Safety Products Supplement Safety Light Curtain 120V AC Interface Presence Sensing Safety Devices Power Supply and Safety Relay Description The Allen-Bradley Guardmaster 120V AC interface box consists of a NEMA 4 rated lockable metal enclosure, a DIN mount 3amp, 24V DC power supply and either a single or dual 22.5mm safety relay(s). The single safety relay module provides 2 N.O. safety and one N.C. auxiliary (nonsafety) “potential free” relay outputs. The dual safety relay configuration allows for two pairs of safety light curtains to independently control one or two machines. The safety relay(s) can be configured for monitored manual reset or automatically reset. The resetting function can be through the key switch mounted on the front cover of the interface box or wired as a remote switch. Prepunched holes located on the bottom of the enclosure allow for easy wiring of the system. 56 Specifications Input Power 120/230V AC Output Power 24V AC ±15% Power Consumption 2W/4W Fuses Input (external, recommended) 500mA time lag Output (external, recommended) 6A quick acting 2 N.C. Symmetric or Asymmetric Inputs Switch Selectable Maximum Input Resistance S11-S12 300 ohms S21-S22 200 ohms S33-S34 250 ohms Reset Monitored Manual or Automatic/Manual Outputs 4 N. O. Safety 2 N.C. Auxiliary nonsafety Output Rating N.O. B300, AC15, 3A/250V AC P300, DC13, 3A/24V DC N.C. B300, AC15, 2A/250V AC P300, DC13, 2A/24V DC Min. Switched Current/Voltage 1mA/10V Power ON Delay Manual Reset 40ms Auto Reset 200ms Response Time 15ms Relay Module Indication LEDs Power Green = Ready K1 Green = K1 Closed, If K1 alone is lit, check for short across reset button K2 Green = K2 Closed Operating Temperature -15°C to +55°C (+5° to +131°F) Humidity 90% RH Enclosure Protection NEMA 4, IP65 Max. Conductor Size 1 x 2.5mm2 (14AWG) stranded 1 x 4mm2 (12AWG) solid Weight 4886/5113g (10.75/11.25lbs) Electrical Life 230 VAC/2 A/460VA/AC 15 100,000 operations Maximum Operating Frequency 1200 cycles/hour Mechanical Life 10,000,000 operations Vibration 0.35mm 10-55Hz Safety Products Supplement Safety Light Curtain 120V AC Interface Ordering Details Inputs Safety Outputs Auxiliary Outputs 2 N.C. 2 N.O. 1 N.C. 4 N.C. 4 N.O. 2 N.C. Power Supply 24V DC Catalog Number 440L-M8400 440L-M8500 Dimensions—mm (in) 200.0 (7.87) 301.6 (11.87) Presence Sensing Safety Devices 161.9 (6.37) 3.17 (0.12) 1.77 (0.07) .0 .12 5 70 63.5 (2.5) 104.7 (4.12) 22.2 (0.87) Application Details Disconnect power. Use a screwdriver to pop open cover to reveal internal switches. L Light Curtain Interface Box L1 1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17 Power LED K3 101.6 (4.0) K1 Receiver Transmitter K4 +24V GND K3 K4 Man. Restart (Jump 15 & 16) Auto Restart (Jump 16 & 17) Man. Restart w/ MPCE feedback (N.C. contacts between 15 & 16 Symmetric Inputs Switch S1 Asymmetric Inputs K2 Machine Prime Mover Elements Automatic Reset Switch S2 Monitored Manual Reset K3 K4 Auto Restart w/MPCE feedback (N.C. contacts between 15 & 16 Arc suppression devices (100Ω, 2.2µF) K3 Or N (Jumper req’d if mts not used) L2 K4 101.6 (4.0) 57 Safety Products Supplement Controllers/Relay Interfaces Specifications min. typ. max. Standards EN 50100 Approvals BG and CE marked for all applicable directives Protection Class I Housing Protection IP 20 (switch cabinet, standard rail) Supply Voltage U V 19.2V 24V 28.8V Residual Ripple ➊ 5V SS Power Consumption (no load) 0.3A (6W) Inputs Command Unit Start key Presence Sensing Safety Devices T 13,T 14 NO contact Command Unit Act. Time Period 30 ms Contactor Monitoring T 21,T 22 Contactor Monitoring NC contacts in series Permissible Cont. Drop-off Time No restrictions Permissible Contactor Resp. Time 200 ms Sensor Signal T 3,T 4 Two-channel Description Input Resistance (active) 606Ω The Allen-Bradley Guardmaster 440L-M8200 safety relay is designed specifically to interface with safety light curtains. It has two normally open safety outputs (control reliable) and one normally closed auxiliary output. The 440L-M8200 requires 24V DC and has convenient connections for the transmitter and the receiver. Signal Active at 17.6V U V Safety Light Curtain Safety Relay Features • • • • • • • Automatic or manual reset MPCE monitoring Din rail mount LED indication of power on outputs 2 N.O. safety outputs 1 N.C. auxiliary output Removable terminal strip for easy replacement Signal LOW at 0V Time Period Tolerance between T3 and T4 15 ms 674Ω 742Ω 2.4 V Outputs 15 ms ➋ Response Time Switching Current <0.1mA➌ 4A Switching Voltage AC/DC 240V AC / 60V DC Switching AC /DC 1200 VA/ 50 W Mech. Life Expectancy (switch actions) 10 7 Elec. Life Expectancy (switch actions) 10 9 Delay on Energization (NO contacts) 40 ms Delay on Energization (NC contacts) 15 ms Supply Voltage Connection UV Pluggable strip terminal Cable Cross Section 2.5 mm 2 Load Capacity of Terminals (C 1 ...4,D 1 ...4) 2.5 A Operating Data Safety Category Type 4 Tested to pr EN 50100 Part 1 and 2 Ambient Operating Temp. 0°C +55°C Storage Temperature –25°C +75°C Relative Humidity (noncondensing) 15% 95% Vibration Specification 5g,10 ...55Hz as per IEC 68-2-29 Shock Resistance 10g,16ms as per IEC 68-2-29 Dimensions (W x H x D) 152 x 73 x 118 mm 3 ➊ Maximum voltage limits must not be exceeded,minimum levels must be acheived. ➋ Response time without attenuation of switching elements (relays), e.g. by means of interference suppressors. ➌ Contact gold plating vaporizes when currents >100mA switched. Minimum switched current becomes 10mA. 58 Safety Products Supplement Controllers/Relay Interfaces Ordering Details Reset 24V DC Manual/ Automatic Floating Blanking Fixed Blanking PSDI Muting Relay Outputs no no no no 2 N.O. Safety 1 N.C. Aux. 4 amp Catalog Number 440L-M8200 Presence Sensing Safety Devices Voltage Dimensions—mm (in) 152 (5.98) 118 (4.65) 70 (2.76) 35 (1.38) Connections Command Without start/ Unit N.O. “Reset” restart Monitoring N.C. interlock of contactors Without N.O. input contact contactor input monitoring input 2) 24V DC 0V 1) or A 1+ A 2- PE T0 PE T 13 T 14 X 12 T21 T 22 2) X 21 X 22 1.3 2.3 3.1 N.O. N.O. N.C. Contacts Auto Power Input Off On Monitor Ext. Contactors Outputs Off Reset Sender Receiver 24V DC 0V D1 X 11 0V 24V DC 0V C1 or 24V DC 0V PE 24V DC 0V C2 D2 24V DC 0V PE 24V DC 0V T3 T4 OSSD OSSD 1 2 AOPD type 4 AOPD type 4 Sender Receiver C3 D3 24V DC 0V PE C4 D4 1.4 2.4 N.O. output 3.2 N.C. contact input N.O. output 1) Potential equalization, if power pack -0V not connected with (VDE 0160) 2) Wire jumper The jumpers X11/X12 for (disabling of) restart inhibit and X21/X22 for (disabling of) contactor monitoring must not be routed externally (only in isolated plastic-sheathed cables). 59 Safety Products Supplement Controllers Application Possibilities and Conditions Areas of Application The 440L-M8100 with an AOPD is used as a control unit in protective applications for point-of-operation guarding, hazardous areas and entry/exit systems. Furthermore, it assumes responsibility for control functions such as the muting of palletizer entry/exit systems or press brakes, as well as blanking and other control functions on presses (e.g. break operation). Typical areas of application are: Presence Sensing Safety Devices General • Presses in the metal-working, plastics, leather and stone industries (functions: guarding, break operation, blanking, etc.) • Press Brakes (functions: guarding, blanking, muting before bottom dead center, etc.) • Palletizer or entry/exit applications (functions: guarding, muting, etc.) The 440L-M8100 Programmable Safety Interface Light Curtain Control Unit is a control unit for active optoelectronic protective devices (AOPD), and is designed as a self-monitoring device in accordance with EN 50100. It is intended for industrial applications and is distinguished by: Regulations for Use • • • • The same applies to applications which take place outside closed rooms (ambient temperature 0°C - 50°C (32°F - 122°F)). High availability No wearing parts Compact construction Universal applicability Note: This product is only for use with POC safety light curtains. It can not be used with SafeShield, PAC or AAC devices. Features • • • • • • • • • • • • • • • • • • Wear-free operation Secure, short-circuit-protected semi-conductor outputs Line monitoring of outputs Modem microprocessor technology Short response time LCD display for programming function indication and diagnostic messages Connection for two pairs of AOPD type 4 sensors or up to four pairs of AOPD type 2 sensors (also mixed operation) Automatic testing of AOPD type 2 sensors User-programmable combinations of defined functions Pre-programmed standard functions: Guard only, single-break, double-break Programming password Contactor monitoring and restart interlock may be selected Fixed/floating blanking for AOPD type 4 (SafeShield Safety Light Curtain) Muting function with connection for up to 4 muting sensors Outputs for indicators of all special functions RS 485 data interface for sensor controls and diagnostics Connection for operating mode selector switch Break operation with up to 8 breaks 60 The 440L-M8100 is designed to be installed in the machine's control cabinet (IP 20). If it is used outside the control cabinet a suitable housing fitted with a DIN rail profile should be used, e.g. an electrical enclosure (IP 54). Operations such as programming or connecting the unit, i.e. all activities on the 440L-M8100 which could affect the safe operation of the unit, should only be carried out by qualified personnel. System Structure Overview of System The 440L-M8100 has a standard housing with two 33-pin plug-in terminal strips. A two-line LCD display and set of control keys are built into the front panel for operation and programming. Three integral LED indicators display the 440L-M8100’s output conditions: green LED illuminate outputs active red LED illuminate outputs inactive yellow LED illuminate malfunction The yellow LED indicates an operational malfunction of the system or the peripheral equipment. Safety Products Supplement Controllers Connecting and Operating Elements The LCD display contains two lines, each capable of displaying 20 characters. In addition to the programming menus, all the system’s operational states are displayed. In the event of operational malfunctions or malfunctions of the peripheral equipment, appropriate diagnostic messages are given. The control keyboard is used in conjunction with the LCD display for programming and diagnostics on the 440L-M8100. Details on programming may be found in the operating instructions. 1 pair of type 4 sensors or 2 pair of type 2 sensors 1 pair of type 4 sensors or 2 pair of type 2 sensor 1 pair of type 4 sensors or 2 pair of type 2 sensors E1 Function and Operation E2 440L-M8100 E1 Presence Sensing Safety Devices Thanks to the plug-in connection terminals, the wiring can be prepared without the 440L-M8100, thus enabling any exchange to be carried out in the shortest possible time, without any need to rewire the connecting leads. E2 440L-M8100 Operating Principle The 440L-M8100 assumes responsibility for control functions as an operational link between the machine control system and the control function from the AOPD, and switches the required control elements (contactors) of the machine control system via dual-channel semiconductor outputs. The signals arriving from the 440L-M8100 and the peripheral equipment are further electronically processed by dual channel microprocessor electronics. Type 2 sensors (testable) and/or Type 4 sensors (self-monitoring) may be operated with the 440L-M8100. The internal control system can distinguish between the different categories. Type 2 sensors are automatically cyclically tested by the 440L-M8100 every 60 minutes. The 440L-M8100 is designed for the connection of two pairs of AOPD type 4 sensors or up to four pairs of AOPD type 2 sensors. (1 pair = 1 emitter and 1 receiver.) "Mixed" operation of sensor type 4 and type 2 AOPDs can also be configured. E1 440L-M8100 E2 E1 E2 A 440L-M8100 Various types of connection to the 440L-M8100 Type 2 sensors are always to be used in pairs, i.e. 2 pairs of type 2 or 4 pairs of type 2 are used. The automatic testing of type 2 sensors increases the protective level of the whole protective system (no external measures needed). Instead of a second AOPD type 4 sensor, an extra 440L-M8100 (type 4) can also be connected, in order to "daisy chain" 440L-M8100s. 61 Safety Products Supplement Controllers/Relay Interfaces Operating Modes External Mode Select Presence Sensing Safety Devices Setting Operating Modes All set up 440L-M8100 operating modes can be called up using a corresponding BCD switch. A bridge connection or direct selection using the "run modes" program is possible for a fixed operating mode. Standard operating modes, such as guard only, single-break, doublebreak are provided preprogrammed, i.e. the interface can be operated without user programming. Input 1 2 3 0 0 0 Furthermore, 3 positions of the selector switch can be devoted to user-definable application programs. keyboard mode (programming) 0 0 1 guard only operation 0 1 0 single-break 1 0 0 double-break 1 1 0 user program 1 1 0 1 user program 2 0 1 1 user program 3 (1 1 1 not used) 0 input not connected with ↓ open 1 input connected with ↓ Restart Interlock/Indicator Lights The function "with/without restart interlock" can be set directly on terminals 52, 53 and 54. This can be done using either jumpers or external changeover contacts, which makes it possible to switch over the restart interlock (RI) without programming, e.g. on presses: • In the dangerous downward motion with RI • In the nondangerous upward motion without RI For direct connection to indicator lights showing the following functions 24 DC outputs are available on terminals 57 to 64: Connection terminals for operating mode selector switch, with assignment "Reset button required" "Muting" "Reduced Resolution/Blanking" and "Dirt build-up" (AOPD) Guard only operation *) Single-break *) Max. output current 0.4A each (minimum current 0.02A for "muting" and "blanking"). Double-break *) Multi-break (3-... 8 breaks) *) Blanking *) Muting *) Mechanical Mounting, Ambient Conditions Reduced Resolution *) Starting sequence for break operation *) The 440L-M8100 is mounted on a DIN rail, or if necessary in a suitable external housing (snap-on mounting). The permissible ambient temperature range is 0°C - 50°C (32°F - 122°F) (IP 54). Sensor test with/without Single stroke restart *) Contactor monitoring: with/without Reset button: latched/unlatched *) Can be programmed or combined into user programs 1, 2 and 3 Operating modes which may be programmed via the 440L-M8100 menu Installation Electrical Installation The 440L-M8100 operates with 24V DC ± 20% and has a current consumption of 0.5A (without load). Connection is potential-free via two 33-pin plug-in terminal strips. This enables the wiring to be carried out before the 440L-M8100 is installed. The terminals are designed for a maximum wire cross-section of: 1 x 2.5 mm2 with sleeve, or 1 x 4 mm2 solid. 62 Safety Products Supplement Controllers/Relay Interfaces A1 and A2 muting muting muting muting - B1 and B2 - (open) muting single-stroke restart “latched restart” single-stroke restart “unlatched restart” single-stroke restart “latched restart” single-stroke restart “unlatched restart” External Indicators Blanking/Reduced Resolution Muting If "Blanking/Reduced Resolution" is used, the corresponding indicators must be connected. These safety related indicators are monitored via the 440L-M8100 (output current 0.02...0.4A). The indicators "Restart Required" and "Weak Signal" are optional (output current 0...0.4A). In case of using this NPN indicator outputs on a PLC, a resistor (i.e. 1 kΩ/1 W) has to be connected between terminal 57-58 and/or 63-64 for potential equalization. The output signal is provided on terminal 58 and/or 64 (NPN function). The 0Vpotential of both power supplies 440L-M8100 and PLC must be linked. Functions dependent on program settings. Type-2 Sensors When type 2 sensors are used, two pairs are to be connected for each 440L-M8100 input circuit. They are tested automatically. The test command to the sensor (terminals 14/16/26/28) can be selected by simple connection to the adjacent terminals (terminals 15/17/27/29) (test with 0V potential or plus potential). The single-channel switching outputs of the type 2 receivers are connected to terminals 9 and 10 (pairs 1 and 2) and/or to terminals 21 and 22 (pairs 3 and 4). 63 Presence Sensing Safety Devices The extent of wiring depends on the particular application. Safety Products Supplement Controllers/Relay Interfaces Specifications 440L-M8100 Blanking Modes 1. Floating Blanking A. 14mm System: Min. = Gap - 0.2" - 0.9" Resolution Max. = Gap - 4.7" - 5.3" Resolution These are in 0.3" Increments Presence Sensing Safety Devices B. 30mm System: Min. = Gap - 0 5" - 1.7" Resolution Max. = Gap - 9.4" - 10.6" Resolution These are in 0.6" Increments Note: You may not use floating blanking with PSDI mode (e.g.: single break mode). 2. Reduced Resolution A. 14mm System Only Min. = 0.2" Gap - 0.9" RESOLUTION Max. = 1.1" Gap - 1.8" RESOLUTION These are in 0.3" INCREMENTS 3. Fixed Blanking A. 14mm and 30mm: Can blank all beams but beam #1 Note: You may blank more than one area. ATTENTION: The safety distance must be recalculated and light curtains must be remounted when floating blanking, reduced resolution or fixed blanking is activated. Supply voltage Ripple 24V DC 20% max. 5VSS Current Consumption approx. 12W (without load) Inputs Run modes Data interface For 2 ESPD type 4, 4 ESPD type 2 fixed/ programmable, called up via selector or fixed setting RS 485 for ESPD sensor failure control and diagnostics, Twisted pair required for cable length>10m Input currents Contactor monitoring: dynamic 100mA for T<1ms, static 10mA. Test inputs: dynamic 100mA for T<1ms, static 10mA Outputs Switching output 2 x PNP, 0.5A, overload protection Response time 5ms Lamp driver For command devices and special functions, max. 0.4A per output Diagnostics Via display for RS 485 interface Requirement In accordance with EN 50100 type 4 Enclosure rating IP 20 Connection terminals Plug-in type Wire cross-section, max. 2.5mm2 with end sleeve/4mm2 solid Ambient operating temp. 0 to 50°C Storage temperature -25°C to +70°C Housing WxHxD Standard housing for top hat rail (snapon mounting) 200 x 123 x 118mm3 Fitting type Top hat rail 35 x 15mm2 Programmable InterfaceOptional 64 Input Voltage Reset Floating Blanking Fixed Blanking PSDI Muting Outputs Catalog Number 24V DC Manual/ Automatic yes yes yes yes 2 PNP OSSD 440L-M8100 Safety Products Supplement Controllers/Relay Interfaces Dimensions—mm (inches) 200 (7.87) 118 (4.65) 4.5 (0.18) Presence Sensing Safety Devices 123 (4.84) 34.5 (1.36) Wiring Diagram PE Input 24V DC K2 K1 K2 24V max 0.5A K1 24V max 0.5A AOPD Sender White Green Yellow Gray Blue Brown Black White Green Blue Brown Black AOPD Receiver No Conn. No Conn, Supply voltage 24V DC ±20% Safety Stop Circuit OutPE PE OutPE puts puts 2 Power Comm 1 2 Power Test 1 Test 2 Power 1 2 Power Test 3 Test 4 1 Receiver 1 Sender 1 Receiver 2 Sender 2 Output Channels PE Auxiliary Inputs Indicators A1 A2 B1 B2 Cycle Relay System Contact Monitor Test External Mode Select Restart Mode Restart Restart Muting Switch Required Active Reduced Reso- Weak lution Signal Receiver 1 or 2 Output Status Ext Int Blanking Lamp (required) (24V DC, 0.02-0.4A) Muting Lamp (requried) (24V DC, 0.02-0.4A) Restart Lamp (optionsal) (24V DC, 0.4A max.) Restart Ext = Automatic Reset Int = Manual Reset Hard wired for user defined mode 1, leave open for keyboard mode. Relay Monitor (or N.C. contact) Muting switches or sensors K1 K2 65 Safety Products Supplement Mat Manager Specifications Standards IEC/EN60204-1, ISOTR12100, EN1760-1, ANSI/RIA 15.06, ANSI B11.19 Safety Category Cat. 3 per EN954-1 Approvals CE marked for all applicable directives, Power Supply 24V AC/DC, 110/230V AC 0.8 to 1.1 x rated voltage, 50/60 Hz Power Consumption Fuses Presence Sensing Safety Devices Safety Mat Manager Description The Safety Mat Manager is designed to monitor multiple safety mats, each with its own connection. The Safety Mat Manager accepts up to 8 individual mats with 4-pin micro quick disconnect connectors. The Safety Mat Manager provides an LED status indication for each of the mat connections. Since the LEDs indicate whether the mat is shorted or open, troubleshooting and replacement of a damaged mat within a mat system, is much quicker when compared a traditional mat system where multiple mats are wired in series. 13W or 13VA Input 500mA internal (2) Output (external) 6A Slow Blow or 10A Quick Blow Safety Inputs 8 4-wire safety mats with micro-QD. Maximum Input Resistance 100 ohms Reset Internal switch selectable Monitored Manual or Auto./Man. Button Front Panel or Remote via Terminals Outputs 2 N.O. Safety; 1 N.C. Auxiliary Output Rating B300, AC-15, 2A/250V AC N300, DC-13, 2A/24V DC Min. Switched Current/Voltage 10mA/10V Response Time 35ms Indication LEDs Green Green Green Green Mat Status LEDs Run Condition Stop Condition Missing Shorting Plug Not Used Green Green-Red (Bi-color) Red Off Power Machine Enabled Auto Reset Mode Manual Reset Mode An internal switch allows for the setting of the reset to Automatic/ Manual or Monitored Manual. When set to Automatic/Manual, the reset circuit can be jumpered, connected auxiliary contacts, or connected to an unmonitored manual reset by adding a momentary normally open switch in the monitoring loop. When set to Monitored Manual, the monitoring circuit must be closed and then opened to activate the outputs. Impulse Withstand Voltage 2500V Pollution Degree 2 Stepping on any one of the mats deactivates the safety outputs. The outputs include 2 normally open safety rated outputs used to shut down the machine and 1 normally closed auxiliary output to indicate the status of the Mat Manager. The safety outputs have independent and redundant internal contacts to help ensure the safety function. Mounting Surface (Wall) Mount Weight 3160g (7lbs) Electrical Life 220V AC/4A/880VA cosφ=0.35 220V AC/1.7A/375VA cosφ=0.6 30V DC/2A/60W 10V DC/0.01A/0.1W 100,000 operations 500,000 operations 1,000,000 operations 2,000,000 operations Mechanical Life 2,000,000 operations Features • • • • Accepts up to 8 individual mats 2 Safety output contacts 1 Auxiliary output contact Automatic/Manual or Monitored Manual Reset 66 Operating Temperature -25°C to +45°C (-13°F to 113°F) Enclosure Protection IP65 (NEMA 13) Steel with Polycarbonate Faceplate Maximum Conductor Size 0.2–2.5mm2 (24-14AWG) Torque Settings—terminal screws 0.4Nm (3.54 lb•in) Vibration 10-55Hz, 0.15mm Shock 10g, 11ms half-sine