Banner Engineering Corp.
•
Minneapolis, MN U.S.A.
www.bannerengineering.com • Tel: 763.544.3164
PICO-GUARD Controller
Instruction Manual
Important
...
read this page before proceeding!
In the United States, the functions that PICO-GUARD Systems are
intended to perform are regulated by the Occupational Safety and
Health Administration (OSHA). Outside of the United States, these
functions are regulated by a variety of agencies, organizations, and
governments. Whether or not any particular PICO-GUARD System
installation meets all applicable requirements depends upon factors
that are beyond the control of Banner Engineering Corp. These factors
include the details of how the PICO-GUARD System is applied,
installed, wired, operated, and maintained.
It is the responsibility of
the purchaser and user to apply this PICO-GUARD System in full
compliance with all relevant applicable regulations and standards.
PICO-GUARD Systems can guard against accidents only when they
are properly installed and integrated into the machine, properly
operated, and properly maintained. Banner Engineering Corp. has
attempted to provide complete application, installation, operation, and
maintenance instructions. In addition, we suggest that any questions
regarding application or use of PICO-GUARD Systems be directed
to the factory applications department at the telephone number or
addresses shown on the back cover.
In addition to OSHA regulations, several other organizations
provide information about the use of safeguarding devices. Refer
to the American National Standards Institute (ANSI), the Robotics
Industries Association (RIA), the Association for Manufacturing
Technology (AMT), and others. Banner Engineering Corp. makes
no claim regarding a specific recommendation of any organization,
the accuracy or effectiveness of any information provided, or the
appropriateness 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 in this manual are followed.
Table of Contents
1. System Overview . . . . . . . . . . . . . . . . . . . . . . . . . page 1
1.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Applications and Limitations . . . . . . . . . . . . . . . . . . . . . . 2
2. System Components and Specifications . . . . . . . . . . Page 3
2.1 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Plastic Optical Fiber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. Installation and Alignment. . . . . . . . . . . . . . . . . . . . Page 7
3.1 Excess Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Security Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Controller Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Optical Fiber Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.6 Optical Element Installation . . . . . . . . . . . . . . . . . . . . . . . .10
3.7 External Stop Device Installation . . . . . . . . . . . . . . . . . . . 10
3.8 Initial System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.9 Electrical Interface to Guarded Machine
(Permanent Hookup) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.10 Preparing for System Operation . . . . . . . . . . . . . . . . . 14
4. System Operation . . . . . . . . . . . . . . . . . . . . . . . Page 19
4.1 Periodic Checkout Requirements . . . . . . . . . . . . . . . . 19
4.2 System Configuration Settings . . . . . . . . . . . . . . . . . . 19
4.3 Resetting the Controller . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.6 Remote Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5. Troubleshooting and Maintenance. . . . . . . . . . . . Page 29
5.1 Troubleshooting Lockout Conditions . . . . . . . . . . . . . 29
5.2 Electrical and Optical Noise. . . . . . . . . . . . . . . . . . . . . 29
5.3 Troubleshooting Weak Signal
(Low Excess Gain) Conditions . . . . . . . . . . . . . . . . . . .32
5.4 Servicing and Maintenance. . . . . . . . . . . . . . . . . . . . . 32
6. Periodic Checkout Procedures . . . . . . . . . . . . . . Page 33
6.1 Schedule of Checkouts . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Trip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.3 Commissioning Checkout . . . . . . . . . . . . . . . . . . . . . . 33
6.4 Daily Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . 35
6.5 Semi-Annual Checkout Procedure . . . . . . . . . . . . . . . 35
U.S. Standards Applicable to Use of PICO-GUARD Systems
ANSI B11 Standards
Safeguarding of Machine Tools
ANSI/RIA R15.06
Safety Requirements for Robot Systems
NFPA 79
Electrical Standard for Industrial
Machinery
See inside back cover for information on these
and other applicable standards,
and where to acquire copies.
