Magnetek LaserGuard2 LG2-H-4 Instruction Manual Download Page 1

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LaserGuard2

Laser Collision Avoidance System

Part Number: 147-20004 R1

April 2015

Distributed by Ergonomic Partners

[email protected]

www.ErgonomicPartners.com

Tel: (314) 884-8884

Summary of Contents for LaserGuard2 LG2-H-4

Page 1: ...aser Collision Avoidance System Part Number 147 20004 R1 April 2015 Copyright 2015 Magnetek Material Handling Distributed by Ergonomic Partners Sales ErgonomicPartners com www ErgonomicPartners com Tel 314 884 8884 ...

Page 2: ...7 2 1 LaserGuard2 Model Numbers 7 2 2 Class 1 Laser Device 7 2 3 Laser Collision Avoidance System Description 7 2 4 Optical Path Fault Detector 8 2 5 Fault Relay 8 2 6 System Specifications 9 3 Installation Information 10 3 1 Mounting Location Considerations 10 3 2 Line Input Considerations 10 3 3 Wiring Considerations 10 3 4 Mechanical Installation 11 3 5 Electrical Installation 17 3 6 Mechanical...

Page 3: ...anada and the United States For more information please visit http www magnetek com 2015 MAGNETEK All rights reserved This notice applies to all copyrighted materials included with this product including but not limited to this manual and software embodied within the product This manual is intended for the sole use of the person s to whom it was provided and any unauthorized distribution of the ma...

Page 4: ...e Occupational Health and Safety Administration OSHA Applicable local state provincial or federal codes ordinances standards and requirements or Safety standards and practices for the industries in which Magnetek Products are used This manual does not include or address the specific instructions and safety warnings of these manufacturers or any of the other requirements listed above It is the resp...

Page 5: ...s DANGER DANGER indicated an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided could result ...

Page 6: ...d immediately and proper alternate precautions should be taken WARNING The crane collision avoidance unit and limit switches if any should be checked at the beginning of each shift or when a new operator takes control of the crane When checking the collision avoidance unit and limit switches the hoist should be centered over an area free of personnel and equipment WARNING The collision avoidance u...

Page 7: ... and energy efficiency The laser communicates with the Laser Support Unit LSU by means of a 4 mA to 20 mA current loop This type of communications link has very high noise immunity and provides the necessary accuracy for a collision avoidance system The laser used in the LaserGuard2 system is set to measure distances from 8 in to 150 ft with an output current of 4 mA at 8 in and 20 mA at 150 ft Th...

Page 8: ...e sequence is corrected The FAULT LED DS5 will flash three times pause and repeat until the sequence is in the correct order 2 4 Optical Path Fault Detector When the system detects a loss in the optical path due to obstructions or misalignment of the laser and its target it will produce a 10 second fault This will cause the fault relay and the range point relays to drop out for 10 seconds After th...

Page 9: ...VDC 9 36 VDC 85 264 VAC or 120 370 VDC 9 36 VDC Accuracy 1 in Hysteresis Approx 12 Control Outputs Three form C relays rated at 10 A 270 VAC and 27 VDC Fault Output One form C relay rated at 10 A 270 VAC and 27 VDC Laser Class 1 Wavelength 660 nm Ambient Light Limit 50000 Lux Enclosure Standard Plastic IP65 NEMA 4 NEMA 4X Unit Dimensions 4 0 x 2 1 x 1 0 Approx 11 8 x 9 8 x 5 9 Weight 0 2 lbs Appro...

Page 10: ...CT VOLTAGE FAILURE TO DO SO MAY DAMAGE THE SYSTEM NOTE The unit should not be connected to lines containing excessive power up transients or continuous commutator noise A line conditioner may be necessary in some installations 3 3 Wiring Considerations 1 Do not connect or disconnect wiring or perform circuit checks while the power is turned on 2 The motor wiring shall be in a separate metal condui...

Page 11: ...t nothing can come between the laser s view of the target Determine the mounting position for the laser and the target such that the center of the laser s faceplate and the center of the target are the same distance above the plane the crane rails are in The laser and target center point should also be the same distance from the rails This is the most important part of a successful installation si...

Page 12: ...LaserGuard2 Instruction Manual April 2015 Page 12 of 31 Figure 3 Mounting Bracket Dimensions in mm ...

Page 13: ...LaserGuard2 Instruction Manual April 2015 Page 13 of 31 Figure 4 Mounting Instructions ...

Page 14: ...ound the previous figure Mount the laser securely to a solid surface so that the crane s load or movement will not affect the laser s alignment The laser and laser support unit should also be mounted as close to the control panel as possible to minimize long cable runs Figure 5 Laser and Target Installation ...

Page 15: ...LaserGuard2 Instruction Manual April 2015 Page 15 of 31 Mounting of the reflector target is not as critical as the laser refer to Figure 6 Figure 6 Target Dimensions ...

Page 16: ...6 of 31 Figure 7 Enclosure Dimensions A 12 00 in 305 mm G 10 50 in 267 mm B 12 00 in 305 mm H 10 50 in 267 mm C 6 00 in 152 mm M 8 74 in 222 mm D 10 20 in 259 mm N 7 10 in 180 mm E 10 20 in 295 mm Figure 8 Enclosure Dimensions for LG H 4X and LG L 4X ...

Page 17: ...out Place a protective end piece on the open end of the conduit to protect the laser cable from sharp edges Pull the supplied laser cable by the end that does not have a connector on it through the conduit starting from the opened laser unit end and into the LSU Leave enough cable on the laser end so that it is twice as long as the distance between the end of the conduit and the laser unit about 2...

Page 18: ...LaserGuard2 Instruction Manual April 2015 Page 18 of 31 Figure 10 Laser Support Unit Wiring for LG2 H 4 ...

Page 19: ...LaserGuard2 Instruction Manual April 2015 Page 19 of 31 Figure 11 Laser Support Unit Wiring for LG2 L 4 ...

Page 20: ...uirements of the power supply used in this system if it does not stop here and notify Magnetek Customer Service Turn on the power to the laser support unit and note that the green LED on the laser head is on continuously after a few seconds If that does not occur turn the power off and recheck all wiring For wiring special crane configurations such as magnetic control timed bypass or stepped stepl...

Page 21: ... and press the gray SLOWDOWN button This distance must be less than that in the previous step 3 Move the crane to the last point where the brakes are to be applied and press the black STOP button This distance must be less than that in Step 2 4 Move the crane away from the target and then back again to verify all range points are triggered at the correct distances Remember to consider the decelera...

Page 22: ...t check the power supply in the laser support unit If 12V is present turn the power off and check the continuity of the cable refer to Figure 10 through Figure 12 Replace defective sub assemblies as necessary If none are found replace the laser head When the laser head is greater than 150 ft from its target or an object is blocking the path of the laser for more than 10 seconds the following condi...

Page 23: ... turned ON and at a distance beyond the range points The LEDs indicate power to the relay The relays are normally energized As the unit moves closer to the target the range points sequentially drop out thus turning off the LEDs in sequence Control Unit DS6 Red Monitors engagement of the Fault Relay Normally ON when receiver turned ON The LED will extinguish when a fault of some type has been detec...

Page 24: ...LaserGuard2 Instruction Manual April 2015 Page 24 of 31 4 Installation Diagrams Figure 13 Component Locations ...

Page 25: ...LaserGuard2 Instruction Manual April 2015 Page 25 of 31 Figure 14 LaserGuard2 Stepped Series 4 VFD Control Protection in One Direction Recommended ...

Page 26: ...LaserGuard2 Instruction Manual April 2015 Page 26 of 31 Figure 15 LaserGuard2 Crane Control Protection in One Direction ...

Page 27: ...LaserGuard2 Instruction Manual April 2015 Page 27 of 31 Figure 16 LaserGuard2 Crane Control with Timed Bypass Protection in One Direction ...

Page 28: ...LaserGuard2 Instruction Manual April 2015 Page 28 of 31 Figure 17 LaserGuard Magnetic Crane Control Protection in Both Directions ...

Page 29: ...LaserGuard2 Instruction Manual April 2015 Page 29 of 31 Figure 18 LaserGuard2 Stepped VFD Control Protection in One Direction ...

Page 30: ...LaserGuard2 Instruction Manual April 2015 Page 30 of 31 Figure 19 Typical LaserGuard2 Interface with Stepless VFD Control ...

Page 31: ...LaserGuard2 Instruction Manual April 2015 Page 31 of 31 Figure 20 Typical LaserGuard2 Interface with P H Stepless Control ...

Page 32: ...a trip point close to the minimum sensing distance it is important to keep in mind the hysteresis inherent with the LaserGuard2 system The LaserGuard2 system has about 1 ft hysteresis around the point where the trip points are set For instance if the crane is physically moved so the laser and reflector have 10 ft between them and the Stop button is pressed the Stop relay will turn on at 11 ft and ...

Page 33: ... LaserGuard2 Laser Support Unit LSU wiring would also have to be wired using the table below The LASER SELECT switch S4 on the control board of the LSU must be moved from the default position of ON to OFF This will prevent nuisance Overcurrent faults when moving the crane to distances approaching 150 feet Laser Connector pin number LaserGuard Designation LaserGuard Wire LaserGuard Board Terminatio...

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