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The entire machine safety

system must be tested at the start of every shift.

Machine testing should include: (1) proper machine

operation and stopping capability; and (2) verification

of proper installation and settings of all point of

operation guards and devices before the operation is

released for production.

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Страница 1: ...Installation Manual for the Metal Box Controller Module ...

Страница 2: ...situation which if not avoided could result in death or serious injury CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to physical injury Safety Instructions or equivalent signs indicate specific safety related instructions or procedures ...

Страница 3: ...keting 800 569 7697 EST www pinnaclesystems com sales pinnaclesystems com service pinnaclesystems com Metal Box Controller Module Installation Manual Pinnacle Systems Inc 3715 Swenson Avenue St Charles IL 60174 P N 28 006r8 6 Customer Service 630 443 8542 CST Please have Model Serial and Software Rev Available Sales and Marketing 800 569 7697 EST www pinnaclesystems com sales pinnaclesystems com s...

Страница 4: ...anual and all procedures have been and will be followed All procedures in this manual must be followed The manufacturer cannot take responsibility for operation if all procedures and warnings in this manual are not followed Warranty Manufacturer warrants that this product will be free from defects in material and workmanship for a period of two years from the date of shipment thereof Within the wa...

Страница 5: ... ____________________________________ Options ______________________________________ Microprocessor Revision No _____________________ The entire machine safety system must be tested at the start of every shift Machine testing should include 1 proper machine operation and stopping capability and 2 verification of proper installation and settings of all point of operation guards and devices before t...

Страница 6: ...e MicroGuard 8 Alignment Procedure 9 Operations 10 ANSI Standard B11 19 2010 11 Safeguarding with Mechanical Guards 12 Light Curtain Testing Procedure 12 Controller Module Setup 13 Single Pylon Set Controller Module Jumper Settings 14 Multiple Pylon Set Controller Module Jumper Settings 15 Wiring 16 Swivel Bracket Dimensions 17 Pylon Dimensions by model Swivel 18 Additional cable information Swive...

Страница 7: ...ons and Guidelines OSHA Regulations B 1 Machine Control Reliability B 1 Safety Guidelines and Management Operational Safety B 2 Power Press Guarding B 3 Power Press Care through Inspection and Maintenance B 3 Safety Enforcement B 3 Supervisor Training B 3 Operator Training B 3 Appendix C Replacement Parts Controller Module Replacement Parts C 1 Pylon Replacement Parts C 2 Appendix D USB Diagnostic...

Страница 8: ...tion 18 Figure 10 Fixed Bracket Dimensions pylon dimensions by model and additional cable information 19 Figure 11 Controller Module Dimensions 20 Figure 12 Cornering Mirror Dimensions 21 Figure 13 Pedestal Dimensions 22 Figure 14 Swing Arm Mounting Bracket Dimensions 22 Figure 15 Controller Module Replacement Parts C 1 Figure 16 Pylon Replacement Parts C 2 Tables Table 1a 5 Beam Spacing Pylons 5 ...

Страница 9: ...s in line very close together on 5 or 1 centers This close spacing makes it impossible to place a body part through the curtain without detection For every infrared emitter there is an infrared detector directly opposite When an obstruction is placed between them the beam is broken and the absence of a beam is observed by the Controller Module which de energizes the output relays and opens the cir...

Страница 10: ...s written to cope with a noisy environment Introduction v CE Approved models Standards UL listed 25GL File E185946 IEC61496 1 IEC61496 2 CSA C22 2 14 95 0 8 M1986 Hengstler Safety Relays EN50205 IEC61810 1 UL508 IEC ratings 61496 1 2 IP54 box IP64 pylons AOPD Type 4 SIL3 SISTEMA PLe Temp Operating 0C to 55C 32F to 131F Storage 40C to 85C 40F to 185F Life Mechanical 50 000 000 cycles Electrical 200...

Страница 11: ...REEMENT Red The Diagnostics Display is a four digit alphanumeric with scroll Internal 12V RED D2 CINN INT GRN D10 5V YEL D4 EXT RELAY GRN D11 5V YEL D3 5V GRN D17 FAULT RELAY GRN D21 Construction Control Unit All 18 Gauge painted steel NEMA 12 lockable box with sealed front panel and sealed cable entry fittings 8 lbs Pylons Heavy duty aluminum extrusion NEMA 4 Replaceable IR lens Sealed bulkhead p...

Страница 12: ...s signal to Terminal 6 and attach nothing to Terminal 5 You must install the jumper J8 bottom board see Installation Procedures Controller Module Setup External Relay Check Description Allows the MicroGuard to monitor a pair of external relays in series using the external relays secondary set of DRY contacts provided that they are N C and captive contacts This captive or force guided contact will ...

Страница 13: ...own if any are found in the wrong position In order for the system to remain safe during a single failure of one relay you must be using the relays such that the second relay can still shut the system down if the first one ever fails This can either be by wiring both relays in series or using both relays separately in two control circuits Usage K1 and K2 have separate outputs and both must be used...

Страница 14: ...n must remain in its exact location permanently Any movement in theAUTO BLANK obstruction and or additional guard penetration will latch the light curtain in a RED condition and must be reset via the keyswitch NOTE If no obstructions were programmed in the guard will still latch in a RED condition should the guard be penetrated 2 Must be reset if auto blank obstruction moves The Auto Blank obstruc...

Страница 15: ...all the blocked beams are next to each other The customer may request different blanking sizes for different applications The Minimum Object Sensitivity MOS and the Depth Penetration Factor DPF change when the key switch position is changed The DPF is used to compute the safety distance Location of the light curtain from the point of operation must include the depth penetration factor D pf equival...

Страница 16: ... CLOSED GUARDED RdyM CLOSED OPEN MUTE OUT MUTE OPEN OPEN FAULT Mute out switch fault CLOSED CLOSED FAULT Mute out switch fault Optional Features Metal Box Controller Module If both signals remain in the same state i e both closed or both open for more than 100mSec a fault will be issued To by pass this feature jumper LS5 terminal 3 to terminal 4 To Activate Feature This feature must be ordered and...

Страница 17: ...ame direction mechanically aligned with one another Locate pylons so the working zone is guarded from reaching around over and under the light curtain system to the point of operation or hazard zone see Installation Procedures Safeguarding with Mechanical Guards For location of pylons in relation to the hazard area refer to Appendix B Regulations and Guidelines Federal Register 1910 217 c 3 iii e ...

Страница 18: ...utton is located inside the MicroGuard Controller Module on the door circuit board left hand side or the lower circuit board underneath the gray ribbon cable to start up the light curtain You can review all previous error messages recorded by holding down the RESET button while turning on the power to the unit for two seconds Each error message will scroll by last error first When you see the mess...

Страница 19: ...ssing or 015A first missing beam is 1 5 from connector and 10 beams are missing 7 Loosen the mounting bracket corresponding to the end of the pylon closest to the missing beam and adjust it to get the unit to go GREEN If you are using mirrors refer to Figure 3 8 Every mirror you use will increase the difficulty of alignment and will reduce the overall maximum optical distance you can achieve A los...

Страница 20: ...ivity will be larger If you have the Resettable Latchout option the display will show PENT to indicate penetration You must cycle the Latchout RESET button to clear the curtain see Optional Features Resettable Latching Relays 4 When RED due to a fault the display will scroll the error message that caused the fault and the board and beam number if it can be pin pointed You must first correct the fa...

Страница 21: ...tween the device and the nearest point of operation hazard in inches K Hand speed constant This value has been determined by various studies and although these studies indicate speeds of 63 in sec to over 100 in sec they are not conclusive determinations The employer should determine this value by considering all factors including physical ability of the operator Ts Stop time of the machine tool m...

Страница 22: ...ines the distances that guards should be positioned from the nearest point of operation hazards The various openings are such that for average sized hands an operator s fingers will not reach the point of operation After installation of point of operation guards and before a job is released for operation a check should be made to verify that the guard will prevent the operator s hands or other bod...

Страница 23: ... monitor input 9 Aux relay K3 N O close when Green Table 3 Controller Module Connection Chart Lower Board 10 Aux relay K3 common 11 Aux relay K3 N C close when Red 12 13 Safety Output 1 N O close when Green 14 15 Safety Output 2 N O close when Green 16 Case Ground Earth 17 18 Neutral and Line alarm Dry relay opens on fault or loss of power Figure 5 Controller Module Lower Board Installation Proced...

Страница 24: ...ivates remote latch resetting see Resettable Latching Relays J9 FAULT RESET BUTTON Push button to reset faults do not hold button in S2 Figure 6 Controller Module Jumper Upper Board Table 4 Single Pylon Set Controller Module Jumper Chart Installation Procedures Metal Box Controller Module 14 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 D0 1 1 1 1 1 1 1 1 D1 1 1 1 1 1 1 1 1 D2 1 1 1 1 1 1 1 1 D3 1...

Страница 25: ...ar light curtain J9 LATCH Activates remote latch resetting see Resettable Latching Relays J9 FAULT RESET BUTTON Push button to reset faults do not hold button in S2 Figure 7 Multiple Pylon Controller Module Connector Jumper Detail Table 5 Multiple Pylon Set Controller DUAL SC Module Length Jumper Chart 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 D0 L0 1 1 1 1 1 1 1 1 D1 L1 1 1 1 1 1 1 1 1 D2 L2 ...

Страница 26: ...Figure 8 Controller Module Wiring Diagram Installation Procedures Metal Box Controller Module Wiring 16 18 W W W W Wiring iring iring iring iring Figure 8 Controller Module Wiring Diagram 16 ...

Страница 27: ...9a Swivel Bracket Dimensions Dimensions Metal Box Controller Module Pylon Dimensions 17 Pylon Dimensions Pylon Dimensions Pylon Dimensions Pylon Dimensions Pylon Dimensions Figure 9a Swivel Bracket Dimensions ...

Страница 28: ...Figure 9b Swivel Bracket Dimensions pylon dimensions by model and additional cable information Dimensions Metal Box Controller Module Pylon Dimensions 18 ...

Страница 29: ...Figure 10 Fixed Bracket Dimensions pylon dimensions by model and additional cable information Dimensions Metal Box Controller Module Pylon Dimensions 19 ...

Страница 30: ...ter through the knockout provided on the bottom left of the controller The bulkhead connectors are water dust oil tight Cables lock onto the bulkhead connectors with a turn Tol 0 10 2 54mm Figure 11 Controller Module Dimensions Table 6 Controller Module Dimensions Dim Single Multiple in mm in mm A 7 177 8 8 203 2 B 4 101 6 7 177 8 C 8 203 2 9 228 6 D 4 101 6 4 101 6 E 8 65 215 9 9 85 248 9 Dimensi...

Страница 31: ...240 10 25 260 12 50 318 TRM 12 MGM 12 15 45 392 14 25 362 16 50 419 TRM 16 MGM 16 19 45 494 18 25 464 20 50 521 TRM 20 MGM 20 23 45 595 22 25 565 24 50 622 TRM 24 MGM 24 27 45 697 26 25 667 28 50 724 TRM 28 MGM 28 31 45 799 30 25 768 32 50 826 TRM 32 MGM 32 35 45 900 34 25 870 36 60 927 TRM 36 MGM 36 39 45 1002 38 25 971 40 50 1029 TRM 40 MGM 40 43 45 1104 42 24 1073 44 50 1130 TRM 44 MGM 44 47 45...

Страница 32: ...after installation they must not be movable 11 183 Standard Single mounting bracket shown 11 184 Special Dual pedestal mounting bracket Has two mounting studs 90 deg apart Allows both Emitter and Receiver pylon on one pedestal Requires SMB option on pylons Figure 13 Pedestal Dimensions Accessories Metal Box Controller Module 22 Stud is 3 8 16 x 10 16 long Model 9000 and 9500 Excellent method of mo...

Страница 33: ...ns or Conditions When an ERROR message is displayed the end of the message will display a set of numbers to indicate where along the pylon the problem resides The first two numbers displayed represent the first problem beam on the guard starting from the cable end of the pylon The third number represents the total number of beams blocked on the guard Boards inside each pylon are exactly four inche...

Страница 34: ...s option selected or number of beams broken Yellow LED on the control unit will also light up OBST Floating Blank Obstruction more than one object was detected in the curtain Optional configuration allows two objects for applications where the piece part is bent twice Auto Blank ABxy Auto Blank x indicates number of beams blanked by object y indicates option selected or number of beams broken in M...

Страница 35: ...TER chip 42 003 SLAVE External infrared source detected xxy Whenever the curtain is RED at power up the unit checks for external sources of infrared that might interfere with normal operation of the curtain xx indicates board number in 4 increments from circular connector y indicates beam number of that board 1 to 8 This could also indicate that the detector circuit is faulty FLIP MASTER microproc...

Страница 36: ...eceiver pylon was detected as different from the jumpers S3 set on the door of the Controller Module xx indicates board number in 4 increments from circular connector y indicates beam number of that board 1 to 8 This could be a cable pulled out missing jumper in the pylon faulty circuit on the computer board Receiver Oscillating xxy More than one pulse was detected during reception of the proper I...

Страница 37: ... is possible that the software versions don t match Waiting for reset button Master is waiting for user to push the RESET button to start scanning This indicates that you pushed the RESET button too soon after getting an error message and prevented the SLAVE from saving the error code in permanent memory You should wait until the message displays one time before pushing the RESET button Watchdog f...

Страница 38: ...aphs b 13 and 14 of this section 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 a safe operating condition and adjustment The employer shall maintain records of these inspections an...

Страница 39: ...egardlessoftheoperator sexperience education or language barrier it is the responsibility of the supervisor to give him a thorough explanation with each new job assignment 8 No employee should be given a work assignment that he does not fully understand Only properly instructed and thoroughly trained personnel should be assigned to work on or with any machine 9 It shall be the responsibility of th...

Страница 40: ...equired to obtain maximum usage of your equipment 5 Releasing a power press for production following maintenance should be the responsibility of a qualified individual assigned by management 6 To maintain the original level of press reliability careful inspection of mechanical electrical and pneumatic areas must be made This may give an advance warning of a hazard which then can be corrected to pr...

Страница 41: ...e 32 001 White Clear or Blue are 2 pole Safety Relays 32 098 Green is a 3 pole Safety Relay 20 001 Glass 20 022 SMT 1A slo blo 11 183 Standard Single pedestal mounting bracket 11 184 Special Dual pedestal mounting bracket Has 2 mounting studs 90deg apart Allows both Emitter Receiver pylon on 1 pedestal Requires SMB option on pylons C 1 Appendix C Replacement Parts 21 019 Rubber Shock Mount Male Fe...

Страница 42: ... Parts Figure 15 Pylon Replacement Parts 52 013 4 Slave receiver 52 080 8 Slave receiver 52 012 4 Lead receiver 52 079 8 Lead receiver NOTE You must provide Model Serial and software revision to obtain the correct part revision or sub assembly revision An individual Part may have been revised since your unit was purchased Part Numbers for Units made prior to 1998 Appendix C Replacement Parts C 2 ...

Страница 43: ...wn with an uncleared Fault E AutoBlank load Should always see this Soft Ver R34r 1012 MG Scroll this string on LED display Only RST F1 push can interrupt this M Version Display scroll finished RST String on LED display Then jmp to FAULT routine Fx Enter Fault routine x 0 Slave in Fault routine 1 Slave not in Fault routine Should be F0 W Writing to EEPROM new Fault code V cr Clearing Active Fault S...

Страница 44: ...ed 1A Reset held down 1B No Ack from memory 1C Short det bad 1D ESTOP OPENED 1E Not Synced up with Slave 1F 51 20 Slave Found 21 Improper operation 22 NO Message FOUND 23 Clock did not drop 24 Old FAULTS from Memory 25 End of Memory 26 27 Proper power up example SEMF0P CR 10 lines of EEPROM memory CR GA0024m for a 24 beam length guard Blocked Beam pattern display If you transmit the ASCII characte...

Страница 45: ...NOTES ...

Страница 46: ...NOTES ...

Страница 47: ... company shall under no circumstances be liable for any consequential or special damages either in law or in equity or for losses or expenses or claims for the same arising from the use of or inability to use the products of the manufacturer for any purpose whatsoever The entire machine safety system must be tested at the start of every shift Machine testing should include 1 proper machine operati...

Страница 48: ... or maintained by Pinnacle Systems Inc We cannot and do not accept responsibility for any overall system performance when factors such as these are beyond our control www pinnaclesystems com sales pinnaclesystems com service pinnaclesystems com Sales and Marketing Offices United States Pinnacle Systems Inc P O Box 100088 Pittsburgh PA 15233 Toll Free Number 800 569 7697 Direct Number 412 262 3950 ...

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