GS-120 Manual Ver. 1.0
Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
GS-120 Photo-Electric Light Curtain Systems
Technical Manual
WARNING
Tapeswitch photo-electric safety systems are intended to protect operators working at or near
dangerous machinery. They can only perform this function if they are correctly fitted to a
suitable machine. It is essential that the full contents of this manual and all the international
documents referred to herein are fully understood before any attempt at installation is made.
If in doubt, contact Tapeswitch Corporation.
IMPORTANT
This manual must accompany the product throughout its working life. Those persons
responsible for the product must ensure that all persons involved in the installation,
commissioning, operation, maintenance and servicing of the product have access to all the
information supplied by the manufacturers of the machine and its safety system.
Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
TABLE OF CONTENTS
1.0
GENERAL
1.1
INTRODUCTION
1.2
PRODUCT Range
1.2.1
1.2.2
1.2.3
1.2.4
1.3
9
9
10
10
11
11
12
LED Option
Diagnostic Option
INSTALLATION
3.1
GENERAL
3.2
MECHANICAL INSTALLATION
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.3
3.3.3
3.3.4
3.4
General Considerations
3.2.1.1 Multi-Sided Guarding
Curtain Dimensions
3.2.2.1 GS-120 Basic System
3.2.2.2 GS-120 Multi-Beam System
3.2.2.3 GS-120 Cascaded System
Separation Distance
3.2.3.1 Normal Approach
3.2.3.2 Parallel Approach
3.2.3.3 Angled Approach
3.2.3.4 Approach to ‘L’ Installation
Optical Alignment
Reflective Surfaces
Systems in Close Proximity
Mounting Brackets
ELECTRICAL INTERFACE, OPERATION, AND INSTALLATION
3.3.1
3.3.2
4.0
GS-120 Light Curtain Order Code
GS-120 Multi-Beam Order Code
Cable Options
Interface and Programming Units
TECHNICAL DESCRIPTION
2.1
CURTAIN
2.2
COMMUNICATIONS
2.3
TEST INPUT
2.4
INDICATORS
2.4.1
2.4.2
3.0
General
Detection Capability
Protected Heights
Accessories
1.2.4.1 Mirror Units
1.2.4.2 Mounting Stands
ORDERING INFORMATION
1.3.1
1.32
1.3.3
1.3.4
2.0
4
4
4
5
5
5
5
7
7
8
8
9
9
General
Emitter Unit
3.3.2.1 General
3.3.2.2. Test Input
Receiver Unit
3.3.3.1 General
3.3.3.2 PNP Version
3.3.3.3 SSR Version
Interfacing to a Machine
3.34.1 PNP Version Manual Reset
3.34.2 PNP Version Auto Reset
3.34.3 SSR Version
INITIAL CHECKING AND ALIGNMENT
INTERFACE AND AUXILIARY UNITS
4.1
GENERAL
4.1.1
4.1.2
35
35
35
36
Methods of Interfacing
Special Interfacing Considerations
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
13
13
13
13
15
16
16
17
18
19
19
21
22
22
23
23
24
24
27
27
27
27
28
28
28
29
30
31
31
32
33
34
2
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Fax: 631-630-0454
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Release 7/2009 Ver. 1.0
4.1.3
5.0
4.1.2.1 PNP Version Manual Reset
4.1.2.2 PNP Version Auto Reset
4.1.2.3 SSR Version
Connections to an AS-i System
36
36
36
37
PERIODIC CHECKING, SERVICING, AND MAINTENANCE
5.1
PERIODIC CHECKING
5.1.1
5.1.2
5.1.3
5.1.4
5.2
5.3
6.0
Technical Manual: GS-120 Light Curtain Systems
Commissioning Checks
6 or 12 Month Periodic Checks
Daily/Setting Examination
Checking Detection Capability
5.1.4.1 GS-120 System
5.1.4.2 GS-120 Multi-Beam System
SERVICING
MAINTENANCE
TECHNICAL SPECIFICATIONS (GS-120Series Emitter & Receiver)
38
38
38
38
39
39
39
40
41
41
42
APPENDIX A: BSRSA INTERFACE UNIT
43
APPENDIX B: BSRUA-2 INTERFACE UNIT
49
APPENDIX C: SRUB INTERFACE UNIT
57
APPENDIX D: SRUS INTERFACE UNIT
63
APPENDIX E: C6 MULTIFUNCTION INTERFACE CONTROLLER
67
APPENDIX F: GDC-1 24 VDC POWER SUPPLY
68
APPENDIX G: LAT LASER ALIGNMENT TOOL
69
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
3
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Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
1.0
GENERAL
1.1
INTRODUCTION
INTERNATIONAL CONSIDERATION: The heritage of
the Tapeswitch GS-120 system is strongly grounded in
international commerce and standards. They were
developed by Tapeswitch Ltd., of Chorley, England.
Both Tapeswitch Ltd. and Tapeswitch U.S. are part of
Indel Corporation, a private U.S industrial group. The
GS-120 product line was developed to meet published
and proposed safety standards for the United States,
Germany, England, Finland, and Sweden, as well as the
common market unified standard. GS-120 systems are
manufactured both in England and the United States.
Tapeswitch GS-120 products have been independently
third party tested to IEC 61496 by BG, and are certified
to this standard (CE approval/certification). Contact
Tapeswitch for more details.
Tapeswitch GS-120 light curtains are through-beam
photo-electric machine guarding devices, designed to
protect operators working at or near dangerous
machinery. They meet the requirements for EN61496
Type 2 light curtains and Category 3 safety control units
as defined in EN954-1.
When correctly installed on a suitable machine, the
system will detect a person (or part of a person) entering
a dangerous area in the vicinity of the machine, and will
signal the dangerous motion to cease before that
person can reach a position where injury could occur.
Tapeswitch can provide additional assistance to
customers wishing to use GS-120 guards in
international applications. Some foreign language
technical manuals are available.
Tapeswitch GS-120 light curtains use infra-red
technology. A curtain of infra-red light is projected
across the dangerous area. Intrusion into this curtain by
a person or part of a person will be detected by the
system. This will cause safety output signals to be
generated which will stop the dangerous motion of the
machine.
PRODUCT RANGE
1.2.1
GENERAL
The GS-120 light curtains are available in a range of
different protected heights and detection capabilities.
These two parameters are known by many other names
and therefore it may be useful to define them here, as
they are intended to be used in this manual. To make
this clearer it is also necessary to define two further
parameters, detection zone and operating range:
WARNING
The information in this manual relates to the
use of the basic GS-120 light curtain, to provide
a basic safety switching device.
Detection Zone: This is the actual curtain of infra-red
light generated between the emitter and receiver units
within which an appropriately dimensioned object will be
reliably detected and, for the GS-120, can be
considered to be a two dimensional, rectangular plane
(see Figure 1).
In some applications, a GS-120 light curtain
may be used together with other Tapeswitch
equipment to provide additional functions and
features. The additional information necessary
for the correct use of a GS-120 light curtain
when used with other Tapeswitch equipment is
provided within this manual.
Operating Range: One dimension of the detection
zone rectangle is given by the distance between the
emitter and receiver units. This is the operating range
(see Figure 1).
In such cases, some installation parameters,
notably the mounting position of the light
curtain in relation to the dangerous part of the
machine, can be affected and close attention
must be paid to all the information supplied
with all equipment.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
1.2
Protected Height: The other dimension of the
detection zone rectangle is commonly known as the
protected height. The word “height” has been adopted
in the latest standards for this equipment because most
curtains are mounted vertically. The protected height is
often related to, but is not the same as, the length of the
emitter and receiver units (see Figure 1).
4
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Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
1.2.3
PROTECTED HEIGHTS
GS-120 light curtains are available with nominal
protected heights as follows:
Detection Capability
Nominal protected heights
(in mm and inches)
30mm (1-3/16 in.)
200-300-400-600-800-9001000-1200-1400-1600 mm
(8-12-16-24-32-36-40-48-5664-72 inches)
70mm (2-3/4 in.)
600-800-1000-1200-14001600-1800 mm
(24-32-40-48-56-64-72
inches)
The minimum separation distance is 0.5 m.
Figure 1
Note:
The actual protected height is 8 mm greater than the
nominal protected height.
Detection Capability: This is the minimum dimension
of an opaque object which will be reliably detected
anywhere within the detection zone.
1.2.4
NOTE: The spacing or pitch of the beams or lenses in a
light curtain is not the same as the detection capability.
The detection capability is always greater than the
spacing or pitch. Spacing or pitch should not be used in
the calculation of separation distances (see Figure 2).
1.2.2
ACCESSORIES
1.2.4.1 Mirror Units
A range of mirror units are available to enable a single
curtain to be used to guard two or three sides of a
machine or to avoid structural obstructions.
DETECTION CAPABILITY
The mirror assembly consists of a high quality silverbacked glass mirror adhesively attached to a length of
extruded aluminum. Two pivot brackets are bolted to
the aluminum extrusion and can be adjusted anywhere
along the length for mechanical attachment. The actual
length of the mirror is 4 inches (1000mm) larger than the
active curtain length to accommodate a wide tolerance
for height alignment. All of the necessary hardware is
supplied to facilitate mounting to the mounting/floor
stands. The dimensions of the pivot brackets, extruded
aluminum and overall mirrors are shown below in
millimeters.
GS-120 light curtains are available with detection
capabilities of 30mm or 70mm.
Figure 2
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
5
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Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
Glass Reflective
Surface
Pivot Bracket
Overall Length =
Protective Height + 4"
X
Pivot Brackets
(180° Rotation;
Distance X is Adjustable)
180° Rotation
in this Plane
Supplied with:
1. 1-40mm x 40mm extrusion, 100mm larger than
protective height.
2. 1-silver backed mirror, 100mm larger than
protective height.
3. 2-pivot joints.
4. 2-40mm x 40mm end covers.
5. 4-5mm T slot nuts.
6. 4-#12 flat washers.
7. 4-5mm spring washers.
8. 4-5mm x 5/8 hex bolts.
40mm
6.8mm
Extrusion Dimensions
6.8m m
Curtain Lengths
Mirror Assembly
Length
P/N
200mm - 8"
300mm - 12"
0960
300mm - 12"
400mm - 16"
0961
400mm - 16"
500mm - 20"
0962
600mm - 24"
700mm - 28"
0963
800mm - 32"
900mm - 36"
0964
900mm - 36"
1000mm - 40"
0965
1000mm - 40"
1100mm - 44"
0966
1200mm - 48"
1300mm - 52"
0967
1400mm - 56"
1500mm - 60"
0968
40m m
For units greater than 56 inches, custom mirrors are available.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
6
Phone: 631-630-0442
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www.tapeswitch.com
Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
1.2.4.2 Mounting Stands
1.3
ORDERING INFORMATION
Floor mounting stands are available for use where the
guard cannot be mounted directly to the machine.
Part numbers for the various models are shown in the
table on the right. To fully specify a model and its
options use an order code as shown in sections 1.3.1
and 1.3.2 on the following page.
5
P/N 0957
3 lev eling bolts
3/8" holes
5"
4"
4"
Supplied with:
1. 5 ft. item 40m m X 40m m extrus ion
2. 1-bas e s tand.
3. 1-40m m X 40m m end cap.
4. 2-T s lot nuts M5.
5. 2-M5 X12m m hex head.
6. 2-M5 s pring lock was hers .
7. 2-flat was hers 5/5.3m m .
8. 2-5/16 bolts .
9. 3-3/8 24 x 1/2" hex head.
5"
The mounting stand set includes a floor-mounted base
into which the 5-foot mounting post can be secured.
The floor base is steel and can be permanently mounted
to the floor surface with the pre-drilled mounting holes.
The post is extruded aluminum with slots to allow the
light curtain to be positioned anywhere along its length.
The mounting stands are supplied with all of the
necessary hardware to facilitate mounting a standard
GS-120 light curtain. Leveling bolts allow for minor
adjustments to the floor stand orientation.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
7
Model Number
Part Number
GS-120/8”(208mm)/30
0801
GS-120/12”(308mm)/30
0802
GS-120/16”(408mm)/30
0803
GS-120/24”(608mm)/30
0804
GS-120/32”(808mm)/30
0805
GS-120/36”(908mm)/30
0806
GS-120/40”(1008mm)/30
0807
GS-120/48”(1208mm)/30
0808
GS-120/56”(1408mm)/30
0809
GS-120/64”(1608mm)/30
0810
GS-120/72”(1808mm)/30
0811
GS-120/24”(608mm)/70
0821
GS-120/32”(808mm)/70
0822
GS-120/40”(1008mm)/70
0823
GS-120/48”(1208mm)/70
0824
GS-120/56”(1408mm)/70
0825
GS-120/64”(1608mm)/70
0826
GS-120/72”(1808mm)/70
0827
GS-120-4
0828
GS-120-3
0829
GS-120-2
0830
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Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
1.3.1 GS-120 LIGHT CURTAIN ORDER CODE
GS120 / XXX / X / XXXX / XX / XXXX / XX
Outputs:
PNP = 2 x PNP outputs
SSR = 2 x Solid-State Relays
Curtain Type:
S = Single Unit
M = Master Unit
A = Slave Unit
D = Double-Ended Slave Unit
Curtain Length:
200 mm to 1800 mm
Detection Capability:
30 mm or 70 mm
Curtain Display:
LED - Discrete LEDs
DIAG - Dot Matrix Diagnostic Display
Bracket options:
CB = Clamp Bracket
AB = Adjustable Bracket
EB = End Cap Bracket
1.3.2 GS-120 MULTI-BEAM ORDER CODE
GS120 / XXX / X / X / XXXX / XX
Outputs:
PNP = 2 x PNP outputs
SSR = 2 x Solid-State Relays
Curtain Type:
S = Single Unit
M = Master Unit
A = Slave Unit
D = Double-Ended Slave Unit
Number of Beams:
2
3
4
Curtain Display:
LED - Discrete LEDs
DIAG - Dot Matrix Diagnostic Display
Bracket options:
CB = Clamp bracket
AB = Adjustable bracket
EB = End cap bracket
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
8
Phone: 631-630-0442
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Release 7/2009 Ver. 1.0
1.3.3
Technical Manual: GS-120 Light Curtain Systems
CABLE OPTIONS
Cable assemblies are used to connect the GS-120
emitter and receiver units to a controller or machine.
The emitter has a 5-wire cable and the receiver has an
8-wire cable. One end of each cable has a keyed quickdisconnect connector and the other end is unterminated.
The cables are IP68 rated, and UL and CSA
recognized.
Order cable options using the following part numbers:
Description
0972
Emitter Cable, 30 ft, 5 Conductor
0973
Emitter Cable, 98 ft, 5 Conductor
0976
Receiver Cable, 15 ft, 8 Conductor
0974
Receiver Cable, 30 ft, 8 Conductor
0975
Receiver Cable, 98 ft, 8 Conductor
0977
From the information above, it can be seen
that safe use of a light curtain relies not only
on the safety integrity of the curtain itself but
also on its proper mechanical and electrical
interfacing to the machine.
Order interface and programming units using the
following part numbers:
BSRSA
Wall-mounted box
The safety integrity of the light curtain itself is
the responsibility of Tapeswitch and the
remainder of this section describes the
features of the design by which safety
integrity is ensured.
Part Number
0950
110/240 Vac or 24 Vdc
BSRUA-2
DIN rail mount
Proper mechanical and electrical interfacing
of the overall system is the responsibility of
the user. Comprehensive information for this
purpose is provided in sections 3 and 4 of
this manual.
0951
110/240 Vac or 24 Vdc
SRUB
DIN rail mount
CURTAIN
IMPORTANT
INTERFACE AND PROGRAMMING
UNITS
(See electrical interface and operation for technical
details)
Description
2.1
The emitter and receiver units together generate a
curtain of infra-red light between them. This curtain is
mounted in such a position in relation to the dangerous
parts of a machine that a person or part of a person
approaching those dangerous parts must first penetrate
the curtain. This penetration is detected by the light
curtain system and, by means of its output switching
devices, the light curtain system causes the dangerous
parts to go to a safe state (e.g. by stopping moving
parts) before the person can reach them.
1.3.4
Model
TECHNICAL DESCRIPTION
A basic GS-120 light curtain consists of two units: an
emitter unit and a receiver unit. Both units are identical
in shape and size. The units are enclosed in a robust
extruded aluminum section with reinforced composite
end covers.
Part Number
Emitter Cable, 15 ft, 5 Conductor
2.0
0952
24 Vdc
SRUS
DIN rail mount
0949
The emitter unit contains a number of infra-red light
emitting diodes (LEDs). The quantity and spacing of
these LEDs depends on the protected height and the
detection capability of the particular light curtain. The
devices are arranged equally-spaced in an array.
24 Vdc
C6
Wall-mounted box
0480
Multi-zone
GDC1
24 Vdc power supply
0953
LAT
Laser alignment tool
0956
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
The receiver unit contains a corresponding number of
infra-red photodiodes similarly arranged.
9
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Technical Manual: GS-120 Light Curtain Systems
Each LED and photodiode is fitted with a precision lens,
which produces an evenly intense, slightly diverging
beam of infra-red light from each LED and an evenly
sensitive, slightly converging ‘reception cone’ into each
photodiode. This arrangement provides a high signalto-noise ratio and maximum operating range for the
system together with ease of alignment and rejection of
extraneous reflected light sources.
Each receiver ASIC, in its turn, generates an output
signal which is proportional to the level of infra-red it
receives from its corresponding LED. Signals from
other sources, such as background lighting, are filtered
out inside the ASIC.
There is one microprocessor in the emitter unit and two
in the receiver unit. All three microprocessors perform
exhaustive checks on their own hardware and software,
prior to and during operation.
The function of each LED and photodiode is controlled
by its own dedicated, specially-designed ASIC
(Application Specific Integrated Circuit). All the circuitry
necessary for the operation of an LED or photodiode is
contained within this single component, resulting in a
very low component count and consequent
improvement in system reliability.
The two in the receiver unit continually communicate
their results to each other such that if a fault occurs in
one device the other can shut the system down.
In the receiver unit there are two independent switching
channels each containing an output signal switching
device (OSSD). Each of the two microcontrollers in the
receiver unit controls one of these OSSDs and monitors
the other.
For each LED in the emitter unit there is a
corresponding photodiode at the same relative position
in the receiver unit. Each LED/photodiode pair makes a
‘beam’ and the curtain is made up of a number of such
beams, all parallel to each other. (See Figure 3.)
The OSSDs are very robust solid state devices. These
devices are intended to be connected directly to the
machine control system, a Tapeswitch interface unit or
a suitable safety relay such that if one or both of them
are in the OFF state, the machine will go to or remain in
a safe condition, for example, by stopping dangerous
motion or by preventing dangerous motion from starting.
2.2
COMMUNICATIONS
The receiver unit incorporates a serial communications
port. Various auxiliary Tapeswitch units can be
connected to this port for the purposes of programming
functions within the light curtain and for interrogating the
system.
No equipment other than Tapeswitch brand should be
connected to this port. Full instructions for the use of
this port with auxiliary equipment are provided within this
manual.
2.3
A pair of terminals is provided across which a pair of
normally closed, volt free contacts should be connected.
When these contacts are opened the emitter unit will
stop scanning, forcing the OSSDs to the OFF state.
This input simulates a curtain obstructed condition.
Figure 3
Only one LED and one photodiode are active at any
time. The emitter unit runs independently from the
receiver unit. There are no connections between the
units.
NOTE: This input is provided to allow the GS-120 to be
used with machine control systems which need to cycle
the safety circuit prior to operation. The GS-120 system
itself does not require this input to be used. If this input
is not used it should be jumpered and remain jumpered
at all times.
The emitter unit activates each of its LEDs in turn and
the receiver unit synchronizes with the emitter unit.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
TEST INPUT
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Technical Manual: GS-120 Light Curtain Systems
2.4
INDICATORS
2.4.1
LED OPTION
The standard/master receiver unit has four status
indicators as shown in Figure 4. The standard/master
emitter unit has two status indicators as shown in
Figure 5. The slave emitter and receiver have one
status indicator as shown in Figure 6.
A description of each indicator is given in Table 1.
Figure 5
Standard & Master Emitter
Figure 6
Slave Emitter & Receiver
Figure 4
Standard & Master Receiver
Table 1 – LED Indicator Descriptions
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2.4.2
Technical Manual: GS-120 Light Curtain Systems
DIAGNOSTIC OPTION
For this option, the LED indicators on the standard and
master emitter units and all slave units are the same as
shown for the LED option above in Figures 4, 5, and 6.
However, the standard and master receiver units
contain a scrolling 4-digit alphanumeric display, shown
in Figure 7, which is used for diagnostic purposes.
The various displays and their meanings are shown in
Table 2.
Figure 7
Diagnostic Receiver
Table 2 – Diagnostic Displays
TAPESWITCH CORPORATION
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Technical Manual: GS-120 Light Curtain Systems
3.0
INSTALLATION
3.1
GENERAL
(f) No devices other than those specified in this manual
should be connected to the internally-generated power
supply of the system.
(g) After installation, the machine/guard system must be
commissioned in accordance with the requirements of
section 5.1.1 of this manual.
WARNING
(h) Any covers removed during installation must be
replaced as soon as possible.
Tapeswitch GS-120 systems are designed to
protect operators working at or near
dangerous machinery. They can only perform
this function if they are correctly fitted and
interfaced to a suitable machine. Those
persons responsible for the machine must
ensure that all persons involved in the
installation of the photo-electric safety
system have the necessary knowledge,
training and experience and that they are fully
aware of all laws, rules, regulations and codes
of practice pertaining to their task.
(i) At power on, after a power interruption or after the
curtain has been actuated, it must not be possible for
the machine to start (or restart) until a manual control
has been operated. This is known as “start/restart
interlock”. The GS-120 can provide this function, but if it
is not installed, it must be provided elsewhere within the
safety system
(j) To avoid nuisance tripping, if a fluorescent lamp with
an electronic ballast is located within 5 feet (1.5 meters)
of the receiver unit, it must be outside of a 20º field of
view from the receiver unit (±10º about the center line).
If this is not practical, a 60 Hz fluorescent light fixture
should be used.
The attention of the installer is drawn to following
general requirements for the installation of a GS-120
system:
(a) The dangerous motion of the machine must be
electrically controllable.
(b) The machine response/stopping performance must
be adequate and consistent.
MECHANICAL INSTALLATION
3.2.1
GENERAL CONSIDERATIONS
ANSI B11.19-1990 gives guidance on the dimensions
and positioning of photo-electric safety devices fitted to
industrial machines. The main considerations are
described below and are illustrated in Figure 8.
(c) It must be possible to stop the dangerous motion of
the machine at any point in its operation, in any
operating mode.
(a) The appropriate protected height must be selected.
The curtain must be of sufficient height such that access
to the dangerous parts, from the direction of approach of
the operator, is only possible by obstructing the curtain
taking into account all possible operator positions.
(d) The control system as a whole must be designed
and constructed to provide the appropriate category of
safety integrity as defined in EN954-1 'Safety of
machinery: Principles for the design of safety related
control systems'. The appropriate category should be as
prescribed in the relevant C type EN standard for the
type of machine concerned. In the absence of such a
standard the appropriate category of safety integrity
should be determined by performing a risk assessment
as described in EN1050 'Safety of machinery: Risk
assessment
(b) The correct minimum separation distance must be
observed. The curtain must be mounted in the correct
position in relation to the dangerous parts of the
machine to take account of the stopping performance of
the machine, the curtain format used and the detection
capability of the curtain.
(e) Steps must be taken to prevent access to the
dangerous parts of the machine from any direction not
covered by the photo-electric curtain. Such steps could
include fixed or interlocking fences or screens,
additional photo-electric devices or pressure sensitive
mats. Similar steps should be taken to prevent a person
from standing between the curtain and the dangerous
parts of the machine.
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3.2
(c) Steps must be taken to prevent access to the
dangerous parts from any direction not covered by the
curtain and to prevent an operator from standing
between the curtain and the dangerous parts without
obstructing the curtain. Additional mechanical guarding
will usually be necessary to achieve this.
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The physical parameters affecting the positioning are
the dimensions of the detection zone of the light curtain
(i.e. the protected height and the range) and the
minimum separation distance. These are described in
the following sections.
Figure 8
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3.2.1.1 Multi-Sided Guarding
By using mirror columns the light curtain beams can be
deflected around corners to form two and three sided
guard configurations. It should be borne in mind that for
each mirror used the range is reduced by approximately
20%. Also the alignment of systems with mirrors can be
difficult especially where the mounting surfaces are
uneven. It is therefore recommended that no more than
two mirrors are used between any pair of emitter and
receiver units. See Figures 9, 10, and 11 for different
multi-sided guarding configurations.
Note: The arrangement shown in Figure 11 is not
recommended, as it is very difficult to determine that the
safety distance S is correct.
Figure 10 – Guarding a 3-sided area
Figure 9 - Guarding a two-sided area
Figure 11 – Incorrect use of two-sided guarding
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3.2.2
Technical Manual: GS-120 Light Curtain Systems
CURTAIN DIMENSIONS
All the dimensions relating to the curtain, for each of the
GS-120 systems are shown in Figure 12. The upper
and lower boundaries of the curtain are indicated by
arrows on the front window labels of each unit.
3.2.2.1 GS-120 Basic System
The curtain dimensions are defined by the protected
height and the range (i.e. the distance between the
emitter and receiver units). The protected height must
be selected to suit the application. The minimum range
for all systems is 500 millimeters. The maximum range
for systems with 30mm or 70mm detection capability is
15 meters (50 feet).
Figure 12
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3.2.2.2 GS-120 Multi-Beam System
All the dimensions relating to the curtain, for
each of the Multi-beam systems (or multi-beam
slave systems) are shown in Figure 13.
Figure 13
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3.2.2.3 GS-120 Cascaded System
Additional flexibility to facilitate guarding in more than
one plane is provided, by the capability to connect slave
units to a basic or multi-beam master system.
The slave units can be basic or multi-beam systems,
with any of the defined detection characteristics of
30mm or 70mm.
The dimensions relating to the curtains, for each slave
unit are as defined in the previous sections for each
model. The upper and lower boundaries of each curtain
are indicated by arrows on the front window labels of
each unit.
A maximum of two sets of slave units can be connected
to a master system as shown in Figure 14. Each
emitter-receiver pair has a type designation where:
Type GS-120/M is a master
Type GS-120/A is a slave
Type GS-120/D is a slave with a connector at each end
Master and slave units can be assembled up to a
maximum of 240 beams. Where:
30mm detection - 12 beams per 200mm curtain
70mm detection - 4 beams per 200mm curtain
Examples:
GS-120/M/1000/30 = 60 beams
GS-120/A/0400/70 = 8 beams
So, total = 68 beams
Figure 14
Notes:
1. When master/slave emitter-receiver sets have
different range capabilities, these must be
respected when systems are configured.
2. When master/slave emitter-receiver sets have
different detection capabilities, the separation
distance must be calculated and adhered to for
each set separately.
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3.2.3
Technical Manual: GS-120 Light Curtain Systems
SEPARATION DISTANCE
Any machine, regardless of the efficiency of its braking
system, will take a certain time to come to rest after a
stop signal is generated.
The time from the instant that the curtain is broken to
the instant that dangerous motion actually ceases is
called the “overall system response time”.
The
dangerous parts will obviously continue to move during
this time. The curtain must therefore be positioned at a
certain minimum distance from the dangerous parts to
prevent a person who has obstructed the curtain from
reaching the dangerous parts before they have stopped.
This distance is the “minimum separation distance” and
is defined as the distance, in the direction of approach,
between the physical point at which the curtain detects
an obstruction and the nearest dangerous parts.
ANSI B11.19-1990 provides guidelines on how to
determine the minimum separation distance for a given
application. Tapeswitch GS-120 systems are primarily
intended for use in normal approach format where the
curtain is perpendicular to the direction of approach,
although they can be used in parallel and angled
approach formats.
3.2.3.1 Normal Approach
Figure 15
Normal approach format is shown in Figure 15. For
normal approach format the inner edge of the front
window of each unit (i.e. the edge which is nearest to
the machine) should be considered to be the point at
which an obstruction is detected. See plane X as
shown in Figure 15.
The effective sensing field of the device shall be located
at a distance from the nearest recognized hazard such
that the operator or others cannot reach the hazard with
a hand or other body part before stopping of the motion
during the hazardous portion of the machine cycle.
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The minimum separation distance depends on the
application. The following formula should be used when
calculating this distance:
TR =
TBM =
DS = K x (TS + TR+ TC+ TBM) + DPF
where:
DS =
K =
TS =
TC =
Response time of the presence-sensing device
and its interface, if any, as stated by the
manufacturer or as actually measured.
Additional time allowed for the brake monitor (if
used) to compensate for variations in normal
stopping time.
Added distance due to the penetration factor,
as recommended in the illustration below. The
minimum object sensitivity is stated by the
manufacturer. If beam blanking or floating
window features are used, these figures should
be added to the object sensitivity figure before
using the chart.
DPF =
Minimum separation distance between the
device and the nearest point of operation
hazard in inches.
Hand speed constant.
See note.
Stop time of the machine tool measured at
the final control element.
Response time of the control system.
NOTE: The value of the hand speed constant, K, has
been determined by various studies.
Although these studies indicate speeds of 63
in/sec to over 100 in/sec, they are not
conclusive determinations. The employer
should consider all factors, including the
physical ability of the operator, when
determining the value of K to be used.
NOTE: TS and TC are usually measured by
a stop-time measurement device.
Blanked Dimensions or Minimum
Object Sensitivity in Inches
2.5
2.0
1.5
1.0
0.5
0.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
Penetration Factor D(pf) in Inches
DPF
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1 inches
14mm
3.1 inches
30mm
8 inches
70mm
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3.2.3.2 Parallel Approach
Parallel approach format is shown in Figure 16. For
parallel approach format the outer curtain detection limit
(as shown on the front window of each unit) minus the
detection capability, should be considered to be the
point at which an obstruction is detected. See Plane X in
Figure 16.
For this type of protective equipment, the height H of the
detection zone shall not exceed 1000mm. If H is greater
than 300mm (200mm for non-industrial applications),
the risk of undetected access beneath the detection
zone should be considered.
Figure 16
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3.2.3.3 Angled Approach
3.2.3.4 Approach to ‘L’ Installation
If it is necessary to install the curtain, at an angle to the
direction of approach as shown in Figure 17, then the
following requirements apply:
If vertical and horizontal master/slave GS-120 light
curtains are used together as in Figure 18, where the
vertical curtain is the main trip curtain and the horizontal
curtain performs presence sensing inside it, the
separation distance calculations for the vertical curtain
are used. However, the detection capability calculations
of the horizontal curtain with respect to its height should
also be observed. Note: Where master/slave
combinations are used:
An angle within ± 5° of normal or horizontal, need not be
considered to be angled, and the relevant formula used.
For detection zones which are positioned at angles
greater than ±5°, to the direction of approach, account
shall be taken of the risks associated with the direction
of approach, and the most appropriate formula used.
Total
Master Unit
Response = Response +
Time
Time
Figure 18
Figure 17
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Response
Time
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3.2.4
Technical Manual: GS-120 Light Curtain Systems
OPTICAL ALIGNMENT
3.2.5
The emitter and receiver units should be mounted facing
each other at the same height with their axes aligned.
Misalignments, as illustrated in Figure 19, should be
avoided. Tapeswitch offers a laser alignment tool to add
visible assistance over longer range or when mirrors are
used. See section 4 for detailed information.
REFLECTIVE SURFACES
There should be no reflective surfaces within the ‘field of
view’ of the curtain units. Reflective surfaces within the
field of view can lead to non-detection of an obstruction.
The field of view of each of the emitter and receiver
units is approximately 5 degrees either side of the
optical axis.
A minimum distance from the optical axis to any
reflective surface must be observed. This distance
depends on the actual operating distance and must take
into account possible misalignment. This is illustrated in
Figure 20. The distance should be determined as
follows:
Operating distance L < 3m: X < 260 mm
Operating distance L > 3m: X > 0.0874L mm
Figure 20
Figure 19
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3.2.6
Technical Manual: GS-120 Light Curtain Systems
SYSTEMS IN CLOSE PROXIMITY
3.2.7
In order to avoid nuisance interference between
adjacent systems, whenever two or more emitterreceiver pairs are used within each other’s sensing
range, ensure that the front window of any unit is not
within the field of view of units of the opposite type
from other systems.
MOUNTING BRACKETS
Mounting brackets and their associated hardware are
provided with the emitter and receiver units. The
brackets have been specially designed to allow
adjustment.
Each unit is supplied with two clamp brackets fitted, one
at each end. The clamp bracket is a short piece of
extruded aluminum which is designed to interlock with
the unit housing extrusion and to clamp in position on
the rear of the housing by means of two set screws.
The set screws can be tightened or loosened with a
2mm Allen wrench, which is supplied with the unit. The
clamp bracket can be slid up and down the emitter and
receiver units to facilitate alternate positioning of the
bracket. The clamp brackets are a tight fit on the emitter
and receiver units and may require some force to slide
them up and down on. The clamp bracket dimensions
are shown in Figure 22.
This can be achieved by ensuring that units of the same
type are mounted facing in opposite directions. See
Figure 21.
The clamp brackets can be moved to any position
over the length of the unit, but it is recommended
that they be kept in the supplied position.
Figure 21
Figure 22
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This makes replacement of a unit much easier as
the new unit will have the brackets already in the
correct position. The position of the clamps on the
units is shown in Figure 23.
The set screws may not be completely tightened in
the supplied position. These set screws must be
fully tightened before proceeding with the
installation. (A 2 mm Allen wrench is supplied for
use in tightening the brackets.) If these brackets are
not properly secured, the emitter and receiver units
may shift causing nuisance tripping, a false lock-out
condition and/or a potential safety hazard.
Four wall brackets are supplied with each system
together with the 8 self-tapping screws needed to fix the
wall brackets to the clamp brackets. The wall bracket
dimensions are shown in Figure 24.
The alternative mounting arrangements which these
brackets facilitate are shown in Figures 25, 26, & 27.
The internal construction of the units is such that they
can withstand normal levels of vibration and shock. In
situations where the vibration of the machine cannot be
reduced to normal levels, vibration proofing mountings
should be used.
Figure 23
Figure 24
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Figure 25
Figure 27
Figure 26
TYPE AB - MOUNTING BRACKETS
Type AB adjustable mounting brackets are an optional
choice for GS-120 Light Curtains. Combining a robust
design and quick release capability, these brackets
allow for speedy installation and easy interchange of a
light curtain unit without the need for re-alignment. To
request this option when ordering your light curtain
please specify "AB" in your order code. (part number
0978)
.95" (24mm)
1.58" (40mm)
Clamp plate
securing screw
2.56" (65mm)
1.85" (47mm)
Angular adjustment
screw
6mm dia.
mounting hole
2.56" (65mm)
2.56" (65mm)
3.15" (80mm)
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3.3
Technical Manual: GS-120 Light Curtain Systems
This output will remain “off” until the integrity of the
other output is restored. This level of integrity must
be maintained throughout the machine control
circuit. It is the responsibility of the end user to
assure any fault within the safety circuit is detected
and that it puts the machine in a safe condition.
ELECTRICAL INTERFACE,
OPERATION, and INSTALLATION
This section is divided into two parts. The first part
discusses the interface and operation of the GS-120
system when the basic set (emitter and receiver) is
interfaced directly to the machine control circuitry by
means of the redundant solid state outputs.
3.3.1
The second section discusses the interface when any
one of the various Tapeswitch control units is used.
Both units must be supplied with 24 Vdc ± 20%. This
DC supply must be isolated by means of a safety
transformer which conforms to the requirements of
IEC61558-2-6. The emitter, receiver and interface unit
must use the same + 24V DC supply. The negative side
of the supply should be grounded and the cables should
be routed separately from power and motor drives.
The basic GS-120 system consists of an emitter and
receiver. The receiver unit provides two safety outputs.
These fail-safe outputs are solid-state PNP transistors
and are actively monitored and short-circuit protected.
The two outputs are independent of each other and
represent part of the redundancy of the overall light
curtain system. The outputs must always be in the
same state (i.e., both outputs either on or off). If one
output should fail in the “on” position, the other output
will remain in the “off” position until the failure is
corrected. In order to maintain redundancy both outputs
must be interfaced to independent switching devices in
the machine control circuit (i.e., safety relays,
emergency stop relay packages, fail-safe PLC’S, etc.).
Both outputs must be used. The solid state outputs
can be interfaced directly to the machine control circuit
provided this circuitry is compatible with the PNP-type
output. A number of manufacturers produce units
containing circuits of this type. Care should be taken to
ensure that the inputs of these units can accept the PNP
outputs of the light curtain.
The maximum cable length for each unit is 30 meters.
The power consumption is dependent on the protected
height of the system but is less than 12 VA.
The emitter and receiver should be powered by a
common DC supply and connected to the system
ground. If power is removed from the emitter only
the system may not automatically re-synchronize,
and may require power removal from the receiver as
well in order to establish optical communication and
synchronization. Power can be removed from the
receiver unit without any consequence to the
synchronization.
• The maximum current is 0.1 A.
• The output voltage, Ua, of each output is dependent
on the supply, Uv and the load and is given by the
following expression Ua > Uv - 2v.
• If the solid state outputs are used directly, the
supply voltage to the light curtain (emitter and
receiver) must be common to the supply voltage of
the device to which it will be interfaced.
• Both outputs must be used to maintain redundancy.
• Each output should be wired to independent switching
devices in the machine control circuit and SHOULD
NOT BE CONNECTED TOGETHER.
IMPORTANT
Power should be applied to both units at the
same time. If power is removed from the
emitter unit, power must also be removed
from the receiver unit.
3.3.2
EMITTER UNIT
3.3.2.1 General
The emitter unit has a five-pin male quick-disconnect
connector. Two pins for the DC supply, two for the test
input (see 3.3.2.2), and one for the ground. (protective
earth PE)
NOTE: The pair of solid state outputs are constantly
monitored and are designed to act as a single
component in a fail-safe condition (i.e., if one of the
outputs fails in the “on” position, the other output
will revert to the “off” position.
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GENERAL
To connect to the emitter, a 5-pin female molded cable
assembly is necessary. This cable assembly is supplied
separately and is available in lengths of 15 feet (p/n
0972), 30 feet (p/n 0973), or 98 feet (p/n 0976). This
cable has an insulated jacket with color coded wires.
The cable has a fixed molded connector on one end and
flying leads at the other. The colors and corresponding
functions are shown in Figures 28 and 29.
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Ground
Figure 29 – Emitter Connections
Figure 28 – Emitter Connector
3.3.3
3.3.2.2 Test Input
RECEIVER UNIT
3.3.3.1 General
On some machines, a test input is used to check the
interface between the photo-electric safety device and
the machine. The input simulates the obstruction of the
curtain in order to cycle the output switching elements
and thereby expose any fault before the next machine
cycle. This input is applied during a safe part of the
machine cycle or at the end of the cycle.
The GS-120 is available with two output modes, PNP
and SSR, as shown in the order codes in section 1.3.
The PNP version has cross-monitored 24Vdc PNP
outputs, start/restart interlock and the ability to monitor
contacts from external devices (EDM). The SSR version
has volt-free contacts which are closed when the curtain
is clear, but does not have any start/restart interlock
function. This must be provided elsewhere in the safety
system. The receiver connector is shown in Figure 30.
If this function is used, a normally closed contact should
be connected as shown in Figure 29.
This contact must open for a minimum of 100ms. When
this contact is opened, the light curtain safety outputs
will be switched off and will remain off until the test
contact closes again and the curtain self-tests have
been successfully performed (assuming that the curtain
is not obstructed).
The 24Vdc supply must have a 2A quick
blow in-line fuse fitted.
If the test input is not used, this input must be
jumpered.
NOTE: If the emitter cable is removed during
normal operation, the system will not return to
normal operation once the emitter is reconnected
until power is cycled on the receiver.
Figure 30 – Receiver Connector
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3.3.3.2 PNP Version
3.3.3.2.1 Safety Outputs
This version has two 24 Vdc PNP outputs. The two
output signal switching devices (OSSDs) should be
wired to independent switching devices in the machine
control circuit. The OSSDs are solid-state devices and
are internally monitored and short-circuit protected. The
connections for the PNP version of the receiver are
shown in Figure 31.
The maximum current is 0.1A.
The output voltage, UA, of each OSSD is dependent on
the supply, UV, and the load which is given by the
following expression:
Figure 32 – Auto Restart
UA > UV - 2V
Ground
Figure 33 - Auto Restart with EDM
Figure 31- PNP Version Receiver Connections
3.3.3.2.2 Start/Restart and External Device
Monitoring (EDM)
In the PNP mode the GS-120 can be set up for either
manual or automatic start and restart. This function is
determined by the connections to the unit. In manual
mode, the outputs will only switch on when the curtain is
clear and a reset switch is closed and then opened. In
automatic mode the outputs will be on whenever the
curtain is clear and off whenever the curtain is
obstructed.
Figure 34 – Manual Restart
The GS-120 also has the ability to monitor external
devices. This is achieved by using normally-closed
contacts of the external device and monitoring that they
are closed before allowing the outputs to switch from off
to on. The various wiring configurations for these
options are shown in Figures 32 to 35.
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Figure 35 – Manual Restart with EDM
3.3.3.3 SSR Version
This version has two voltage-free solid-state outputs. It
operates in automatic mode, so the outputs will be on
whenever the curtain is clear and off whenever the
curtain is obstructed. See Figure 36.
Ground
Figure 36 – SSR Version Wiring
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3.3.4
Technical Manual: GS-120 Light Curtain Systems
INTERFACING TO A MACHINE
The interfacing of a light curtain to a machine can be
achieved by using discrete components or by means of
an interface unit such as the Tapeswitch SRUB.
Note: N/C contacts of K1 and K2 are used for
monitoring purposes. If EDM is carried out elsewhere,
the reset switch should be connected between pin 2 and
pin 6 of the Receiver unit.
All the relays shown are safety relays with positively
guided contacts. If this circuit is implemented using
discrete components, it is essential that this type of relay
is used.
IMPORTANT
A number of manufacturers produce units containing
circuits of this type. Care should be taken to ensure that
the inputs of these units can accept the PNP outputs of
the light curtain.
3.3.4.1 PNP Version Manual Reset
It may be possible to connect the GS-120 directly to the
Machinery Primary Control Elements (MPCE) as shown
in Figure 37. The GS-120 provides the Start/Restart
function necessary to avoid unintended initiation of the
machine.
Figure 37 – PNP Version Manual Reset
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3.3.4.2 PNP Version Auto Reset
IMPORTANT
The GS-120 can be used in Auto Restart mode as
shown in Figure 38. If this mode is selected, the Manual
Restart function must be provided elsewhere in the
machine safety control system (for example, in the
SRUB interface unit).
A number of manufacturers produce units containing
circuits of this type. Care should be taken to ensure that
the inputs of these units can accept the PNP outputs of
the light curtain.
Note: The connection through 41 and 42 is used for
external monitoring (EDM). If an alternative safety relay
is used which does not have N/C contacts for
monitoring, then connect pin 2 to pin 6 on the Receiver
unit.
Figure 38 – PNP Version Auto Reset
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IMPORTANT
3.3.4.3 SSR Version
A number of manufacturers produce units containing
circuits of this type. Care should be taken to ensure that
the inputs of these units can accept the volt-free outputs
of the light curtain, and that the outputs of the light
curtain are wired with one channel "pull up" and one
channel "pull down" so as to maintain the failure mode
integrity.
The interfacing of a GS-120 light curtain to a machine
can be achieved by means of an interface unit such as
the Pilz PNOZ 8. The circuit diagram for the PNOZ 8
and the typical connections to the GS-120 light curtain
and the machine are shown in Figure 39 below.
Figure 39 – SSR Version
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examination, inspection and test of a machine and its
safety devices. It is for the user to determine if such
requirements exist for the machine in question and to
ensure that those requirements are met.
3.4 INITIAL CHECKING AND ALIGNMENT
The procedure for alignment is described below.
Apply power to the GS-120 system.
The amber indicators on the emitter and receiver units
should be lit. If either of the indicators is not lit, check
the wiring.
The yellow indicators on the emitter and the receiver
units should be in the off state. If either of these two
indicators is flashing, there is a fault, contact your
Tapeswitch distributor. If the yellow indicator on the
emitter unit is on constantly, check the wiring as
described in sections 3.3.2 and 3.3.3.
The green indicator on the receiver unit should be lit, if
not, adjust the units into general alignment until the
green indicator comes on.
Adjust the units to optimum alignment as follows:
1. Slowly turn the emitter unit clockwise until the green
indicator on the receiver unit goes off and the red
indicator comes on. (Note this position.)
2. Then turn the emitter unit counter-clockwise, again
until the green indicator goes off and the red indicator
comes on. (Note this position.)
3. Set the emitter at the center of the two noted
positions.
4. Repeat steps 1, 2 and 3 but this time turning the
receiver unit.
Using the test piece provided, obstruct the curtain. On
the receiver unit the green indicator should go off and
the red indicator comes on.
Move the test piece in and out of the curtain several
times and check that the indicators change state
appropriately each time.
See section 5.2 of this manual if the system does not
function as described above.
The installation of the machine can now be completed.
Before putting the machine into use, the complete
system (i.e. the machine and all its safeguarding
devices) should be commissioned by qualified personnel
and, as a minimum, the commissioning checks
described in section 5.1.1 of this manual should be
performed.
Periodic checks in accordance with section 5.1.2 should
be carried out at the prescribed intervals. Daily checks
to be performed on the GS-120 system are detailed in
section 5.1.3 of this manual. In some cases there are
specific statutory requirements concerning the
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4.0
INTERFACE AND AUXILIARY UNITS
4.1
GENERAL
Technical Manual: GS-120 Light Curtain Systems
The interface will only allow the safety relays to move to
the ON state if both channels are working correctly
together.
All interface units are provided with indicator lamps
which show the status of the interface. The number,
color, meaning and location of the indicators may
change with the type of interface. All interfaces
however, have indicators which specifically show the
commanded state of the output safety relays.
In applications where the two PNP or solid state outputs
are not suitable for the machine control circuit, an
interface unit must be utilized. This interface unit may
be user supplied, provided it is compatible with either
the PNP or SSR outputs and has two channels. A
number of manufacturers produce units containing
circuits of this type. The interface unit must be designed
to the same level of integrity as the GS-120 in order to
maintain the same overall level of safety.
Both of these outputs must be used to take
advantage of the inherent redundancy of the
interface unit.
Several Tapeswitch interface units are available which
offer options in configuring the input power source,
mounting package and type of electrical interface
desired. All of the units perform the actual switching of
the electrical circuit of the dangerous machine using
positively-guided safety relays. All of the ac-powered
interface units (BSRSA and BSRUA-2) provide the
stepped-down +24 Vdc power for the GS-120 emitter
and receiver pair. The dc-powered interface units,
(SRUB and SRUS), are powered by an external +24
Vdc power supply and this supply must also power the
GS-120 emitter and receiver pair. All of the interface
units provide isolation from the low amperage GS-120
solid state outputs (0.5 A each) and the potentially
higher amperage required by the machine control
circuitry. Each interface unit provides LED status
indicators. All LEDs will be discussed in the description
of the applicable interface units. These units are
described in the appendices of this document.
4.1.1
The two safety outputs are normally (NO). The outputs
are closed when no obstructions are in the light curtain
and no faults exist. Once the light curtain is broken the
outputs open. The state of the output may remain open
until a reset switch is applied (MANUAL RESET) or will
automatically close (AUTOMATIC RESET) once the
light curtain is cleared. Details of the resetting features
are discussed in the individual interface sections found
in the appendices.
The safety outputs can be used in several ways,
depending on the MPCEs found on the machine being
guarded. MPCE is the abbreviation for Machine
Primary Control Element. An MPCE is an electricallypowered control device which directly controls the
guarded machines motion and is the final device in the
operating sequence when motion is either initiated or
halted. This would be the main hydraulic control valve
in a hydraulically controlled press. Some of the
common arrangements are described below:
METHODS OF INTERFACING
• Normal risk machine - These usually have a single
MPCE. In this case both normally open safety outputs
should be used together as shown in Figure 40.
All of the interface units have a minimum of two safety
outputs. These outputs are to be interfaced with the
machine primary control elements (MPCEs). An
MPCE is defined as an electrically controlled element
which directly controls the normal operating motion of a
machine such that it is the last (in time) to operate when
motion is initiated or arrested.
• High risk machines - These should have 2 MPCEs. In
some countries, it is customary for both MPCEs to
operate in the same mode. In this case, each of the
normally open (NO) outputs controls a single MPCE.
See Figure 41 for an illustration of the type of
interface. Any additional output contacts can be used
as a monitor, e.g. as an input to a PLC.
The safety output contacts of the interface unit must be
connected to a machine’s MPCEs in such a way that if
either of the safety output relays is switched off, then the
machine will be brought to rest, regardless of the state
of the other relay.
To protect the contacts of the safety output relays from
the effects of switching inductive loads, an appropriately
rated power factor correction device must be installed
across the MPCE coils. Figures 40 and 41 show Arc
Suppressors used for this purpose. Arc Suppressors
are user supplied.
This gives assurance that the failure of a single relay
cannot prevent the machine from being stopped. The
safety output relays are cross-monitored within the
interface unit. This means any disparity between the
two relays will be detected. The machine will be
disabled until the cause of the disparity has been
removed. Such a disparity could be the loss of signal on
one of the two channels coming from the light curtain.
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CAUTION
which could cause the contact to weld. Fuses with a
current rating less than that of the output contacts
should be used.
Arc Suppressors must not be connected
across safety relay contacts.
Machine
Control
Voltage
On the BSRSA Interface Unit, these safety (output
protection) fuses are part of the unit. All of the other
interface units do not provide safety fuses (output
protection) and these fuses should be supplied
externally by the user.
Arc
Suppres s or
Safety
Fuse
Safety
Output
1
Safety
Output
2
4.1.2 SPECIAL INTERFACING CONSIDERATIONS
4.1.2.1 PNP Version Manual Reset
It may be possible to connect the GS-120 directly to the
Machinery Primary Control Elements (MPCE). The GS120 in this configuration provides the Start/Restart
function necessary to avoid unintended initiation of the
machine.
MPCE
1
4.1.2.2 PNP Version Auto Reset
Figure 40 - Interfacing a Machine with 1 MPCE
Machine
Control
Voltage
Safety
Fuse
The GS-120 can be used in Auto Restart mode. If this
mode is selected, the Manual Restart function must be
provided elsewhere in the machine safety control
system (for example, in the SRUB interface unit).
Arc
Suppres s or
Safety
Output
1
4.1.2.3 SSR Version
The interfacing of a GS-120 light curtain with SSR
outputs requires a controller that is compatible with
these devices. Care should be taken to ensure that the
inputs of this unit can accept the volt-free outputs of the
light curtain, and that the outputs of the light curtain are
wired with one channel "pull up" and one channel "pull
down" so as to maintain the failure mode integrity.
MPCE
1
Arc
Suppres s or
Safety
Fuse
Safety
Output
2
MPCE
2
Figure 41 - Interfacing a Machine with Dual
Identical MPCEs
SAFETY FUSES: It is good practice to protect the
safety relays against welding due to a current surge.
This can be done by current limiting designs in the
machine’s controls, or by simple fusing as shown in
Figure 40 and 41. The current through the safety
output contacts should be limited to a level below that
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4.1.3 CONNECTIONS TO AN AS-i SYSTEM
Note: The power supply leads of the GS-120 system
should not be connected directly to the YELLOW AS-i
cable as this may cause AS-i data transmission
problems. It is recommended that this connection be
made using a decoupling network.
A GS-120 system can be connected to an AS-i Safe
System using standard AS-i Safe I/O modules as shown
in Figure 42.
The connection of the Emitter and Receiver units to the
system is simply achieved by plugging into standard
AS-i components using the cables supplied.
Alternatively the guard can be connected to the BLACK
AS-i cable (the auxiliary power cable).
Figure 42
Connecting a GS-120 to an AS-i System
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(h) Examine the stopping performance monitor (if
installed) to ensure that it is installed and functioning
correctly. Ensure that the means whereby the stopping
performance can be assessed by the operator is
indicating correctly.
(i) Test the muting arrangements (if installed).
5.0 PERIODIC CHECKING,
SERVICING, AND MAINTENANCE
5.1
PERIODIC CHECKING
5.1.1 COMMISSIONING CHECKS
(j) Examine brakes or clutches (if installed) as
recommended.
The commissioning examination should be carried out
by persons who are competent and who possess all the
information supplied with the machine and its safety
equipment. The results of the examination should be
recorded and copies of this record should be kept by the
user and the employer of the person performing the
examination. The person carrying out the examination
should ensure that the following general standard of
performance is met:
NOTE: No stopping performance monitor or muting
facility is provided with the basic GS-120 system
and there is no means provided for the connection
of such devices to the system. These devices may
however have been provided elsewhere in the
machine control system.
5.1.2
(a) It should not be possible for the dangerous parts of
the machine to be set in motion while the light curtain is
penetrated.
These examinations should be carried out by competent
persons. The results should be recorded and a copy
kept by the user.
(b) Penetration of the light curtain during a dangerous
phase of the operation of the machine should result in
the dangerous parts being arrested or, where
appropriate, assuming an otherwise safe condition,
before any part of a person can reach them. It should
not be possible for the dangerous parts to be set in
motion until the curtain has been cleared, the safety
system has been restored to its normal condition, and
the machine controls have been reset.
The person should ensure that the general standard of
performance as described in section 5.1.1 (a) and (b) is
achieved.
The person should perform the commissioning
inspections and tests detailed in section 5.1.1. When
checking the stopping performance monitor, item (h),
any equally effective means of determining that the
overall system response time, as recorded on the
machine information label or plate, is not exceeded is
acceptable.
The person performing the examination should also:
(c) Inspect the position of the light curtain to ensure that
it is set at the correct distance from the dangerous parts
of the machine as recorded on the machine information
label or plate.
In addition the person should:
(d) Ensure that additional safeguarding measures have
been provided where necessary to prevent access to
the dangerous parts of the machine not protected by the
light curtain.
(a) Examine all switching elements in the switching
paths controlled by the light curtain outputs to ensure
that they are functioning correctly and are not in need of
maintenance and or replacement.
(e) Where appropriate, test the overall system response
time using a suitable device and ensure that it is the
same or less than that recorded on the machine
information label or plate.
(b) Inspect the machine to ensure that there are no
mechanical or structural aspects which could prevent
the machine from stopping or assuming an otherwise
safe condition when called upon to do so.
(f) Test the detection capability of the light curtain as
described in section 5.1.4 of this manual.
(c) Examine and inspect the machine controls and the
connections to the GS-120 system to ensure that no
modifications have been made which could adversely
affect that system, and that suitable modifications have
been correctly performed and properly recorded.
(g) Examine the machine controls and connections to
the GS-120 system to ensure that the requirements
described in this manual and in the machine manual
have been met.
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5.1.3
Technical Manual: GS-120 Light Curtain Systems
DAILY/SETTING EXAMINATION
(b) Insert the test piece provided with the 30 mm model
into the light curtain beams. The axis of the test piece
should be perpendicular to the plane of the light curtain.
Starting at the top of the emitter unit, position the test
piece less than 150 millimeters from the emitter surface,
and pass it slowly down the front of the unit. While the
full diameter of the test piece is within the area defined
by the two arrow markers on the front window, the green
indicator should GO OFF AND REMAIN OFF and the
red indicator should BE LIT AND REMAIN LIT.
The following tests should be carried out daily by a
designated person appointed by the machine user. The
results should be recorded and a copy should be kept
on or near the machine. Specific statutory requirements
may apply to certain types of machines. The designated
person should:
(a) Check that access to the dangerous parts of the
machine is not possible from any direction not protected
by the light curtain and that side and rear guards are in
order.
(c) Repeat the above test with the test piece inserted
close to the front of the receiver unit and with the test
piece inserted at the midpoint between the emitter and
receiver units. The indicators should behave as
described above whenever the test piece is between the
arrow markers.
(b) Check that the minimum distance from the
dangerous parts of the machinery to the light curtain is
not less than the distance stated on the machine
information label or plate.
(c) Check that it is not possible for a person to stand
between the dangerous parts of the machine and the
light curtain.
WARNING
At no time while the test piece is obstructing
the curtain should the green indicator come
on. If it does, the machine must be isolated
and must not be used until the cause has
been investigated.
(d) Check that when the muting facility (if installed) is
operative, the moving parts are no longer dangerous.
(e) Check that the stopping performance monitor (if
installed) is in use and is set up and functioning
correctly.
(d) If the system passes the above tests proceed as
follows. Initiate a cycle of the machine and then insert
the test piece into the curtain. Upon insertion of the test
piece during dangerous motion, the dangerous parts
should come to rest without apparent delay.
(f) Check that electrical enclosures are closed and
locked and that any keys have been removed for
retention by a designated person.
WARNING
(g) Check for external signs of damage to equipment or
to electrical wiring.
If the machine does not stop or there is any
delay in its response, the machine must be
isolated and must not be used until the fault
has been rectified.
(h) Check the detection capability of the GS-120 as
described in section 5.1.4.
5.1.4
CHECKING DETECTION CAPABILITY
Test piece
5.1.4.1 GS-120 System
The detection capability of the light curtain should be
checked as required in the previous sections using the
method described below. See Figure 43.
(a) With power applied to the GS-120 system and with
the machine at rest, check that the light curtain is
functioning by observing the state of the appropriate
indicators. The green indicator should be on and the
red indicator should be off.
<150 mm
<150 mm
Figure 43 – Light Curtain Detection Test
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5.1.4.2 GS-120 Multi-Beam System
The operation of the light curtain should be checked as
required in the previous sections using the method
described below and as shown in Figure 44.
(a) With power applied to the GS-120 system and with
the machine at rest, check that the light curtain is
functioning by observing the state of the appropriate
indicators. The green indicator should be on, and the
red indicator should be off.
(b) To test the curtain is operating correctly, insert your
hand in between the emitter and receiver units and
obstruct one of the beams. While the beam is
obstructed, the green indicator should GO OFF AND
REMAIN OFF and the red indicator should BE LIT AND
REMAIN LIT. Move your hand in and out of the beam
several times and check that the indicators change state
each time as appropriate.
(c) Repeat the above test for each of the beams. The
indicators should behave as described above whenever
the beams are obstructed.
Figure 44
WARNING
At no time while a beam is obstructed should the
green indicator come on. If it does, the machine
must be isolated and must not be used until the
cause has been investigated.
(d) If the system passes the above tests proceed as
follows. Initiate a cycle of the machine and then insert
your hand into the curtain. Upon insertion of your hand
during dangerous motion, the dangerous parts should
come to rest without apparent delay.
WARNING
If the machine does not stop or there is any delay in
its response the machine must be isolated and must
not be used until the fault has been rectified.
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5.2
Technical Manual: GS-120 Light Curtain Systems
SERVICING
5.3
The GS-120 system is designed to be serviced at unit
level. There are no user-serviceable parts within the
units.
MAINTENANCE
There are no mechanical, electrical or optical
adjustments necessary.
Apart from occasionally
cleaning of the windows on the emitter and receiver
units, GS-120 systems are maintenance free. Use a
soft, lint-free cloth and an anti-static cleaner.
When a safety-critical fault occurs in the GS-120 system
or in the machine interface, the machine will be
disabled. It is first necessary to establish whether the
fault is in the GS-120 system or in the machine
interface.
Do not use solvents of any kind.
Use Tables 1 and 2 in section 2.4 and Table 3 below to
identify faults within the GS-120 system.
UNIT
Emitter
STATE OF
INDICATORS
CAUSE(S)
ACTIONS(S)
Amber LED
not lit.
No power
to unit
Connect power
Red LED
lit steady
Test input
is open
Close test input
Red LED
flashing
Emitter unity
faulty
Replace emitter
unit
Amber LED
not lit
No power
to unit
Connect power
Units out
of alignment
Check alignment
Test input
open on
emitter
Red LED
fully lit (no
obstruction
of curtain)
Check emitter
red LED
Emitter unit
faulty
Receiver
No power on
emitter unit
Check emitter
amber LED
Yellow LED
flashing
Receiver
outputs are
shorted
Remove short
between outputs
Yellow LED
Steady
Light Curtain
has been
programmed
Reconnect hand
held blanking unit
and re-configure
to correct setting
Table 3 – Fault Table
NOTE: The emitter and receivers are not matched
pairs. They become mated pairs only upon
power up. It is not necessary to replace both
units, should one become faulty.
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6.0 TECHNICAL SPECIFICATIONS (Basic GS-120, Emitter and Receiver ONLY)
EN 13849-1:2006 PLE, EN 954-1 CAT 4
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APPENDIX A – BSRSA INTERFACE UNIT
1.0
(loss of power or failure) it will be necessary to reset the
system.
GENERAL DESCRIPTION
The BSRSA interface unit is designed as a standalone
control panel. It interfaces a GS-120 light curtain
(emitter and receiver) with the guarded machine’s
controls.
2.0
The monitoring output will follow the state of the safety
outputs and should be used for non-safety functions (i.e.
indication and status).
OPERATIONAL SEQUENCE AND LED
STATUS DESCRIPTION
• External remote reset can be accomplished by
connecting a normally-open, momentary-contact switch
to terminal X2 between connections 1 and 2. (This will
operate in conjunction with or replace the front panel
key reset switch.)
When power is first applied to the light curtain system
via the BSRSA:
• A red LED (H3) on the BSRSA controller should
illuminate indicating that the control unit has power.
3.0
• No power will be supplied to the emitter or receiver
of the light curtain and the output status indicators in the
BSRSA controller will not be illuminated. All of the
outputs will be de-energized and the output contacts will
be open, until a reset has been applied.
MECHANICAL INFORMATION
Figure 45 shows the metal enclosure size and mounting
dimensions of the BSRSA interface unit.
The
dimensions are in inches. The BSRSA enclosure is
rated for the operating environments found in most
manufacturing plants. Figure 46 shows an internal view
of the BSRSA interface unit.
• Reset the system by the front panel key switch or the
external remote reset, if used. See below for details.
After the reset switch is released, both the emitter and
receiver units of the light curtain should have amber
indicators illuminated which shows that power has been
applied. If the light curtain is properly aligned, the
receiver should have a green LED illuminated which
shows the light curtain is clear. If the receiver shows a
red LED illuminated, then the light curtain is either not
properly aligned, faulty, or obstructed. Once the units
are properly aligned and any obstructions are removed,
the green LED should be illuminated and the receiver
LEDs should follow the state of the light curtain (green
indicates curtain clear and red indicates curtain is
blocked, obstructed, or misaligned). With the green
LED illuminated on the receiver, the output status
indicator on the BSRSA controller should be green (H2).
The output status indicator on the BSRSA controller will
be red (H1) when the curtain is blocked, obstructed, or
misaligned.
6.94
6.00
5.00
4.00
GUARDSTAR
4.12
R
by Tapeswitch
Type no:
BSRSA
Serial no:
Supply
Voltage:
24V DC
110-240VAC
50/60 HZ
POWER
CONSUMPTION:
30VA
TYPICAL
Output Contacts:
RESET
4.0A@ 240VAC
RESISTIVE LOAD
Safety System
8.75
8.00 9.50
Resp ons e Ti me
Equals
Sensing U nit
Resp ons e Ti me
+10MS
B SERIES
System Controller
Tapeswith
CORPORATION
100 SCHMITT BLVD FARMINGDALE. NY 11735 1-800-2348273
The redundant safety outputs will follow the state of the
light curtain, i.e., if the light curtain is clear; safety
outputs 1 & 2 will be closed (energized), but if the light
curtain is obstructed, safety outputs 1 & 2 will be open
(de-energized)). The safety outputs reset automatically
the light curtain is cleared again. The safety outputs will
not reset (close/energize) if a fault exists.
Figure 45 – BSRSA Interface Unit Outline and
Dimensions
The lockout contact will close (energize) once the reset
sequence has been completed. It will remain closed at
all times unless a fault has occurred or power has been
removed. The lockout contact does not follow the state
of the light curtain. Once the lockout condition occurs
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The interconnection diagram (Figure 49) and the wire
run list (WRL) (Figure 50) show the proper terminal
numbers and associated functions for the cabling
between the GS-120 emitter and receiver units and the
BSRSA interface unit. Be sure to observe the color
coding shown to assure proper operation.
The cables for the interface between the GS-120 emitter
and receiver units and the BSRSA unit are not included
with the light curtain and must be ordered separately.
The emitter cable has five conductors in an insulated
jacket. The receiver cable has eight conductors in an
insulated jacket. The cables have different connectors
and will only mate to the proper component of the light
curtain.
Figure 46 - BSRSA Interface Unit Internal View
4.0
The metal enclosure has four double knockouts capable
of accepting standard ½” or ¾” conduit fittings. It is
recommended that any high voltage connection to the
BSRSA control unit be made with suitable cabling
and/or conduit protections. The connections between
the BSRSA and the GS-120 emitter and receiver units
are non-hazardous, low-voltage signals and additional
protection of these cables is not necessary. It is
recommended that suitable fittings or cable grips be
used to maintain the moisture integrity of the installation.
It is strongly recommended that the low-voltage
connections be separated from the high-voltage
connections. Local electrical codes should be
observed.
ELECTRICAL CONNECTIONS
Emitter
The BSRSA interface unit has four internal terminal
strips, designated X1, X2, X6, and X7. Each connection
point is mechanically suitable for (1) 2.5mm2, 14 AWG
wire. Crimped ferrules or tinning must be used on all
stranded wires. Figure 47 shows the system block
diagram for the BSRSA controller.
5.0
W1
Power
Input
BSRSA
Controller
The BSRSA is equipped with four fuses, F1, F2, F3, and
F4. See Figure 46 for the location of these fuses. Fuse
F1 is a 500 mA, 250 Vac slow-blow type, and is
intended to protect from potential shorts and surges on
the high voltage side of the interface unit. Fuse F2 is a
1.2 A, 250 Vac quick-blow type and is intended to
protect from potential shorts in the low voltage, 24 Vdc,
circuitry of the interface unit. Fuses F3 and F4 are
output protection fuses. These fuses are 3.15 A, 250
Vac slow-blow types, and protect the safety output relay
contacts from welding due to current surges or excess
loading. Care should be taken to replace any fuses with
the correct rating. While replacing any fuses, particular
attention should be given to the fuse holder. Excess
stress on the fuse holders during replacement can lead
to intermittent connections, which may cause nuisance
tripping and/or a nuisance lock-out condition.
Safety Outputs
to Machine Controls
Receiver
W2
Figure 47 - BSRSA System Block Diagram
Terminal X7 is for AC input power. Terminal X6 is for
the +24 Vdc power input. All connections between the
BSRSA interface unit and the GS-120 light curtain
emitter and receiver units are made at terminal X2. All
connections between the BSRSA interface unit and the
machine’s control are made at terminal X1. Figure 48
show details of the connections for the power, output,
and reset functions.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
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FUSES
44
Phone: 631-630-0442
Fax: 631-630-0454
www.tapeswitch.com
Release 7/2009 Ver. 1.0
6.0
Technical Manual: GS-120 Light Curtain Systems
8.0
TEST INPUT
The BSRSA interface includes a test input. This input is
used to check the interface between the photo-electric
safety system and the machine. It electrically simulates
an obstruction in the light curtain. While in the normal or
run mode, the test input is jumpered (closed). It is
opened and closed when used for testing. The
machine’s control logic can verify that the safety output
relays did, in fact, cycle, thereby exposing any fault
before the next machine cycle.
Specifications
Tolerance
Supply Voltages
24 VDC
Positively guided, forced
contact
Contacts
Two (NO) for use with FSDS
(Final Switching Devices)
One (NO) for lockout use,
(Secondary Switching Device)
Rating
4.0 A resistive load @
240VAC
4.0 A resistive load @
24VDC
5 Hz maximum rate
Fusing
Two (2), 3.15Amp, internal
Monitor/Auxiliary
Output
0.5 Amp, 48 VDC 10 Watt
max
Dimensions
MONITOR/AUXILLIARY OUTPUT
A non-safety monitor/auxiliary output is also provided.
This is a solid state relay output which is closed when
the light curtain is clear and is open when the light
curtain is obstructed, a fault exists, or a lockout
condition is present. This output is provided on terminal
X1, locations 1 and 2. This output can be used for
display and status indication purposes. It must not be
used for safety-related machine control and switching
functions.
Weight
Enclosure Rating
Connecting
Terminals
45
+ 10%
- 15%
Type
Safety
Outputs
The test input is located on terminal XI, connections 9
and 10. If the test input is not utilized, a jumper should
be installed across these connections. (This feature is
seldom used and, therefore, a removable jumper is
installed at the factory.)
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
Data
110 VAC + 10%
240 VAC - 15%
This test should be conducted during a safe part of the
machine cycle, or at the end of the cycle. While the test
input is opened, power is removed from the light curtain
(both emitter and receiver). Once the test input is
closed, power is restored to the light curtain. The
emitter and receiver may take a few seconds to resynchronize, and, consequently, the safety outputs may
take a few seconds to resume their normal state. The
device connected to the test input should have a dry
contact which is closed during the run mode and
momentarily opened during the test mode.
7.0
TECHNICAL SPECIFICATIONS
9.50 in. (241mm) high
7.00 in. (178mm) wide
4.12 in. (105mm) deep
Approximately 7 lbs.
NEMA TYPE 1 (standard)
NEMA TYPE 12 (available)
Type
Captive terminals, with
removable headers
Capacity
One 2.5mm sq. (AWG 14)
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Technical Manual: GS-120 Light Curtain Systems
X6
Test Input
(jumper if not used)
1
24 VDC In
9
10
X1
X6/1: +24 VDC
X6/2:
0 VDC
Safety Output 1 (NO)
DC POWER CONNECTIONS
Lockout Output (NO)
X7
Terminal X1: 9 and 10 must be
jumpered if not used.
Ground
Neutral
3
MACHINE CONTROL CONNECTIONS
2
X2
1
1
2
Line
5
6
Monitor Output (NO)
Non-Safety
4
1
2
3
4
5
6
7
8
2
Safety Output 2 (NO)
110 / 240
VAC
For 110V:
Jumper 1 to 3
Jumper 2 to 4
For 240V:
Jumper 2 to 3
N/C 1
Momentary Contact N/O
External Reset switch - (if used)
AC POWER CONNECTIONS
REMOTE RESET
Figure 48 - BSRSA Terminal Numbers and Functions
NOTE: Connection from the emitter and receiver
is made to terminal X2, see Figure 44 for details.
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Technical Manual: GS-120 Light Curtain Systems
P1
J1
W2
X2
7 8
P2
J2
WH BN GN YL GY PK BU SHIELD
1
2
3
4
5
6
W1
7
GND
4 5 6
+24Vdc
0V
PNP OUT 1
PNP OUT 2
DATA 1
DATA 2
GND
0V
+24Vdc
GND
1 2 3
TO
TI
B Series
Emitter
B Series
Receiver
1 2 3 4 5
_
+
BN WH BU BK GY
8
9
10
BSRSA Controller Light Curtain Schematic Diagram
Figure 49 –Light Curtain to BSRSA Interconnection Diagram
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
47
Phone: 631-630-0442
Fax: 631-630-0454
www.tapeswitch.com
Release 7/2009 Ver. 1.0
Cable #
Technical Manual: GS-120 Light Curtain Systems
Cable Type
Color
Code
Function
RKT5-612/XX
From
To
Emitter
5 Pin Quick Disconnect
BSRSA
Terminal X2
W1
"
Brown
+24VDC
1
10
W1
"
White
OV DC
2
9
W1
"
Blue
Test Out
3} Jumper 3 to 4, if not used
No Connection
W1
"
Black
Test In
4} Jumper 4 to 3, if not used
No Connection
W1
"
Gray
Ground
5
4
Receiver
8 Pin Quick Disconnect
BSRSA
Terminal X2
RKT8-09/XX
W2
"
White
OV DC
1
5
W2
"
Brown
24VDC
2
6
W2
"
Green
Ground
3
3
W2
"
Yellow
Output 1
4
7
W2
"
Gray
Output 2
5
8
W2
"
Pink
Data (-)
6} Isolate 6 & 7
No Connection
W2
"
Blue
Data (+)
7} Isolate 6 & 7
No Connection
W2
"
Shield
Ground
8
Ground
Figure 50 – Wire Run List for BSRSA
TAPESWITCH CORPORATION
100 Schmitt Boulevard
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Technical Manual: GS-120 Light Curtain Systems
APPENDIX B – BSRUA-2 INTERFACE UNIT
1.0
information), and the light curtains are clear with no
faults, the BSRSUA-2 Controller should have two green
LEDs illuminated. These LEDs indicate the output
status (for channel 1 and channel 2) is “on” and the
redundant output safety relays are in the “on” state or
closed. The outputs will remain closed until an
obstruction or fault occurs in either of the two light
curtains. When a light curtain is obstructed, the
corresponding red LED will illuminate and flash. These
LEDs indicate the output status (both redundant safety
outputs are “off”), and also identify which light curtain
(emitter 1/receiver 1 or emitter 2/receiver 2) has been
obstructed. Channel 1 flashing red indicates that light
curtain one has been obstructed, and channel 2 flashing
red indicates that light curtain two has been obstructed.
For the light curtain which is unobstructed, the green
output status LED will remain steadily lit.
GENERAL DESCRIPTION
The BSRUA-2 interface unit is designed to be
incorporated into the user’s machine control system. It
interfaces either one or two GS-120 light curtains with
the protected machine’s controls.
2.0
OPERATIONAL SEQUENCE AND LED
STATUS DESCRIPTION
2.1
CONFIGURED FOR ONE LIGHT CURTAIN
When power is first applied to the light curtain system:
• Two amber LEDs on the BSRUA-2 Controller should
illuminate, indicating that the control unit has power
(system status LEDs for channel 1 & channel 2).
It is important to note that although a green LED status
indicator may be illuminated, the redundant safety
outputs may actually be off as a result of the other light
curtain being obstructed. The LEDs are designed to
assist the user determine which light curtain has caused
the output to go to the off state.
• Power is automatically applied to the emitter and
receiver units and, if the system is properly connected
and aligned (see the following wiring information), and
the light curtain is clear with no faults, the BSRUA-2
controller should have two green LEDs illuminated.
These LEDs indicate that the output status (for channel
1 and channel 2) is “on” and the redundant output safety
relays are in the “on” state or closed. The outputs will
remain closed until an obstruction or fault occurs in the
light curtain. When the light curtain is obstructed, both
red LEDs will illuminate and flash. These LEDs indicate
that the output status (channel 1 and channel 2) is “off”
and the redundant output safety relays are in the “off”
state or opened.
The outputs will remain opened until both light curtains
are clear. The outputs follow the states of the light
curtains and reset AUTOMATICALLY without any
operator intervention. It is important to note the
BSRUA-2 does not distinguish between a light curtain
fault, obstruction, misalignment, or wiring error. All of
these conditions cause the BSRUA-2 to respond as if a
light curtain is obstructed, and the redundant safety
outputs will be in the “off” state (opened).
The outputs will remain opened until the light curtain is
clear. The outputs follow the state of the light curtain
and reset AUTOMATICALLY without any operator
intervention. It is important to note the BSRUA-2
controller does not distinguish between a light curtain
fault, obstruction, misalignment, or wiring error. All of
these conditions cause the BSRUA-2 to respond as if
the light curtain is obstructed and the redundant safety
outputs will be in the “off” state (opened).
2.2.
3.0
MECHANICAL INFORMATION
Figure 51 shows the case size and mounting
dimensions of the BSRUA-2 interface unit. All
dimensions are in millimeters. The unit must be
mounted in an enclosure rated for the known operating
environment. In most cases, the unit will fit into an
existing machine’s control unit panel. The unit snaps
onto a common electrical mounting rail, style DIN EN 50
022-35.
CONFIGURED FOR TWO LIGHT CURTAINS
When power is first applied to the light curtain system:
• Two amber LEDs on the BSRUA-2 Controller should
illuminate indicating that the control unit has power
(system status LEDs for channel 1 and channel 2).
• Power is automatically applied to the emitters and
receivers on both light curtains, and, if the system is
properly connected and aligned (see the following wiring
TAPESWITCH CORPORATION
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Technical Manual: GS-120 Light Curtain Systems
73
cabling between the GS-120 Series emitter and receiver
units and the BSRU-2A controller.
Emitter
118
Be sure to observe the color coding shown to assure
proper operation.
152
MOUNT ON TOP HAT DIN RAIL
- DIN EN 50 022-35
W1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
BSRUA-2
Controller
Power
Input
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Figure 51 - BSRUA-2 Interface Unit
Outline & Dimensions
W2
ELECTRICAL CONNECTIONS
Receiver
Figure 51 also shows the 32 integral connection
terminals, in two rows along the top of the interface unit.
The terminals are numbered 1 to 32. Each terminal is
suitable for up to two (2) 2.5mm2 (14 AWG) solid wires.
Crimped ferrules or tinning must be used on all stranded
wires.
Emitter #1
Figures 52 and 53 show system block diagrams for the
BSRUA-2 Controller. Figure 52 shows the configuration
for one light curtain. Figure 53 shows the configuration
for two light curtains. Figure 54 shows the terminal
numbers for the input and output functions (Input Power,
ac/dc, and the redundant safety outputs). These
functions and terminal numbers are the same for either
the one or two light curtain configuration. The necessary
jumpers for the different configurations are noted. They
must be installed properly in order to insure the correct
and safe operation of the system. Some jumpers may
be factory installed, and the user must insure that the
unit is configured properly for the intended use.
W1
Power
Input
All connections between the BSRUA-2 and the light
curtain(s) must be made with the proper emitter and
receiver cables (ordered separately).
W1A
BSRUA-2
Controller
W2
Receiver#1
For the case where one light curtain is used, refer to
Figures 55 and 56. These show the interconnection
diagram and the wire run list (WRL) and give the proper
terminal numbers and their associated functions for the
cabling between the GS-120 Series emitter and receiver
units and the BSRU-2A controller.
Safety Outputs
to Machine Controls
W2A
Figure 53 - System Block Diagram
for the BSRUA-2 Interface Unit
Configured for TWO Light Curtains
(See Figures 57 and 58 for detailed connections)
For the case where two light curtains are used, refer to
Figures 57 and 58. These show the interconnection
diagram and the wire run list (WRL) and give the proper
terminal numbers and their associated functions for the
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
Emitter #2
Figure 52 – System Block Diagram
for the BSRUA-2 Interface Unit
Configured for ONE Light Curtain
(See Figures 55 and 56 for detailed connections)
Receiver#2
4.0
Safety Outputs
to Machine Controls
50
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5.0
Technical Manual: GS-120 Light Curtain Systems
FUSES
7.0
The BSRUA-2 is equipped with two fuses, F1 and F2.
Both fuses are located on the top of the Din Rail
enclosure. These fuses are secured with a springloaded twist mechanism. They are easily accessed with
a common flathead screw driver. Fuse F1 is a 1 amp,
250 Vac, quick-blow type, and is intended to protect
from potential shorts and surges on the high-voltage
side of the interface unit. Fuse F2 is a 2 amp, 250 Vac
quick-blow type, and is intended to protect from shorts
and surges in the low-voltage, 24 Vdc circuitry of the
interface unit. It is recommended that external fuses be
used to prevent the safety output contacts from welding
(as described in section 4.1.1 of the main document).
6.0
TECHNICAL SPECIFICATIONS
Specifications
Data
Tolerance
110 VAC
240 VAC
+ 10%
- 15%
24 VDC
+ 10%
- 15%
Supply Voltages
Type
Positively guided, forced
contact
Contacts
Two normally open (NO)
Rating
4.0 A resistive load @ 240VAC
4.0 A resistive load @ 24VDC
5 Hz maximum rate
Fusing
3.0 A recommended, by user
Safety
Outputs
TEST INPUT
The BSRUA-2 interface provides a test input for each
light curtain. This input is used to check the interface
between the photo-electric safety system and the
machine. It electrically simulates an obstruction in the
corresponding light curtain. While in the normal or run
mode, the test input is jumpered (closed). It is opened
and closed when used for testing. The machine’s
control logic can verify that the safety output relays did,
in fact, cycle, thereby exposing any fault before the next
machine cycle.
Dimensions
Weight
Enclosure Rating
Enclosure Mounting
This test should be conducted during a safe part of the
machine cycle, or at the end of the cycle. While this
input is open, power is removed from the corresponding
light curtain (both emitter and receiver). Once the test
input is closed, power is restored. The emitter and
receiver may take a few seconds to re-synchronize, and,
consequently, the safety outputs may take a few
seconds to resume their normal state. The device
connected to the test input should have a dry contact
which is closed during the run mode and momentarily
opened during the test mode.
Connecting
Terminals
6.00 in. (152mm) long,
2.88 in. (73mm) wide,
4.65 in. (118mm) high
Approximately 2 lbs.
IP 20
DIN EN 50 022-35
Type
Captive terminals
Capacity
Two 2.5mm sq. (AWG 14)
The test inputs are located at terminals 7 and 8 for light
curtain number one and terminals 19 and 20 for light
curtain number two. The test input on terminals 19 and
20 is active for the TWO light curtain configuration
ONLY. This input will have no effect in the single light
curtain configuration. If these inputs are not used,
jumpers should be installed on these terminals. (This
feature is seldom used and, therefore, removable
jumpers are installed at the factory).
TAPESWITCH CORPORATION
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51
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Technical Manual: GS-120 Light Curtain Systems
Redundant
Safety Outputs
DC Input Power
2
3
+24V DC
24
N/O
Output 1
OV DC
23
22
N/O
Output 2
AC Power Input
26
27
21
Live
Test Inputs (if used)
Ground
7
19
8
20
Neutral
28
FOR AC POWER
110VAC: Jumper 29 to 31 and 30 to 32
240VAC: Jumper 30 to 31
JUMPERS
For ONE Light Curtain
Jumper 1 to 2, 4 to 9
5 to 14, and 7 to 8 (if not used)
For TWO Light Curtains
Jumper 1 to 2, 7 to 8 (if not used)
19 to 20 (if not used)
Figure 54 - Input and Output Functions, Jumper Details and
Terminal Numbers for the BSRUA-2
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Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
P1
J1
W2
7 8
P2
J2
WH BN GN YL GY PK BU SHIELD
1 2
4 5
7 8
W1
9 14 15
GND
4 5 6
+24Vdc
0V
PNP OUT 1
PNP OUT 2
DATA 1
DATA 2
GND
0V
+24Vdc
GND
1 2 3
TO
TI
B Series
Emitter #1
B Series
Receiver #1
1 2 3 4 5
_
+
BN WH BU BK GY
16
25
27
BSRUA-2 Controller
Figure
55 – Interconnection
Diagram
forfor
theONE
BSRUA-2
ONEUnit
Light
Curtain Configuration
BSRUA-2
Controller Wiring
Diagram
Sensing
Configuration
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
53
Phone: 631-630-0442
Fax: 631-630-0454
www.tapeswitch.com
Release 7/2009 Ver. 1.0
CABLE #
Technical Manual: GS-120 Light Curtain Systems
CABLE TYPE
COLOR
CODE
FUNCTION
RKT5-612/XX
FROM
TO
Emitter
5 Pin Quick Disconnect
BSRUA-2
W1
"
Brown
+24V D.C.
1
15*
W1
"
White
OV D.C.
2
16*
W1
"
Blue
Test Out
3} Jumper 3 to 4, if not used
No Connection
W1
"
Black
Test In
4} Jumper 4 to 3, if not used
No Connection
W1
"
Gray
Ground
5
25, 27, or Ground
Receiver
8 Pin Quick Disconnect
BSRUA-2
RKT8-09/XX
W2
"
White
OV D.C.
1
16*
W2
"
Brown
24V D.C.
2
15*
W2
"
Green
Ground
3
25, 27, or Ground
W2
"
Yellow
Output 1
4
4
W2
"
Gray
Output 2
5
5
W2
"
Pink
Data (-)
6} Isolate 6 & 7
No Connection
W2
"
Blue
Data (+)
7} Isolate 6 & 7
No Connection
W2
"
Shield
Ground
8
Ground
* Denotes Double Connection
Figure 56 – Wire Run List for the BSRUA-2 ONE Light Curtain Configuration
TAPESWITCH CORPORATION
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Technical Manual: GS-120 Light Curtain Systems
Figure 57 – Interconnection Diagram for the BSRUA-2 TWO Light Curtain Configuration
Release 7/2009 Ver. 1.0
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
55
Phone: 631-630-0442
Fax: 631-630-0454
www.tapeswitch.com
Release 7/2009 Ver. 1.0
CABLE #
Technical Manual: GS-120 Light Curtain Systems
CABLE TYPE
COLOR
CODE
FUNCTION
RKT5-612/XX
FROM
TO
Emitter #1
5 Pin Quick Disconnect
BSRUA-2
W1
"
Brown
+24V D.C.
1
17*
W1
"
White
OV D.C.
2
18*
W1
"
Blue
Test Out
No Connection
W1
"
Black
Test In
TWIST PAIR TOGETHER
Black and Blue Wire
W1
"
Gray
Ground
5
25, 27, or Ground
Emitter #2
5 Pin Quick Disconnect
BSRUA-2
RKT5-612/XX
No Connection
W1A
"
Brown
+24V D.C.
1
15*
W1A
"
White
OV D.C.
2
16*
W1A
"
Blue
Test Out
No Connection
W1A
"
Black
Test In
TWIST PAIR TOGETHER
Black and Blue Wire
W1A
"
Gray
Ground
5
25, 27, or Ground
Receiver #1
8 Pin Quick Disconnect
BSRUA-2
RKT8-09/XX
No Connection
W2
"
White
OV D.C.
1
18*
W2
"
Brown
24V D.C.
2
17*
W2
"
Green
Ground
3
25, 27, or Ground
W2
"
Yellow
Output 1
4
4
W2
"
Gray
Output 2
5
5
W2
"
Pink
Data (-)
6} Isolate 6 & 7
No Connection
W2
"
Blue
Data (+)
7} Isolate 6 & 7
No Connection
W2
"
Shield
Ground
8
25, 27, or Ground
Receiver #2
8 Pin Quick Disconnect
BSRUA-2
RKT8-09/XX
W2A
"
White
OV D.C.
1
16*
W2A
"
Brown
24V D.C.
2
15*
W2A
"
Green
Ground
3
25, 27, or Ground
W2A
"
Yellow
Output 1
4
9
W2A
"
Gray
Output 2
5
14
W2A
"
Pink
Data (-)
6} Isolate 6 & 7
No Connection
W2A
"
Blue
Data (+)
7} Isolate 6 & 7
No Connection
W2A
"
Shield
Ground
8
25, 27, or Ground
* Denotes Double Connection
Figure 58 – Wire Run List for the BSRUA-2 TWO Light Curtain Configuration
TAPESWITCH CORPORATION
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Farmingdale, New York 11735
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Release 7/2009 Ver. 1.0
Technical Manual: GS-120 Light Curtain Systems
APPENDIX C – SRUB INTERFACE UNIT
1.0
GENERAL DESCRIPTION
• Once a reset is applied the two LEDs will illuminate,
and the safety output relays will return to the “on”
(closed) state.
The SRUB interface unit is designed to be incorporated
into the user’s machine control system. It interfaces a
GS-120 light curtain with the protected machine’s
controls. The SRUB requires a +24 Vdc input, which
must be common with the +24 Vdc. supplied to the light
curtain.
2.0
2.1.2
Automatic Reset
When power is first applied to a light curtain system in
automatic reset mode:
• Both green LEDs will illuminate and the safety output
relays will be “on” (closed). The LEDs and outputs will
remain on, provided the light curtain is clear.
OPERATIONAL SEQUENCE AND LED
STATUS DESCRIPTION
Note: The LEDs on the SRUB provide status indication
of the output state of the safety relays only. No status
indicators for the light curtain (emitter and receiver) are
provided on this unit.
• When the light curtain is obstructed, both LEDs will go
off and the safety outputs contacts will also go to the
“off” (open) state. They will remain off until the light
curtain is clear.
2.1
• Once the obstruction is removed, both LEDs will
illuminate and both safety output relays will return to the
“on” state.
RESETTING OPTIONS
The SRUB interface can be configured for either a
manual (latched) reset or and automatic reset. In the
manual reset mode, the safety outputs will go to the “off”
state (opened) once the light curtain is obstructed and
remain in the “off” state until the obstruction is removed
and an external (user supplied) reset switch is activated.
Once this reset sequence is completed, the safety
outputs will resume the “on” state (closed). In the
automatic reset mode, the safety outputs will follow the
state of the light curtain (i.e., light curtain clear: outputs
“on” (closed), light curtain obstructed: outputs “off”
(opened). The operational sequence for both reset
options is described below.
2.1.1
• If one of the output signals from the GS-120 light
curtain is disconnected, the corresponding LED
(channel 1 or channel 2) will go off. Both safety output
relays will also go off and remain off. The system will not
reset, even if the signal is restored. This condition is
considered a catastrophic failure and requires a powerdown/power-up cycle to restore normal operation
(provided this failure has been rectified).
3.0
MECHANICAL INFORMATION
Figure 59 shows the case size and mounting
dimensions of the SRUB interface unit. All dimensions
are in millimeters. The unit must be mounted in an
enclosure rated for the known operating environment.
In most cases, the unit will fit into an existing machine’s
control unit panel. The unit snaps into a common
electrical mounting rail, style DIN EN 50 022-35.
Manual Reset
When power is first applied to a light curtain system in
manual reset mode:
• No LEDs will be illuminated until a manual (external)
reset is applied.
• Once the external reset is applied, the two green
LEDs (channel 1 and channel 2) will illuminate.
(Provided the system is properly wired, no faults exist
and the GS-120 emitter and receiver units have power
and are properly aligned.) This indicates that both
safety relay outputs are in the “on” or closed state. Both
LEDs must be illuminated in order for the guarded
machine to operate.
• These outputs will remain “on” (closed) until the light
curtain is obstructed, faulty or misaligned. If an
obstruction occurs, both green LEDs will go off and
remain off. The LEDs will remain off, even if the light
curtain is cleared, until a reset is applied.
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Note: Improper installation of the jumpers may lead to
false indication of the two green LEDs (channel 1 and
channel 2).
For example, both LEDs may be
illuminated, indicating both safety outputs are “on”
(closed), however, the outputs may actually be “off”
(opened) without the proper jumper configuration.
100.0m m
Figures 62 and 63 show the interconnection diagram
and the wire run list (WRL) and give the proper terminal
numbers and their associated functions for the cabling
between the GS-120 Series emitter and receiver units
and the SRUB controller. All connections between the
SRUB and the light curtain (emitter and receiver) must
be made with the proper emitter and receiver cables
(order separately).
72.0m m
Emitter
Mount on Top Hat
DIN Rail
DIN EN 50 022-35
W1
70.0m m
+24V D.C.
Supply
W3
SRUB
Controller
Safety Outputs
to Machine
Controls
113.6m m
118.7m m
W2
4.0
Receiver
Figure 59 - SRUB Interface Unit
Outline & Dimensions
ELECTRICAL CONNECTIONS
The SRUB controller has twenty integral connection
terminals, in two rows, along the top of the unit. The
terminals are marked according to their intended
function. Each terminal is suitable for up to two (2)
2.5mm² (14 AWG) solid wires. Crimped ferrules or
tinning must be used on all stranded wires. Figure 60
shows the system block diagram for the SRUB
controller. Figure 61 shows the terminal numbers for
the various input and output functions.
Figure 60 System Block Diagram
For the SRUB Interface Unit
Particular attention should be given to the jumper
placements for configuring MANUAL RESET and
AUTOMATIC RESET. These jumpers must be installed
properly in order to insure the correct and safe operation
of the system.
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4.1
Technical Manual: GS-120 Light Curtain Systems
MONITOR INPUT
(Manual Reset Mode ONLY)
6.0
The SRUB interface unit provides a machine monitor
input. This monitor input receives a closed contact from
the machine’s control circuit. Under normal conditions
this input will be closed at all times. If a fault occurs
external to the light curtain system, the machine’s
control circuit must provide an open to this input. This
open contact must remain open until the external fault is
rectified. If the fault persists (input remains open) and
the light curtain system is cycled while obstructed, the
SRUB unit will not reset. Under this condition, all of the
LEDs will be off. The system will be capable of resetting
only after this monitor input is closed (machine/external
fault corrected). If this feature is not used, the most
common case, a jumper must be installed between X1
and X2 (when in the manual reset mode).
4.2
EXTERNAL RESET
(Manual Reset Mode ONLY)
In the manual reset mode, the SRUB Controller requires
an external reset switch. This switch should be a
normally-open, momentary-contact type. The location of
the reset switch must be such that any person resetting
the safety system must be able to completely see the
hazardous area. The system should not be able to be
reset if an operator is within the hazardous area, or if a
fault exists in the safety system and/or machine control
circuitry. The reset circuit of the SRUB Controller is
designed to protect against a failure (failed closed) or
by-pass of the reset button. The reset circuit requires a
closure and return to an open position. Replacing the
reset switch with a simple jumper will not convert the
SRUB Controller to automatic reset operation. (For
automatic reset operation, see the jumper configuration
in Figure 61.)
4.3
TECHNICAL SPECIFICATIONS (SRUB)
Operating voltage
24 VDC at +/- 10%
Power consumption
approximately 5 VA
Contact configuration
2 N/O safety contact,
1 N/C auxiliary contact
Contact type
Relay positive guided
Operating temperature
-25ºC to +50ºC
Terminal/Housing style
DIN 40050 (Terminal IP20)
(Housing IP40)
Conductor connection
2 x 2.5mm2 solid wire DIN 26206
or 1 x 1.5mm2 stranded wire with
ferrule DIN 46228
Max switching capacity
1500 VA
Switching voltage
250 VAC, 24 VDC Resistive load
Switching current
6A AC, 6A DC
MONITOR/AUXILLARY OUTPUT
A non-safety monitor/auxiliary output is also provided.
This output is a normally-closed relay contact which is
open when both safety outputs are closed (light curtain
clear) and closed when both safety outputs are open
(light curtain obstructed). This output can be used for
display and status indication purposes. It must not be
used for safety-related machine control and switching
functions.
5.0
FUSES
The SRUB interface unit contains no user-accessible
fuses. It is recommended that the +24V DC supply
voltage be self-regulated and protected against any
possible faults or surges from the SRUB controller. It is
also recommended that external fuses be used to
prevent the safety output contacts from welding (as
described in section 4.1.1 of the main document).
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13
A1 (+)
N/O
Output 1
+24V DC
41
N/C
Output
14
A2 (-)
OV DC
42
+24V DC Power Input
23
N/O
Output 2
24
Auxilary Output
(non-safety)
Redundant
Safety Outputs
X1
T11
T34
X2
External Reset
Manual Operation ONLY
Open on
External Fault
Monitor Input(if used)
Manual Operation ONLY
JUMPERS
For MANUAL Operation
On the SRUB Jumper
X1 to X2 (if monitor feature is not used)
For AUTOMATIC Operation
On the SRUB Jumper
T11 to X2 ONLY
Figure 61 Input and Output Functions, Jumper Details and
Terminal Markings for the SRUB
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L
Technical Manual: GS-120 Light Curtain Systems
N
B Series Receiver Unit
Power
Supply
24V DC
-
1
2
-
+
WH
3
+
BN
B Series Emitter Unit
5
4
1
+
GN
YE
GY
5
2
3
4
BN WH BU
BK
GY
Test input
if required
Fuse 2A
Reset
A1(+)
T11
T34
X1
SRUB
X2
T12
K3
T44
K1
T22
K2
K2
+
PE
K3
K1
23
K2
K2
K3
K3
K1
K1
41
K2
K3
K1
-
K1
13
K2
K3
gn
A2(-)
gn
14
24
42
Safety outputs
to machine
control circuit
Figure 62 –Light Curtain to SRUB Interconnection Diagram
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CABLE #
Technical Manual: GS-120 Light Curtain Systems
CABLE TYPE
COLOR
CODE
FUNCTION
RKT5-612/XX
FROM
TO
Emitter 5 Pin
Quick Disconnect
Molded/Pre-wired
+24V DC
Power Supply
W1
"
Brown
+24V DC
1
+24V DC
W1
"
White
OV DC
2
OV DC
W1
"
Blue
Test Out
3
W1
"
Black
Test In
4
TWIST PAIR
TOGETHER
Black & Blue Wire
W1
"
Gray
Ground
5
Ground
Receiver 8 Pin
Quick Disconnect
Molded/Pre-wired
Split Cable
+24V DC
Power Supply
RKT8-09/XX
W2
"
White
OV DC
1
OV DC
W2
"
Brown
+24V DC
2
+24V DC
W2
"
Green
Ground
3
Ground
Receiver 8 Pin
Quick Disconnect
Molded/Pre-wired
SRUB
W2
"
Yellow
Output 1
4
T12
W2
"
Gray
Output 2
5
T22
W2
"
Pink
Data (-)
6
W2
"
Blue
Date (+0
7
No Connection
Isolate 6 & 7
W2
"
Shield
Ground
8
PE
User
Supplied
User
Defined
24V DC
Power Supply
SRUB
W3
"
"
+24V DC
-
A1 (+)
W3
"
"
OV DC
-
A2 (-)
W3
"
"
Ground
-
PE
Figure 63 – Wire Run List for the SRUB Interface Unit
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APPENDIX D – SRUS INTERFACE UNIT
1.0
INTRODUCTION
Tapeswitch SRUS interface control units are designed
to be used with GS-120 Light curtains to form a
complete safety system. Full system installation
instructions are supplied with the light curtains.
In manual or auto reset mode, reset will be prevented
while the light curtain is obstructed, if there is a fault in
the reset circuit or if the two output relays are in
disparity.
2.0
The safety output contacts of the control unit are
connected to the machine primary control element(s) in
such a way that if either of the safety output relays is deenergized then the machine will be brought to rest
regardless of the state of the other relay.
PRODUCT DESCRIPTION
The SRUS interface unit operates from 24Vdc supply.
The unit is housed in a DIN rail mounting enclosure with
16 integral terminals. This unit is intended to be
mounted in an existing electrical enclosure on the
machine. This existing enclosure must be sealed to
minimum rating of IP54.
3.0
NOTE: A machine primary control element or MPCE is
defined as 'an electrically controlled element which
directly controls the normal operating motion of a
machine such that it is the last (in time) to operate when
motion is initiated or arrested'.
PRINCIPLE OF OPERATION
When power is first applied, relays K1 & K2 are deenergized and there is no path through the safety
contacts 13-14 and 23-24. When the reset switch is
closed (Y1 - Y2 ) there will still be no path through the
safety contacts. When the reset switch is opened again
the path through the safety contacts is established.
In addition, where the machine control system has two
MPCEs, these devices can be monitored by connecting
normally closed auxiliary contacts from each MPCE in
series with the reset input. Disparity between the two
MPCEs will prevent a reset.
If the light curtain is then obstructed, its outputs go off
and the safety contacts open. Even when the light
curtain is clear again the safety outputs remain open
until the reset is repeated.
4.0
WARNING
TAPESWITCH SAFETY SYSTEMS ARE DESIGNED TO
PROTECT OPERATORS WORKING AT OR NEAR
DANGEROUS MACHINES. THEY CAN ONLY PERFORM
THAT FUNCTION IF THEY ARE CORRECTLY FITTED AND
INTERFACED TO A SUITABLE MACHINE. EVERY EFFORT
HAS BEEN MADE TO PROVIDE COMPREHENSIVE AND
ACCURATE INFORMATION. IT IS THE RESPONSIBILITY
OF THE USER TO ENSURE THAT ALL PERSONS
INVOLVED IN THE INSTALLATION OF THE PRODUCT
HAVE THE KNOWLEDGE, TRAINING AND EXPERIENCE
NECESSARY AND THAT THEY ARE FULLY CONVERSANT
WITH ALL LAWS, RULES, REGULATIONS AND CODES OF
PRACTICE PERTAINING TO THEIR TASK.
The unit provides both a manual or auto reset function.
In manual reset mode, the reset function provides start
and restart interlock functions as follows:
START INTERLOCK - When power is applied to the
system, the output relays cannot be energized until
a reset signal has been applied.
RESTART INTERLOCK - Once the light curtain has
been obstructed and the output relays have deenergized, they cannot be energized again until the
light curtain has been cleared and a reset signal has
been applied.
The start/restart interlock function must be incorporated
somewhere in the machine safety system. However, this
function may be provided by equipment other than the
light curtain, i.e., it may already be included in the
machine control circuit. In such a case, the light curtain
interface should function in an auto-reset mode.
4.1
MECHANICAL
4.1.1
GENERAL
The SRUS interface unit should be mounted in the
machine control unit on standard 'top hat' terminal rail
type DIN EN 50 022-35. The machine control unit must
provide sealing to IP54 according to IEC 529. The
dimensions of the SRUS interface unit are shown in
Figure 64.
In auto-reset mode the output relays will be energized
whenever power is applied to the system and the light
curtain is clear, and the output relays will re-energize
immediately after an interruption is cleared.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
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INSTALLATION
Mechanical vibrations greater than 5g / 33Hz should be
avoided when in transportation and when in operation.
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4.2.5 SAFETY OUTPUT CONNECTION
Two normally open safety outputs are provided. In low
to medium risk applications the machine is normally
provided with a single MPCE. In such cases both safety
outputs should be connected in series with the MPCE
coil as shown in Figure 68. If the machine is fitted with
two MPCEs one safety output should be connected in
series with each MPCE coil as shown in Figure 69.
To protect the contacts of the safety output relays from
the effects of switching inductive loads, it is
recommended that arc suppressors should be fitted in
parallel with the MPCE coils as shown Figures 68 and
69. Arc suppressors must not be fitted across the safety
relay contacts.
Figure 64 – Dimensions
To protect against the possibility of both safety outputs
welding in, due to an overcurrent fault in the machine
circuit, 6A quick blow, or 4A slow blow fuses should be
fitted in series with the MPCE coils as shown in Figures
68 and 69. This limits the current through the safety
output contacts to well below that which could cause the
contacts to weld.
4.1.2 RESET INPUT DEVICE
A normally open switch, preferably a 22 mm industrial
pushbutton, should be used to provide the reset input.
The switch should be housed in a suitable enclosure
and should be mounted in such a position that it is safe
from passing traffic and such that the person operating
the switch can see all of the dangerous area.
4.2.6 MONITOR OUTPUT
4.2 ELECTRICAL
If auxiliary signal contacts are required, the normally
open contacts across terminals 33 & 34 can be used.
4.2.1 GENERAL
NOTE: All outputs of the SRUS are safety outputs
and can be used in the machine stop circuit.
The connections for the SRUS interface unit are shown
in Figure 67. Crimped ferrules should be fitted on all
stranded wires. The exact cabling requirements are at
the discretion of the installer and depend to a large
extent on the siting of the various control system
elements. In general, it is recommended that high
voltage cables are routed away from low voltage cables.
4.2.2 LIGHT CURTAIN CONNECTION
Connect the fail-safe PNP inputs from the GS-120 light
curtain terminals 4 & 5 (cable colors yellow & grey) to
terminals S12 & S22, as shown in Figure 67.
4.2.3 POWER CONNECTION
Connect +24Vdc to terminal A1 (+) & connect 0V to
terminal A2 (-) as shown in Figure 67. The power
consumption is approximately 2.5VA.
Figure 65 - Cross-monitoring of MPCEs - Manual Reset
4.2.4 RESET INPUT CONNECTION
If the machine has two MPCEs, a pair of normally
closed auxiliary contacts from each MPCE can be
connected in series as follows: For manual reset
connect across terminals Y1 & Y2 see Figure 65. For
Auto Reset connect across terminals Y1 & Y2 see
Figure 66. This provides cross-monitoring of the
MPCEs such that if they are in disparity due to a fault,
reset will be prevented until the fault is rectified.
If there is no external monitoring, fit a link across the
terminals.
TAPESWITCH CORPORATION
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Figure 66 - Cross-monitoring of MPCEs –Auto Reset
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The diagram shows
manual reset function
with the GS-120 guard.
For automatic reset
put a link between
the contacts
BR1
BR2
and an additional
link between
Y1
Y2
Figure 67 – SRUS Connection Details
Figure 69 - Safety Output Connection (Two MPCEs)
Figure 68 – Safety Output Connection (Single MPCE)
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5.0
Technical Manual: GS-120 Light Curtain Systems
TECHNICAL SPECIFICATION
Operating Voltage
24 Vdc +/- 10%
Power Consumption
approx. 2.5 VA
Response Time
< 30ms
Temperature Range:
Operating
-25ºC to +55ºC
Reset Function
Manual or Auto
Contact Configuration
3 x N/O safety contacts
Contact Type
Relay positive guided
Max. Switching Capacity
1500 VA (resistand load)
Max. Switching Capacity
250 Vac, 24 Vdc
Switching Current
6A ac, 6A dc
Enclosure:
Protection Rating
Terminal Capacity
Material
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
DIN 40050 (Terminal IP20) (Housing IP40)
2 x 2.5mm² solid wire DIN 26206 or
1 x 1.5mm² stranded wire with ferrule DIN 46228
Self-extinguishing according to UL 94 V-0
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Technical Manual: GS-120 Light Curtain Systems
APPENDIX E – C6 MULTIFUNCTION INTERFACE CONTROLLER
1.0
PRODUCT DESCRIPTION
When the zone(s) is set in Manual Mode, the safety
outputs will remain open until the sensing device is clear
and a reset signal is applied. When the zones are set to
AUTO, the safety outputs will reset automatically after
the sensing device is clear.
The C6 Multifunction Interface Controller serves as an
interface between various Tapeswitch low-voltage
sensors and an end-user device (machine and/or
process control). It is ideal for existing machines in enduser and OEM applications. The C6 Multifunction
Interface Controller is designed to monitor up to six
sensor zones comprised of a combination of 1 to 3 GS120 Light Curtains and/or 1 to 6 other sensing devices.
It provides the necessary power to the GS-120 emitter
and receiver units, and monitors the output signals. In
addition to the light curtains, the C6 is specifically
engineered for operation with various pressuresensitive, normally-open switches such ad ribbon
switches, sensing edges/ bumpers and switching mats.
Each of the six zones is equipped with three indicator
lights: Manual Mode, Output On and Output Off,
providing the status of each zone. The C6 Controller
also has non-safety monitor output relays for each zone.
They are Form C (normally-open, common, normallyclosed) contact arrangements. The monitor relays are
intended for status purposes only.
2.0 INSTALLATION INSTRUCTIONS
A complete technical description of the C6
Multifunction Controller, including installation
instructions, can be found in the separate C6
Technical Manual which comes with the unit (part
number 0480).
The C6 Controller provides constant monitoring of all
sensing devices. In the event of a failure within a sensor
or its cable (open or short circuit), the controller
automatically detects the failure. In addition to the ability
to detect a failure within the sensor or its cabling, the C6
is designed to detect a failure within the controller itself.
The C6 Controller is a fully self-contained unit within a
metal enclosure. See Figure 70. It is intended to be wall
mounted and has six knockouts capable of accepting
standard 1/2" or 3/4" conduit. It will accept an input
power of source range of 85 to 264 Vac at an input
frequency range of 47 to 63 Hz. The unit will also accept
a regulated 24 Vdc supply.
8.94" (227mm)
8" (203mm)
7" (178mm)
The C6 Controller provides the option of setting each
zone for automatic or manual reset. To manually reset
the controller, a key switch is provided on the front
panel.
6" (152mm)
4.12" (105mm)
GUARDSTAR
by Tapeswitch
R
MANUAL
MODE
The controller provides two redundant safety output
relay contacts (dry contact or voltage free) in which the
output can be configured as normally-open (closed
when the relay is energized) or normally-closed (open
when the relay is energized). When the output relays
are configured as normally-open, the two closed
contacts will open when the sensing device is actuated
(i.e., safety mat is stepped on), or should a fault occur
within the safety device, or in the event that the power is
removed. The outputs will remain open until the sensing
device is clear and reset is applied. When the output
relays are configured as normally-closed, the two open
contacts will close when the sensing device is actuated
(i.e., safety mat is stepped on), or should a fault occur
within the safety device, or in the event that the power is
removed. The outputs will remain closed until the
sensing device is clear and reset is applied.
TAPESWITCH CORPORATION
100 Schmitt Boulevard
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Type No:
OUTPUT
ON
OUTPUT
OFF
ZONE 1
C6
Serial No:
Supply Voltage:
110-240VAC
50/60 HZ
Power
Consumption:
30VA TYPICAL
Output Contacts:
4.0A@ 240VAC
RESISTIVE LOAD
Safety System
Response Time
Equals
Sensing Unit
Response Time
ZONE 2
ZONE 3
ZONE 4
ZONE 5
ZONE 6
10.75"
(273mm)
10"
(254mm)
11.5"
(292mm)
RESET
+10MS
B SERIES
System
Controller
C6
C6
MULTIFUNCTION
CONTROLER
Multifunction Controller
Tapeswitch
CORPORATION
100 Schmitt Blvd., Farmingdale, NY 11735
Toll Free: 1-800-234-8273
Figure 70 – C6 Multifunction Controller Outline Drawing
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Technical Manual: GS-120 Light Curtain Systems
APPENDIX F – GDC-1 24 VDC POWER SUPPLY
1.0
PRODUCT DESCRIPTION
A green LED will illuminate, indicating that +24 Vdc is
present. The +24 Vdc output voltage is adjustable with
a small Philip’s head screwdriver. The output voltage
should be adjusted with a calibrated meter, once all of
the loads are connected. The dimensions and terminal
markings are shown in Figure 71. The Technical
Specifications are shown in Figure 72.
The GDC-1 power supply converts an ac voltage input
to +24 Vdc, which can be used to power a GS-120 light
curtain (emitter and receiver) and an SRUB Controller.
It will accept a wide range of input voltages, from 88 to
264 Vac, automatically. No jumpers or voltage strapping
is necessary. The ac input is fuse-protected against
current surges or short circuits within the high-voltage
side of the unit.
97
mm
159mm
Connections:
L
N
PE
OV
+24V
1
2
3
4
5
99 mm
97 mm
1.
2.
3.
4.
5.
37
mm
38mm
Figure 71 GDC-1 Dimensions and Terminal Markings
Input Voltage
88 to 264 Vac
Input Freguency
47 to 63 Hz
Input Current
1.3 A at 115 Vac
0.8 A at 230 Vac
Inrush Current
33 A at 230 Vac, cold start
Output Voltage
24 V, adjustable ± 10%
Output Current
2.2 A
Ripple
120 mv p-p
Line Regulation
± 0.5%
Load Regulation
± 0.5%
Overload Protection
110 to 150% of rated output power
with automatic recovery
Overvoltage Protection
Auto recovery after fault condition is removed
Operating Temperature
-25 °C to +70 °C
MTBF
228,000 hours
EMC
EN 55022 (C15PR22)
EN 61000-3-2, -3
Safety Standards
UL 60950-1, TUV EN 60950-1 approved
Figure 72 – GDC-1 Technical Specifications
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Technical Manual: GS-120 Light Curtain Systems
APPENDIX G – LAT LASER ALIGNMENT TOOL
1.0
PRODUCT DESCRIPTION
The Laser Alignment Tool provides a visual indication of
the alignment between a GS-120 emitter and receiver.
It is particularly useful for long range installations and
installations requiring mirrors. The Laser Alignment
Tool simply snaps into one of the GS-120 sensing units
(emitter or receiver). See Figure 73. It projects a beam
of light across the sensing field and places a targeting
dot on the (emitter or receiver). The dot gives the
installer visual feedback on the accuracy of the
alignment. The laser can be focused by simply rotating
the beam projection head. The beam is kept on by
applying inward pressure to the projector head until the
“on” switch actuates.
BEAM CAN BE FOCUSED FOR ANY DISTANCE
ALIGNMENT
TOOL SLIDES
UP & DOWN
BY THE THUMB
WHEEL HANDLES
For optimum alignment, the laser target dot should be
located at the center of the clear lens of the emitter or
receiver. Initially, the target dot may not land on the
emitter or receiver at all. In this case, place a sheet of
cardboard or a similar target behind the unit in order to
provide a larger area for the laser dot to land. Once the
laser dot is found, it will give the installer an indication
as to which direction the sensing units need to be
adjusted.
Figure 73 – LAT Alignment Tool Setup
The Laser Alignment Tool is for initial set-up ONLY. It
can not be used during normal machine operation since
it will obstruct the light curtain. The laser MUST NOT
BE POINTED OR DIRECTED TOWARDS ANY
PERSONS. Figure 74 shows the outline dimensions,
and Figure 75 lists the technical specifications.
2.6”
2.0”
Laser Type
Class llla Laser Diode
Maximum Output
<5mW
Wavelength:
640nm (± 10)
Beam Diameter
Adjustable
Power Requirements
2-LR44 Alkaline batteries (incl)
Operating Time
2.5 hours continuous
Dimensions
0.40" Dia x 2.5" L
Weight
2.0 oz. with batteries
Switch
Momentary On/Off
Figure 74 – LAT Dimensions
Figure 75 – LAT Technical Specifications
TAPESWITCH CORPORATION
100 Schmitt Boulevard
Farmingdale, New York 11735
69
Phone: 631-630-0442
Fax: 631-630-0454
www.tapeswitch.com
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