators on the control board and at the receiver will flash on and off.

off

on

S1

Figure C-6. Floating Window Switch S1

1107200 Shadow VI User Manual

page 128 Appendix C Installation of Shadow VI-WPC Control Board

NOTE

The other settings covered in "Making settings at the control" in Chapter 2 of this manual are not applicable and not available for the Shadow VI-WPC option.

J12 Setting

These instructions explain how to set the control board for a second set of light curtains. The factory setting is already at "1 SET". If you have a second set, follow these steps:

Locate jumper location J12 at the lower right corner of the board (refer to Figure C-3 for location of components). Notice that the jumper is set on pins 2 and 3 for "1 SET". Move the jumper so that it is on pins 1 and 2. See the next illustration.

"1 SET" setting(Jumpers on 2 right pins)

J12

** notice that there are 2 jumpers next to each other at J12

J12

"2 SET" setting(Jumpers on 2 left pins)

2 SET I SET2 SET I SET

Figure C-7. Jumper Position for "1 SET" and "2 SETS"

You also need to perform some diagnostics to verify this setting. To do this, refer to the section, "Aligning and tightening down Shadow VI components" in Chapter 2.

Shadow VI User Manual 1107200

Installation of Shadow VI-WPC Control Board Appendix C page 129

Reset button

A black Reset button is located towards the lower half of the control board to the right of the floating window enable switch. This button replaces the reset keyswitch located on the standard Shadow VI control box.

Reset ButtonS3

(next to Floating Window switch S1)

Figure C-8. Reset Button

NOTICE References throughout the manual to "reset keyswitch" are applicable to this Reset button.

Rather than turning the reset keyswitch, which is standard on the Shadow VI control box, you will press the Reset button, which is located on the Shadow VI-WPC control board. Access to this button is imperative.

You press the Reset button when the curtain is blocked ("red") and you have carefully removed the obstruction and corrected the situation. You also press the Reset button when the light curtain goes into a “reset required” condition. This allows you to resume operation.

NOTICE You cannot clear a “reset required” condition unless the optic heads are properly aligned

and the indicator(s) on the receiver(s) light up green.

If the receiver(s) indicate a red condition, you will not be able to reset the system by pressing Reset on the control board. You first must properly align the optic heads and check that the indicator(s) light up green. Refer to Chapter 4 Troubleshooting for more information about error conditions and using the Reset button.

1107200 Shadow VI User Manual

page 130 Appendix C Installation of Shadow VI-WPC Control Board

Shadow VI User Manual 1107200 Replacement Parts Appendix D page 131

Appendix D – Replacement Parts

WARNING! INCORRECT REPLACEMENT PARTS

Use only factory replacement parts. If you use non-factory parts as replacements, this may impair the safety performance of this equipment.

Failure to comply with these instructions could result in death or serious injury.

Use the following replacement parts for your light curtain.

Table D-1. Replacement Parts List

Description Wintriss part number

Component designation

Fuse, Slo-Blo, 0.25A 250V 3AG type (US)

XF20543A06 F1

Fuse, Slo-Blo, 4A 250V 2054316 F2 - F4

Mounting brackets for optic heads (pair) (order one pair for each head)

4275201

Keylock reset switch 2244201

Reset keys (pair) 2244203

Door lock key 2069005

Control PC board 4288801

Shock mount kit (order one set for each head or control box)

4245402

Master blanking window (6” - 24”) 4280602

Master blanking window (30” - 48”) 4280603

Master blanking window (60” - 72”) 4280604

Slave blanking window 4280601

1107200 Shadow VI User Manual

page 132 Appendix D Replacement Parts

Shadow VI User Manual 1107200 Index page 133

Index

AC wiring

Shadow VI - WPC, 125

standard and panel mount, 50

alignment, 33

brackets, 35

checking, 87

American National Standards Institute (ANSI), 1, 2, 6, 19, 22, 97

extracts from B11.1-2009, 98

extracts from B11.19-2003, 105

standard B11.1-2009, 1

standards, 2

Angle of Divergence and Acceptance, 13

ANSI. See American National Standards Institute (ANSI)

safety distance formula, 21

blanking windows, 10, 14, 24, 69

and safety distance, 24

master, 72

part numbers, 131

slave, 75

bolster, mounting to, 28, 33

brackets, 28

brake monitor, 22

cables, 3, 12

shields, terminating, 46

captive-contact relays, 7

channels, 8

checkout, 66

cleaning lenses, 87

clutch/brake controls, 56, See also Wintriss Clutch/Brake Control

components, location of

Shadow VI control, standard, 44

Shadow VI-WPC, 123

connector, quick-connect, 64

construction, 12

control, 2, 3, 12, 15

dimensions, standard, 43

control board

dimensions, panel mount, 118

dimensions, Shadow VI - WPC, 122

location of components, 44

location of components, Shadow VI - WPC, 123

control relays, 90

control reliability, 6

cross talk, 39, 92

curtain clear, 8, 80

depth penetration factor, 70

dimensions

cutout, panel mount, 118

mirror, 37

mounting, Shadow VI-WPC, 119

optic heads, 31, 32

Shadow VI-WPC control board, 122

standard control, 43

emergency stop circuit, 53

external fixed blanking, 69, See also blanking windows

fixed blanking, 10, See also blanking windows

floating enabled indicator LED, 13

floating window, 8, 10, 24, 60, 69, 77, 80

setting on Shadow VI-WPC control board, 127

Floating window, 10

floor stands, 28

FSD1, 54

FSD2, 54

fuses

checking and replacing, 88

part numbers, 131

gap frame presses, 28

green indicator, 7, 80

1107200 Shadow VI User Manual

page 134 Index

ground

electric service, 51

RF terminal (top of housing), 42

guards, 35

hand-speed constant, 20, 22

heads, 2, 12

connecting to standard control, 46

connecting, Shadow VI - WPC, 124

two sets, avoiding cross talk, 39, 92

two sets, troubleshooting, 85

using two sets of, 65

indicators, 8, 10, 13

control, 8, 80

heads, 80

on control board, Shadow VI - WPC, 123

installation, 17

aligning and tightening down Shadow, 62

blanking window(s), 72

calculating the safety distance, 17

checkout, 66

connecting AC wiring, 50

connecting power (Shadow VI-WPC control board), 125

connecting stop circuits (Shadow VI-WPC), 126

designing and mounting brackets, 26

making jumper block setting, 60

overview, 16

jumper(s)

J12 (1set/2sets), 60

J12 (1set/2sets), Shadow VI-WPC control board, 128

MPCE, 58

on TB4, 53, 54

removing for PLC installation, 56, 57

transmitter interrupt, 82

labels

daily test, panel mount, 117

for panel mount installation, 116

for Shadow VI-WPC installation, 120

operator instructions, panel mount, 117

laser alignment tool, 33

LED(s), 5, 87

DS1, DS2, 64, 65

DS1-DS4, 8

DS3, DS4, 63

DS5, DS6, 85

indicators (Shadow VI-WPC control board), 122

using for troubleshooting, 83

lens(es)

checking and cleaning, 87

light emitting diode. See LED(s)

machine primary control element. See MPCE

master blanking window, 72

matched sets, 5

mirror

dimensions, 37

using, 36

mirrors, 14

mounting brackets, 28

mounting dimensions (Shadow VI-WPC control board), 122

mounting into panel enclosure, 115

MPCE, 58

monitor input, 13

troubleshooting, 85

object sensitivity, 8, 23, 24, 70, 71, 78

Occupational Safety and Health Administration. See OSHA

optic heads. See heads

options, 14

orange indicator, 7, 80

OSHA, 6, 19

extracts from 1910.217, 93

regulation 1910.212, 1

regulation 1910.217, 1, 93

regulations, 2

safety distance formula, 20

OSHA/ANSI compliance, 2

outputs, 13

panel mount, 115

parts, replacement, 131

pass-through protection, 25

Shadow VI Safety Light Curtain 1107200

Index page 135

PC board. See control board, See components, location of

perimeter guarding, 10, 24

phototransistor, 5

pinch point, 16, 25

PLC

removing jumper when connecting to, 56, 57

wiring to, 56

power indicator, 7, 80

power-up reset disable

switch S4, setting, 59

programmable logic controller. See PLC

quick connect cables, 15

receiver, 1, 2, 3

red indicator, 7, 80

relays, 6, 56

detection of failed, 7

safety, replacing, 91

testing with voltmeter, 90

remote reset, 13

reset button

Shadow VI - WPC control board, 122, 127, 129

reset keyswitch, 2

reset on interrupt

switch S4, setting, 59

reset required, 8, 13, 80

resetting the system, 2

response time, 7, 20, 21, 22

S1 settings, 59

S4 settings, 60

safety distance, 16, 19, 20, 22, 24, 70, 71, 78, 96

additional with floating window, 78

scanning heights, 12

sequenced light pulses, 5

settings

jumper, 61

shields, terminating head cable, 46

shock mounts

kit part number, 131

mounting heads with, 40

side guards, 35

slave blanking window, 72

slave blanking windows, 24

spares, 131

status, 13

status relay, 10

stop circuit

operation, 7

specifications, 13

wiring, 50

wiring (Shadow VI - WPC), 126

stop signal, 8, 80

stopping time, 22, 96

straight side presses, 28

switch(es)

floating window (S1), 59

on Shadow VI-WPC control board, 122

power-up reset disable (S4), 59

reset on interrupt (S4), 59

S1 and S4, 59

status follows stop outputs (S1), 59

voltage selector (S2), 51

Tbm, stop time adjustment for brake wear, 102

terminal blocks

location, Shadow VI - WPC, 123

location, standard control board, 44

Shadow VI-WPC control board, 122

three-sided guarding, 36, 38

transmitter, 1, 2, 3, 5

troubleshooting, 63, 79

universal mounts, 11, 27

vibration, 33, See also shock mounts

voltage selector

Shadow VI-WPC control board, 126

switch S2, 51

voltage selector switch, 126

weight, 12

weld shield kit, 11

weld shield kit, ordering, 39

Wintriss WPC 1000 Clutch/Brake Control

wiring to, 55, 119

1107200 Shadow VI User Manual

page 136 Index

Wintriss WPC Clutch/Brake Control

wiring to, 55, 119

wiring. See also installation

optic heads (Shadow VI-WPC), 124

optic heads, standard control, 46

Shadow to a PLC, 56

Shadow to WPC, 55

WPC. See Wintriss WPC Clutch/Brake Control

WPC 1000. See Wintriss WPC 1000 Clutch/Brake Control

page 137

Wintriss Manuals

Wintriss Product Installation Manual

Doc. No.User Manual/CD

Doc. No.

AutoSet (1500, 1500 Plus, 1504, 1504 Plus) DA71747 DA71447

AutoSetPAC (Tonnage Monitor) DA71413 DA71443

Die Protection Handbook N.A. * 1130300 *

DiPro 1500 DA71428 DA71447

DSI 2 Sensor Interface N.A. * DA66970 *

MultiPAC Types 1 and 2 DA71409 DA71443 MultiPAC Types 4 and 5 DA71410 DA71443 ProCam 1500 DA71430 DA71447 ProPAC (Process Monitor – In-die Measurement) DA71411 DA71443 RamPAC (Shut Height, Counterbalance & Cushion Control)

DA71412 DA71443

Servofeed Interface – Coe/Wintriss DA71415 DA71443 Servofeed Interface – CWP/Wintriss DA71416 DA71443 Servofeed Interface – DiPro 1500 DA71429 DA71447 Servofeed Interface – Electrocraft/Wintriss DA71417 DA71443 Servofeed Interface – Indramat/Wintriss DA71418 DA71443 Servofeed Interface – ProCam DA71431 DA71447 Servofeed Interface – SmartPAC DA71420 DA71443 Servofeed Interface – Waddington/Wintriss DA71419 DA71443 Shadow V Safety Light Curtain DA71433 DA71449 Shadow VI Safety Light Curtain DA71422 DA71445 Shadow VII Safety Light Curtain N. A. * 1129400 *

Shadow 8 Safety Light Curtain N. A. * 1139300 *

SmartPAC (w/ DiProPAC & ProCamPAC) DA71439 DA71454 SmartPAC Hydraulic DA71435 DA71451 SmartPAC Run Mode (Spanish) N. A. * DA71443

SmartPAC w/ WPC II Integration DA71440 DA71455 SmartPAC 2 (w/ DiProPAC & ProCamPAC) DA71406 DA71441 SmartPAC 2 Hydraulic DA71436 DA71451 SmartPAC 2 Servo DA71437 DA71452 SmartPAC 2 w/ WPC 2000 Integration DA71407 DA71442 SmartPAC 2 w/WPC 2000 Run Mode (Spanish) N. A. * DA71443 WaveFormPAC (Advanced Load Analyzer) DA71414 DA71443 Wintriss Brake Monitor DA71432 DA71448 Wintriss Clock Display N. A. * DA67206 *

WPC II Wintriss Press Control DA71438 DA71453 WPC 1000 Wintriss Press Control DA71423 DA71446 WPC 2000 Wintriss Press Control DA71421 DA71444 WPC 2000 Option 2 DA71408 DA71442

* Installation Manual not available; User Manual available in hard copy only. Die Protection Handbook available in hard copy (1102400) and on CD (1130300).