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Banner PICO-GUARD SFCDT-4A1, Instruction Manual

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Printed in USA 

04/04

 

P/N 69761 rev. B

9714 10th Avenue North • Minneapolis, MN 55441

Phone: 763.544.3164 •  http://www.bannerengineering.com

Email: [email protected]

Controller Instruction Manual

Models SFCDT-4A1, SFCDT-4A1C

Section Contents

Section 1 

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . Page 1 

Section 2 

System Components and Specifications  . . . . . . . Page 3

Section 3 

Installation and Alignment . . . . . . . . . . . . . . . . . . Page 6

Section 4  

System Operation   . . . . . . . . . . . . . . . . . . . . . . . Page 18

Section 5 

Troubleshooting and Maintenance . . . . . . . . . . . Page 28

Section 6 

Periodic Checkout Procedures . . . . . . . . . . . . . . Page 32

PICO-GUARD

™

  

Fiber Optic Safety System

Patent Pending

Summary of Contents for PICO-GUARD SFCDT-4A1

Page 1: ... Instruction Manual Models SFCDT 4A1 SFCDT 4A1C Section Contents Section 1 System Overview Page 1 Section 2 System Components and Specifications Page 3 Section 3 Installation and Alignment Page 6 Section 4 System Operation Page 18 Section 5 Troubleshooting and Maintenance Page 28 Section 6 Periodic Checkout Procedures Page 32 PICO GUARD Fiber Optic Safety System Patent Pending ...

Page 2: ...ness of the provided information for a specific application The user has the responsibility to ensure that all local state and national laws rules codes and regulations relating to the use of this safeguarding system in any particular application are satisfied Extreme care is urged to ensure that all legal requirements have been met and that all installation and maintenance instructions contained ...

Page 3: ...ect equipment critical tooling or critical materials in process The controller has two solid state diverse redundant safety outputs OSSDs to control 24V dc loads If an ac powered MPCE or other load is required an accessory interface module or redundant positive guided contactors may be used to convert the PICO GUARD outputs to isolated forced guided relay contacts e g model IM T 9A or IM T 11A see...

Page 4: ...ions to allow easy installation and proper operation on a variety of doors and other hard guarding applications Each optical element can be used as either an emitter or a receiver they have no electrical connection This can greatly reduce the required inventory and simplifies installation Plastic fibers are available in three versions solid core fiber solid core fiber with integral fluoropolymer s...

Page 5: ...ntroller 2 System Components and Specifications Components and Specifications Fiber 1 mm 0 04 Polyethylene Jacket 2 2 mm 0 09 Standard no Sheath PVC Sheath Fiber 1 mm 0 04 Polyethylene Jacket 1 8 mm 0 07 Fiber 1 mm 0 04 PVC Sheath 5 mm 0 20 Polyethylene Jacket 2 2 mm 0 09 Fluoropolymer Sheath 2 2 mm 0 09 Fluoropolymer Sheath Length Standard Polyethylene Jacket PVC Sheath PVC Sheath Bulk Fiber 9 m ...

Page 6: ...eak Fault Rating 1 2 3 4 5 7 8 9 10 12 13 14 15 17 18 1 2 3 4 5 7 8 9 10 12 13 14 15 17 18 OSSD EDM 1 USSI 2 USSI 1 1 2 a b c d Reset EDM 2 a b a b a b c d R1 R2 R3 R4 E1 E2 E3 E4 35 mm 66 mm 2 6 132 mm 5 2 93 8 mm 3 69 112 4 mm 4 43 7 mm 0 27 122 6 mm 4 78 85 5 mm 3 37 2 3 Accessories NOTE If used two contactors per controller are required See Figures 3 7 and 3 10 2 5 Literature 2 6 Dimensions 2 ...

Page 7: ...for monitoring output contacts or handshake compatible safety solid state outputs of other safety stop devices OFF stop signals cause the PICO GUARD OSSDs to latch OFF Latch condition See Section 3 7 USSI 2 Input Dual channel redundant inputs for monitoring output contacts or handshake compatible safety solid state outputs of other safety stop devices OFF stop signals cause the PICO GUARD OSSDs to...

Page 8: ...ed Channel 4 bi color Red Green each shows the status of one optical channel USSI 2 bi color Red Green status of the USSI input channels a b and c d USSI 1 Reset bi color Yellow Red status of USSI 1 reset input indicates USSI 1 reset needed EDM bi color Red Green status of the EDM input channels OSSD bi color Red Green status of the OSSD outputs Config bi color Red Green status of the system confi...

Page 9: ...pends upon the appropriateness of the application and upon its proper mechanical and electrical installation and interfacing to the guarded machine If all mounting installation interfacing and checkout procedures are not followed properly the System cannot provide the protection for which it was designed Installation must be performed by a Qualified Person as defined in Section 3 2 See Warning bel...

Page 10: ...the switch This will hinder a reset while the key is under the control of an individual but must not be relied upon solely to guard against accidental or unauthorized reset Spare keys in the possession of others or additional personnel entering the safeguarded area unnoticed may create a hazardous situation WARNING Reset Switch Location All reset switches must be Outside the hazardous area in a lo...

Page 11: ...en terminals 1 and 23 will cause a lockout condition but will allow connection to a common source of 24V dc Refer to Figures 3 7 3 8 3 9 and 3 10 Connect the external System Reset switch to the System Reset terminal 23 and to the 24V dc supply Connect the USSI 1 Reset switch if used to the USSI 1 Reset terminal 1 and to the 24V dc supply 3 4 2 System Power Hookup DO NOT apply power to the controll...

Page 12: ...for resolution of lockout conditions WARNING Installing Multiple External Stop Devices Whenever two or more external stop devices contact output are connected to the same USSI input contacts of each output channel must be connected together in series This series combination is then wired to the respective USSI input i e a to b and c to d See the PICO GUARD Application and Design Guide for further ...

Page 13: ... after configuring the System and after installing and connecting the optical elements per the applicable instructions and standards The procedure is performed on two occasions To ensure proper installation when the System is first installed and To ensure proper System function whenever any maintenance or modification is performed on the System or on the machinery being guarded by the System See S...

Page 14: ...cedure is completed and all problems are corrected 3 9 Electrical Interface to the Guarded Machine Permanent Hookup Make the electrical connections as described in Sections 3 9 1 to 3 9 5 as required by each individual application System power and the System Reset switch should already be connected by this point The PICO GUARD system must also have been aligned and passed the Initial System Checko...

Page 15: ...p Circuits A safety stop allows for an orderly cessation of motion for safeguarding purposes which results in a stopping of motion and removal of power from the MPCEs assuming this does not create additional hazards A safety stop circuit typically comprises a minimum of two normally open N O contacts from forced guided mechanically linked relays which are monitored through EDM to detect certain fa...

Page 16: ...15 See the top PICO GUARD controller in Figure 3 10 NOTE EDM AND CONTROL RELIABILITY In the U S Control Reliability requires that a single failure does not prevent a normal stop from occurring or issues an immediate stop command and the next cycle is prevented from occurring until the fault is corrected A common method of satisfying these requirements is through the use of dual channel control wit...

Page 17: ... 34 35 Load Load Load Ch1 Ch2 Ch3 Ch4 36 Load only for model SFCDT 4A1C 1 See Section 3 4 1 for information on Reset input and hookup 2 2 Channel EDM shown See Section 3 9 3 for information on EDM input and hookup 3 Must meet External Stop Device requirements See Section 3 7 Single Channel Safety Stop Circuit Dual Channel Safety Stop Circuit See Section 3 9 on interfacing of safety stop circuits F...

Page 18: ...ut USSl 2 Input 31 30 29 28 10 8 5 4 2 3 Remote Interface V OVdc Safety Device Contact Outputs 9 7 Load Load Load Load 33 34 35 Ch1 Ch2 Ch3 Ch4 36 only for model SFCDT 4A1C 1 See Section 3 4 1 for information on Reset input and hookup 2 2 Channel EDM shown See Section 3 9 3 for information on EDM input and hookup 3 Must meet External Stop Device requirements See Section 3 7 Figure 3 8 PICO GUARD S...

Page 19: ... c d b a c d b USSl 1 Input USSl 2 Input 31 30 29 28 10 8 5 4 2 3 Remote Interface V OVdc 7 9 V OV 1 See Section 3 4 1 for information on Reset input and hookup 2 1 Channel EDM shown See Section 3 9 3 for information on EDM input and hookup 3 Must meet External Stop Device requirements See Section 3 7 Ch1 Ch2 Ch3 Ch4 only for model SFCDT 4A1C Load Load Load Load 33 34 35 36 Figure 3 9 PICO GUARD S...

Page 20: ...ad Aux Weak Fault 4 Tx Tx a c d b a c d b USSl 1 Input USSl 2 Input 31 30 29 28 10 8 5 4 2 3 Remote Interface V OVdc See Section 3 9 on interfacing of safety stop circuits Safety Device Solid State Outputs V OV 3 Safety Device Contact Outputs 7 9 33 34 35 Load Load Load Ch1 Ch2 Ch3 Ch4 36 Load only for model SFCDT 4A1C 33 34 35 Load Load Load Ch1 Ch2 Ch3 Ch4 36 Load only for model SFCDT 4A1C 1 See...

Page 21: ...ure 4 2 If the switches are set for Auto Power Up the controller will automatically perform a system reset on power up after the internal system tests are completed If the switches are set for Manual Power Up the controller will require a system reset at power up The controller indicates it is ready for a system reset after power up by double flashing the System Reset indicator see Figure 4 3 Trip...

Page 22: ...ed after power up System Reset indicator double flashes See Section 4 5 5 Auto Power Up When power is applied the controller will conduct self tests to detect critical internal faults determine configuration settings and prepare the system for operation If a critical fault is detected the OSSD outputs remain OFF and diagnostic information is displayed via the controller s status indicators If no f...

Page 23: ...or Yellow Red status of the USSI 1 reset input or USSI 1 reset needed Yellow input signal is high Yellow Flashing waiting for USSI 1 latch reset Red Flashing external fault of the input detected OFF input signal is low or during lockout except for USSI 1 Reset faults Red Flashing Burst noise on the USSI 1 reset input EDM Indicators bi color Red Green status of the EDM inputs one indicator for each...

Page 24: ... signal has been removed both USSI 2 input channels ON closed the controller will resume normal operation NOTE If the OSSD outputs do not turn ON after the USSI 2 stop signal is cleared check for a USSI stop or latch condition or for an optical channel open blocked or latch condition The USSI 2 input must be jumpered if it is unused see Section 3 7 and it will have no effect on the operation of th...

Page 25: ...or USSI 2 Indicators OSSD Output Indicator OSSD Outputs Power up Apply power Flash Red Flash Green OFF Flash Red Flash Yellow OFF Flash Red Flash Green OFF Flash Red Flash Green OFF OFF Run Pass internal tests USSI 1 and 2 Closed ON Green OFF Green Green ON USSI 1 Stop USSI 1 Open OFF OFF OFF Green Red OFF USSI 1 Latch USSI 1 Closed ON Green Single Flashing Yellow Green Green OFF Run USSI reset re...

Page 26: ... or external PICO GUARD system error or fault See Figure 4 4 for Auxiliary output operation and see Section 5 for resolution of error fault conditions The Fault output is a light duty 24V dc solid state output used for system monitoring functions that are not safety related A typical use is to communicate with a programmable electronic system PES such as a PLC that a fault has been detected and a ...

Page 27: ...ystem status via the optional remote display see Section 2 3 Accessories or via a computer PLC PES or other monitoring device The optional remote display provides the same status infor mation as the controller status indicators see Section 4 4 A diagnostic software program is available on the PICO GUARD CD to use with PC compatible computers for easy viewing of System status and or diagnosis of Sy...

Page 28: ... Trip Mode Selected Auto Power up Configur ation Invalid 13 14 USSI 1 USSI Input a b State Invalid Reserved USSI Input c d Invalid Reserved USSI 1 Input a b State USSI 1 Input a b Noisy USSI 1 Input c d State USSI 1 Input c d Noisy 15 16 USSI 2 USSI 2 Input a b State Invalid Reserved USSI 2 Input c d Invalid Reserved USSI 2 Input a b State USSI 2 Input a b Noisy USSI 2 Input c d State USSI 2 Input...

Page 29: ...Switches are set to Auto system is set for Auto Power up 0 Auto Man Switches are set to Man system is set for Manual Power up Configuration Invalid 1 The system configuration is invalid or unknown not available 0 The system configuration is valid Aux Output 1 ON 0 OFF Weak Output 1 ON 0 OFF Fault Output 1 ON 0 OFF System Status 001 The PICO GUARD is in Manual Power up mode and is waiting for a Sys...

Page 30: ... of this byte indicates the Microcontroller A Advanced Diagnostic Code number Factory use only Microcontroller B Advanced Diagnostic Code The value of this byte indicates the Microcontroller B Advanced Diagnostic Code number Factory use only Channel 1 Enabled Config Invalid bit must be 0 1 Channel 1 Switch is set to ON 0 Channel 1 Switch is set to OFF Channel 1 Clear 1 Channel 1 is Clear Strong si...

Page 31: ...d correct the cause of the error see Figure 5 1 2 Cycle the external stop device connected to the USSI input closed ON and then open OFF Both channels of the external stop device must open or go OFF within 3 seconds of each other NOTE for USSI 1 errors After lockout recovery a USSI 1 reset is required when both channels go closed ON 5 2 Electrical and Optical Noise The PICO GUARD System is designe...

Page 32: ...FI noise 1 System Status OSSD 1 or System Status OSSD 2 OSSD Error OSSD 1 or 2 overload OSSD 1 or 2 external wiring fault Check load rating Must be 0 5A dc Disconnect loads If OK then check wiring If error continues replace controller 2 System Status System Reset System Reset Error System Reset switch closed on power up or during recovery from a USSI lockout System Reset external wiring fault Exce...

Page 33: ... for loose connections and or EMI RFI noise 10 System Status EDM 1 EDM 2 EDM Error Incorrect EDM configuration EDM 1 and EDM 2 mismatch 2 channel EDM Excessive EMI RFI noise on EDM 1 and EDM 2 Check EDM configuration see Section 3 9 3 Check input signal level for proper operation Intermittent error check for loose connections and or EMI RFI noise 11 System Status Channel 1 Optical Channel 1 Error ...

Page 34: ...tching point emitter optical element A red light should be present If very dim replace suspect element emitter element or previous receiver element or splice in a fiber loop to see if problem is resolved 8 Ensure that the environment does not negatively affect the optical fiber or the optical elements 5 4 Servicing and Maintenance 5 4 1 Cleaning The PICO GUARD System controller housing is construc...

Page 35: ... the guarded machine as described in Section 3 9 or whenever changes are made to the System either a new configuration of the PICO GUARD System or changes to the machine Checkouts must be performed by a Qualified Person as defined by OSHA and in the Safety Glossary of the manual A copy of the checkout results should be kept on or near the machine see OSHA 1910 217 e 1 To prepare the System for thi...

Page 36: ...l stop device inputs are closed ON and after a external stop device Reset A lockout condition indicated by System Status indicator flashing Red Additional indicators may also flash Red to indicate the error type 10 o If in a run condition go to step 11 If in a lockout condition refer to Section 5 A stop condition indicates that an optical element is misaligned or interrupted or that a external sto...

Page 37: ...ult in serious bodily injury or death 6 5 Semi Annual Checkout Procedure To Be Performed Every Six Months Following System Installation Perform this checkout procedure as part of System installation after the System has been interfaced to the guarded machine as described in Section 3 9 and every six months following the installation of the System Semi Annual checkouts must be performed by a Qualif...

Page 38: ...ch condition indicated by System Status indicator steady Red USSI 1 Reset indicator flashing Yellow Both USSI 1 Input indicators Green The USSI 1 latch will be cleared only when both USSI 1 inputs are closed ON and after a USSI 1 Reset A lockout condition indicated by System Status indicator flashing Red Other indicators indicating error type may also flash Red 10 o If in a run condition go to ste...

Page 39: ...med Auto Power up requires no system reset 17 o Test the machine stopping response time using an instrument designed for that purpose to verify that it is the same or less than the overall system response time specified by the machine manufacturer Banner s Applications Engineering Department can recommend a suitable instrument WARNING Do Not Use Machine Until System Is Working Properly If all of t...

Page 40: ...Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 PICO GUARD Controller Instruction Manual 38 P N 69761 rev B ...

Page 41: ...P N 69761 rev B 39 Banner Engineering Corp Minneapolis U S A www bannerengineering com Tel 763 544 3164 PICO GUARD Controller Instruction Manual P N 69761 rev B 39 ...

Page 42: ...Banner Engineering Corp Minneapolis MN U S A www bannerengineering com Tel 763 544 3164 PICO GUARD Controller Instruction Manual 40 P N 69761 rev B ...

Page 43: ... Two Hand Control Devices Functional Aspects Principles for Design ISO 13853 prEN 811 Safety Distances Lower Limbs ISO 13849 EN 954 1 Safety Related Parts of Control Systems ISO DIS 13855 EN 999 The Positioning of Protective Equipment in Respect to Approach Speeds of Parts of the Human Body ISO 14121 EN 1050 Principles of Risk Assessment ISO 14119 EN 1088 Interlocking Devices Associated with Guard...

Page 44: ...e from defects for one year Banner Engineering Corp will repair or replace free of charge any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period This warranty does not cover damage or liability for the improper application of Banner products This warranty is in lieu of any other warranty either expressed or implied P N 69761 rev B ...

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