MINI-SCREEN ™ System

MINI-SCREEN ™ System
This manual is for systems that use control box MSCA-1, MSCB-1, or MSCT-1
MINI-SCREEN ™ System
Instruction Manual
• An optoelectronic point-of-operation guarding
device for production machinery such as hydraulic
and pneumatic power presses, molding presses, and
automated production equipment
• Highly visible LEDs on control box and receiver give
system status and emitter/receiver alignment
indications; system diagnostic LEDs visible through
transparent window in control box cover
• Compact package for smaller production machines
• Controller uses "diverse redundancy" design
concept to achieve a higher level of control reliability
• Creates a curtain of synchronized, modulated
infrared sensing beams from 4 inches to 4 feet high
(in 12 different length increments; see page 6)
• Remote TEST input terminals for simulating a
"blocked" condition
• Replaceable redundant output relays with "forced
guided" contacts to ensure control reliability
• Features floating blanking, which is easily
configured inside the lockable control box
• FMEA tested to ensure control reliability
Listed
Presence
Sensing
Device
10Y8
• Highly immune to EMI, RFI, ambient light, weld
flash, and strobe light
• Modular design with no "matched sets" necessary:
any emitter and receiver (of equal length) and any
control box may be used together
• Vibration-tolerant factory burned-in emitter and
receiver circuitry for toughness and dependability
• Swivel mounting brackets and small, light-weight
tubular sensors for quick installation and ease of
alignment both on new equipment and in retrofit
applications; anti-vibration mounts provided
C
Banner MINI-SCREEN™ Systems are designed and built in the U.S.A.
Printed in USA
P/N 39022G7C
Applications and
Limitations
of MINI-SCREEN™
Systems
MINI-SCREEN Systems
are typically used
in the following applications:
• Hydraulic and pneumatic
power presses
• Molding presses
• Automated production
equipment
MINI-SCREEN Systems
may NOT be used
with the following
machinery:
Any machine that cannot be stopped
immediately after a stop signal is issued,
such as single stroke (also known as
"full-revolution") clutched machinery.
Any machine with inadequate or
inconsistent machine response time and
stopping performance.
Any machine that ejects materials or
component parts through the defined
area.
MINI-SCREEN Systems may not be used
in any environment that is likely to
adversely affect the efficiency of a
photoelectric sensing system. For
example, corrosive chemicals or fluids
or unusually severe levels of smoke or
dust, if not controlled, may degrade
the efficiency of Banner MINI-SCREEN
Systems.
Banner MINI-SCREEN Systems may
not be used as tripping devices to
initiate machine motion (PSDI
applications) on mechanical power
presses, per OSHA regulation 29 CFR
1910.217.
Banner Engineering Corp.
9714 - 10th Avenue No.
Minneapolis, MN 55441
Telephone: (612) 544-3164
FAX: (applications) (612) 544-3573
2
Important... read this page first!
In the United States, the functions that Banner MINI-SCREEN™ Systems are intended to perform
are regulated by the Occupational Safety and Health Administration (OSHA). However, whether
or not any particular MINI-SCREEN System installation meets all applicable OSHA requirements
depends upon factors that are beyond the control of Banner Engineering Corporation. These factors
include the details of how the MINI-SCREEN System is applied, installed, wired, operated, and
maintained.
Banner Engineering Corp. has attempted to provide complete application, installation, operation,
and maintenance instructions. In addition, we suggest that any questions regarding application or
use of MINI-SCREEN Systems be directed to the factory applications department at the telephone
numbers or address shown at the bottom of this page.
Banner MINI-SCREEN Systems can guard against accidents only when they are properly
installed and integrated into the machine, properly operated, and properly maintained. See
Section 3 of this manual for installation procedures, considerations, and precautions. See
Sections 4 and 5 for operating and maintenance information. It is the responsibility of the
purchaser and/or user to apply this MINI-SCREEN System in full compliance with OSHA
regulations.
The user of the MINI-SCREEN System shall ensure that all machine operators, maintenance
personnel, electricians, and supervisors are thoroughly familiar with and understand all
instructions regarding the use and maintenance of the MINI-SCREEN System and the
machinery upon which it is installed, as well as all appropriate safety regulations. Failure
to follow all instructions or warnings could result in serious bodily injury or death.
In addition to OSHA regulations, several other organizations provide informational material on
the use of machine guard devices. The user is referred to the American National Standards
Institute (ANSI), the Robotics Institute of America (RIA), the American Metal Stamping
Association (AMSA), and others. Banner Engineering Corp. makes no claim regarding a specific
recommendation of any organization, the accuracy or effectiveness of any information provided, or the
appropriateness of the provided information for a specific application.
The user has the responsibility to ensure that all local, state, and national laws, rules, codes, and
regulations relating to the use of this machine guarding system in any particular application are
satisfied. Extreme care is urged to ensure that all legal requirements have been met and that all
installation and maintenance instructions contained in this manual are followed.
Caution!!
Banner MINI-SCREEN™ Systems are for use only on machinery that can be stopped immediately
after a stop signal is issued. They may be used with part-revolution clutched machines that have
the ability to stop at any point in their stroke. Under no circumstances may the MINI-SCREEN
System be used on full-revolution clutched machinery. Banner MINI-SCREEN Systems may not
be used as tripping devices to initiate machine motion (PSDI applications) on mechanical power
presses, per OSHA regulation 29 CFR 1910.217.
U.S. Standards Applicable to Use of MINI-SCREEN™ Systems
ANSI B11.1 through B11.20 ............. Safeguarding of Machine Tools
ANSI/RIA 15.06 ................................ Safety Requirements for Robot Systems
Copies are available from:
Safety Director
National Machine Tools Builders Association
7901 Westpark Drive
McLean, VA 22101-4269
See page 56 for information on these and other applicable standards,
and where to acquire copies.
Table of Contents
Table of Contents
Important Information ........................................................................................ page 2
1.
MINI-SCREEN System Introduction ..................................................... page 4
1.1
MINI-SCREEN Components and Kits ............................................ page 6
2. Overview of MINI-SCREEN Operation ................................................. page 7
2.1
Blanking ....................................................................................... page 7
2.2
Auto Power-up .............................................................................. page 7
2.3
Lockout Conditions and Key Resets .............................................. page 8
2.4
Operating Status Indicator Lights .................................................. page 9
2.5
Diagnostic Indicator LEDs .......................................................... page 10
2.6
Output Relay Operation .............................................................. page 11
2.7
Control Reliability: Redundancy and Self-Checking ..................... page 12
3. System Installation and Alignment ........................................................ page 13
3.1
Appropriate Application .............................................................. page 13
3.2
Mechanical Installation Considerations ....................................... page 14
3.2.1
Separation Distance .................................................................... page 14
3.2.2
Hard Guarding ............................................................................ page 16
3.2.3
Emitter and Receiver Orientation .................................................. page 17
3.2.4
Adjacent Reflective Surfaces ........................................................ page 18
3.2.5
Use of Corner Mirrors ................................................................... page 18
3.2.6
Installation of Multiple MINI-SCREEN Systems .......................... page 19
3.3
Mounting Procedure .................................................................... page 20
3.4
Controller Module Configuration ................................................ page 23
3.5
Electrical Hookup and Checkouts ............................................... page 24
3.5.1
Emitter and Receiver Hookup ..................................................... page 25
3.5.2
System Power (temporary connection) ........................................ page 26
3.5.3
MINI-SCREEN System Initial Checkout .................................... page 26
3.5.4
Output Relay Connections .......................................................... page 29
3.5.5
System Power (permanent connection) ....................................... page 31
3.5.6
Auxiliary Monitor Relay ............................................................. page 31
3.5.7
Accessory Connections ............................................................... page 31
4. Operating Instructions ........................................................................... page 32
4.1
Security Protocol ......................................................................... page 32
4.2
Periodic Checkout Requirements ................................................ page 32
4.3
Normal Operation ....................................................................... page 33
5. Troubleshooting and Maintenance ........................................................ page 34
5.1
Troubleshooting Lockout Conditions .......................................... page 34
5.2
Effects of Electrical and Optical Noise ........................................ page 36
5.3
Servicing and Maintenance ......................................................... page 36
5.3.1
Fuse Testing and Replacement .................................................... page 36
5.3.2
Controller Module and Relay Replacement ................................. page 36
5.3.3
Cleaning ....................................................................................... page 37
6. Alignment and Checkout Procedures .................................................... page 38
6.1
MINI-SCREEN System Alignment .............................................. page 38
6.2
Commissioning Checkout ........................................................... page 42
6.3
Shift Change & Machine Setup Change Checkout ........................ page 44
6.4
Semi-annual Checkout ................................................................ page 45
Initial Checkout: MINI-SCREEN System only ........................... page 26
Glossary of Terms .......................................................................................... page 46
Specifications ............................................................................................ page 52
Models and Ordering Information ............................................................. page 54
Replacement Parts ....................................................................................... page 55
Standards Information ............................................................................... page 56
© Banner Engineering Corp. All rights reserved.
3
System Introduction
1. MINI-SCREEN System Introduction
The Banner MINI-SCREEN System is a microprocessor-controlled opposed mode
optoelectronic "curtain of light". It is designed for use as a point-of-operation
guarding device, and is especially suited to smaller production machinery.
Banner's microprocessor-based circuit establishes a higher level of control reliability
in machine guard design. The MINI-SCREEN System uses the design concept of
"diverse redundancy", in which two microprocessors of different design, running
from two different instruction sets, constantly check all system components,
including each other. Banner MINI-SCREEN Systems are extensively FMEA
(Failure Mode and Effects Analysis) tested to establish an extremely high degree of
confidence that no system component will ever, even if it does fail, cause a failure
to danger.
In typical operation, if any part of an operator's body (or any opaque object) of more
than a certain cross section enters the guarded area of the machine, the output relays
of the MINI-SCREEN System will open. The contacts of the output relays are
connected to the guarded machine's primary control elements (MPCEs) which
immediately stop the motion of the guarded machine. The output relays have
forced-guided contacts for enhanced control reliability.
The floating blanking feature of the MINI-SCREEN System allows for the movement
of multiple workpieces through the curtain at any point. With the floating blanking
feature "on", objects with a cross section of 0.8 inches (20 mm) or smaller are ignored.
The Banner MINI-SCREEN is a
modular machine guard system. Each
system is made up of an MSE Series
emitter unit, an MSR Series receiver
unit, and a model MSCA-1, MSCB-1 or
MSCT-1 control box (see Figure 1 and
cover photo). The three MINI-SCREEN
System components are interconnected
using two 5-wire shielded cables with
QD (Quick Disconnect) connectors on
their emitter and receiver ends.
±30˚ Rotation
Antivibration
mounts (4)
(supplied
w/ sensor)
Specified test piece
(2 diameters supplied
with control box)
Emitter
Defined area
Receiver
QDC-5..C
Quickdisconnect
cables (2)
6" to 30'
Status indicators
on 3 sides of
receiver plus
control box door
Control
Box
Strain relief
cable glands
(2 supplied with
control box)
Lockable latch
Power cable gland
(supplied by customer)
Figure 1. Banner MINI-SCREEN System: emitter, receiver, control box, and
two interconnecting cables.
4
System Introduction
Emitter units consist of a row of synchronized modulated infrared (invisible) light
emitting diodes (LEDs) in a compact rectangular metal housing. Receiver units consist
of a corresponding row of synchronized phototransistors. Emitters and receivers are
available in various sizes (based on the height of the defined area), in 12 lengths ranging
from 4 inches to 4 feet (see page 6). The rectangular sensor design includes a swivel
bracket at each end for quick mounting and ease of alignment. Control boxes and
receivers have LED indicators for system operating status and alignment. Each receiver
has three sets of status LEDs (front and both sides) for high visibility. Emitters have
POWER ON indicators.
The control box contains a power supply (to power the control box itself and an
emitter and receiver), a microprocessor controller module to control sensing logic,
and a replaceable relay board with forced-guided output relays. Diagnostic LEDs on
the controller module (visible through a clear window in the control box cover)
identify eight trouble causes. There is a keyed panel switch for resetting the system
at power-up or from fault (lockout) conditions.
WARNING . . .
The MINI-SCREEN System
uses one pair of sensors
connected to one control box.
Connection of multiple pairs of sensors to
a single control box can result in serious
bodily injury or death, and is prohibited.
!
NOTE: Banner MULTI-SCREEN™
Systems and dual MINI-SCREEN control
boxes are designed for connection of two
sensor pairs.
The Banner MINI-SCREEN System is rated at a sensing range (emitter-to-receiver
separation distance) of 30 feet. The patented modulated receiver design produces
exceptionally high immunity to ambient light interference.
Banner MINI-SCREEN Systems are designed for convenient and dependable
operation in difficult industrial environments. The microprocessor controller
module has a plug-in design for easy configuring or replacement. The output relay
module is easily replaceable. The control box enclosure is rated NEMA 13 (IP 64)
and features a lockable cover.
Emitter and receiver circuits are designed to meet high standards for vibration
resistance. Every MINI-SCREEN System emitter, receiver, and controller module
is serialized and undergoes extensive burn-in testing at the factory.
Any MINI-SCREEN System emitter and receiver (of equal length) may be used
together with any control box. Unlike some competitive systems, matched sets are
not required.
A functional schematic diagram of the MINI-SCREEN System appears on page 11.
For MINI-SCREEN System dimension drawings, see pages 21 and 22. For
specifications, see page 52.
The components of a MINI-SCREEN system may be purchased separately, or they
may be purchased bundled together in kit form. The components and kits are listed
on the next page.
5
System Introduction
1.1 MINI-SCREEN Components and Kits
MINI-SCREEN Systems are sold as kits which include a control box, an emitter and receiver of equal length, emitter and receiver mounting
hardware, and two quick-disconnect cables. Cables are interchangeable between the emitter and the receiver. Components are also available
separately (below left).
MINI-SCREEN Components
MINI-SCREEN System Kits
Emitter/receiver
Models
Height of
Defined Area
Number of
Light Beams
Part
Number
MSE424 emitter
MSR424 receiver
4.5 in. (114 mm)
8
37444
37445
MSE824 emitter
MSR824 receiver
8.5 in. (215 mm)
16
37446
37447
MSE1224 emitter
MSR1224 receiver
12 in. (305 mm)
24
37448
37449
MSE1624 emitter
MSR1624 receiver
16 in. (406 mm)
32
37450
37451
MSE2024 emitter
MSR2024 receiver
20 in. (508 mm)
40
37452
37453
MSE2424 emitter
MSR2424 receiver
24 in. (610 mm)
48
37454
37455
MSE2824 emitter
MSR2824 receiver
28 in. (711 mm)
56
37456
37457
Kits with 115 V ac Control Box (model MSCA-1)
Array
Length
w/(2) 15-ft
cables
P/N
w/(2) 25-ft
cables
P/N
w/(1) 15 &
(1) 25-ft cable
P/N
4.5”
8.5”
12”
16”
20”
24”
28”
32”
36”
40”
44”
48”
MSKA424C1
MSKA824C1
MSKA1224C1
MSKA1624C1
MSKA2024C1
MSKA2424C1
MSKA2824C1
MSKA3224C1
MSKA3624C1
MSKA4024C1
MSKA4424C1
MSKA4824C1
41100
41101
41102
41103
41104
41105
41106
41107
41108
41109
41110
41111
MSKA424C2
MSKA824C2
MSKA1224C2
MSKA1624C2
MSKA2024C2
MSKA2424C2
MSKA2824C2
MSKA3224C2
MSKA3624C2
MSKA4024C2
MSKA4424C2
MSKA4824C2
41112
41113
41114
41115
41116
41117
41118
41119
41120
41121
41122
41123
MSKA424C3
MSKA824C3
MSKA1224C3
MSKA1624C3
MSKA2024C3
MSKA2424C3
MSKA2824C3
MSKA3224C3
MSKA3624C3
MSKA4024C3
MSKA4424C3
MSKA4824C3
41124
41125
41126
41127
41128
41129
41130
41131
41132
41133
41134
41135
Kits with 230 V ac Control Box (model MSCB-1)
MSE3224 emitter
MSR3224 receiver
32 in. (813 mm)
64
37458
37459
Array
Length
MSE3624 emitter
MSR3624 receiver
36 in. (914 mm)
72
37460
37461
MSE4024 emitter
MSR4024 receiver
40 in. (1016 mm)
80
37462
37463
MSE4424 emitter
MSR4424 receiver
44 in. (1118 mm)
88
37464
37465
MSE4824 emitter
MSR4824 receiver
48 in. (1219 mm)
96
37466
37467
4.5”
8.5”
12”
16”
20”
24”
28”
32”
36”
40”
44”
48”
Control Boxes
MSCA-1
MSCB-1
MSCT-1
115 V ac control box
(One per system)
230 V ac control box
(One per system)
24 V dc control box
(One per system)
37931
37932
43536
Cables (2 required per system)*
QDC-515C
QDC-525C
QDC-550C
*
6
15' cable, straight
QD connector.
One cable per sensor.
25' cable, straight
QD connector.
One cable per sensor.
37442
37443
50' cable, straight
37498
QD connector.
One cable per sensor.
Contact factory Applications Department for information
on cable lengths greater than 50 feet.
w/(2) 15-ft
cables
P/N
w/(2) 25-ft
cables
P/N
w/(1) 15 &
(1) 25-ft cable
P/N
MSKB424C1
MSKB824C1
MSKB1224C1
MSKB1624C1
MSKB2024C1
MSKB2424C1
MSKB2824C1
MSKB3224C1
MSKB3624C1
MSKB4024C1
MSKB4424C1
MSKB4824C1
41136
41137
41138
41139
41140
41141
41142
41143
41144
41145
41146
41147
MSKB424C2
MSKB824C2
MSKB1224C2
MSKB1624C2
MSKB2024C2
MSKB2424C2
MSKB2824C2
MSKB3224C2
MSKB3624C2
MSKB4024C2
MSKB4424C2
MSKB4824C2
41148
41149
41150
41151
41152
41153
41154
41155
41156
41157
41158
41159
MSKB424C3
MSKB824C3
MSKB1224C3
MSKB1624C3
MSKB2024C3
MSKB2424C3
MSKB2824C3
MSKB3224C3
MSKB3624C3
MSKB4024C3
MSKB4424C3
MSKB4824C3
41160
41161
41162
41163
41164
41165
41166
41167
41168
41169
41170
41171
Kits with 24 V dc Control Box (model MSCT-1)
Array
Length
w/(2) 15-ft
cables
P/N
w/(2) 25-ft
cables
P/N
w/(1) 15 &
(1) 25-ft cable
P/N
4.5”
8.5”
12”
16”
20”
24”
28”
32”
36”
40”
44”
48”
MSKT424C1
MSKT824C1
MSKT1224C1
MSKT1624C1
MSKT2024C1
MSKT2424C1
MSKT2824C1
MSKT3224C1
MSKT3624C1
MSKT4024C1
MSKT4424C1
MSKT4824C1
43300
43301
43302
43303
43304
43305
43306
43307
43308
43309
43310
43311
MSKT424C2
MSKT824C2
MSKT1224C2
MSKT1624C2
MSKT2024C2
MSKT2424C2
MSKT2824C2
MSKT3224C2
MSKT3624C2
MSKT4024C2
MSKT4424C2
MSKT4824C2
43312
43313
43314
43315
43316
43317
43318
43319
43320
43321
43322
43323
MSKT424C3
MSKT824C3
MSKT1224C3
MSKT1624C3
MSKT2024C3
MSKT2424C3
MSKT2824C3
MSKT3224C3
MSKT3624C3
MSKT4024C3
MSKT4424C3
MSKT4824C3
43324
43325
43326
43327
43328
43329
43330
43331
43332
43333
43334
43335
For Yellow Emitters and Receivers:
The models listed are for black emitters and receivers. To order yellow
emitters and receivers, add "Y" at the end of the model number (e.g.
MSE3624 becomes MSE3624Y).
System Overview
2. Overview of MINI-SCREEN System Operation
In operation, an emitter and receiver (of equal length) are mounted and aligned
opposite each other at a separation distance of from 6 inches (150 mm) to 30 feet (9
meters). This establishes a curtain of invisible infrared light beams called the
defined area (Figure 1). Center-to-center spacing between adjacent light beams is 0.5
inch (12,7 mm).
The following features of the MINI-SCREEN System are discussed in the listed
subsections:
• Blanking (Section 2.1)
• Auto power-up (Section 2.2)
• Lockout Conditions and Key Resets (Section 2.3)
• Operating Status Indicator Lights (Section 2.4)
• Diagnostic Indicator LEDs (Section 2.5)
• Output Relay Operation (Section 2.6)
• Control Reliability: Redundancy & Self-checking (Section 2.7)
Beams of
Defined
Area
2.1 Blanking
MINI-SCREEN Systems may be configured to be "blind" to the passage of multiple
objects of limited size through the defined area. This is useful in press brake and
other applications where multiple blanked zones (moveable or stationary) are
needed. NOTE: Blanking "on" is indicated by a flashing green receiver or control
box Status Indicator LED.
Floating blanking is the "blinding" of groups of two adjacent sensing beams, which
will appear to change position ("float") in order to allow multiple objects of up to
0.8 inch in cross section* (usually workpiece material) to move through the defined
area, at any point, without tripping the final switching device relays of the MINISCREEN System. With floating blanking "on", any and every one- or two-beam
blockage(s) will be ignored. See Figure 2.
Workpiece
Figure 2. Two-Beam Floating Blanking
*NOTE: This assumes that the object
encounters the curtain perpendicular to the
plane of the light beams.
With floating blanking "on", minimum object sensitivity is specified as 1.75 inches
(44 mm). Objects of this diameter or greater will be detected anywhere in the
defined area. Minimum object sensitivity is 0.75 inch (19 mm) with blanking "off".
Floating blanking preference ("on" or "off") is set via a pair of DIP switches on the
controller module inside the control box (see Figure 18 and Section 3.4, both on
page 23, for details). The control box is supplied with a lockable cover to prevent
unauthorized access to the blanking settings.
2.2 Auto Power-up
Normal operation of the MINI-SCREEN System requires a key reset each time
power is applied to the system. This is usually a desired response to a power failure
or interrupt, and is required by some design standards. In applications where a key
reset is difficult to perform, the auto power-up feature puts the MINI-SCREEN
System directly into RUN mode when power is applied.
Auto power-up is enabled or disabled via a pair of DIP switches located on the
controller module inside the control box. See Figure 18 and Section 3.4 on page 23
for details.
7
System Overview
2.3 Lockout Conditions and Key Resets
A lockout condition of the MINI-SCREEN System causes all of its output relays to
open, sending a "stop" signal to the guarded machine. A lockout condition will
occur:
1) Upon "power-up" of the MINI-SCREEN System (unless Auto Power-up is
"on"; see Figure 5, page 10),
2) If ac power to the MINI-SCREEN System is interrupted (unless Auto Powerup is "on"; see Figure 5),
3) If the control box key switch is in the RESET position, at power-up, (with
auto power-up "on"); or if the key switch is switched to RESET while the
system is in the RUN mode,
4) If an FSD (Final Switching Device - see Glossary) relay does not "drop out"
within it's specified time,
5) If the SSD (Secondary Switching Device - see Glossary) relay has
de-energized,
6) If the controller module switch settings are inconsistent with each other or if
they are changed while the system is in the RUN mode, or
7) If the self-checking circuits of the microprocessor detect a component failure
within the MINI-SCREEN System itself.
A lockout condition resulting from an internal system fault is indicated by a flashing
red status indicator LED on the control box and the receiver unit. The green and
yellow LEDs will be "off". See Fig. 5, page 10.
Power-up/power interrupt lockouts (Auto Power-up "off", conditions #1 and 2
above, yellow LED only double-flashing) are normal and require a key reset for
operation to continue.
Internal lockout conditions (#3 through #6 above) result from component failures or
incorrect controller settings, which must be corrected before the system will allow
operation to continue (Section 2.7). Diagnostic Indicator LEDs (located inside the
control box on the controller module, and visible through a window in the control
box cover) will indicate the cause of the lockout (Section 2.5). Internal lockout
conditions also require a RESET of the keyed switch on the control box cover (a key
reset) to return the system to the RUN mode. A valid key reset consists of turning
the key switch to the RESET position, holding it there for at least 1/2 second, and
then returning the key switch to the RUN position.
8
System Overview
2.4 Operating Status Indicator Lights
The control box panel and the receiver have the following Operating Status Indicator
LEDs (see Figure 3 and 4): green (CLEAR), red (BLOCKED), and yellow
(RESET). Their indications are as follows:
RED "on" steadily and YELLOW single-flashing* (blocked condition): the
MINI-SCREEN System has been reset and is in the RUN mode, but either there is
an obstruction in the defined area or the emitter and receiver are misaligned. FSD1,
FSD2, and Auxiliary Monitor contacts are open (de-energized). SSD relay is closed
(energized).
A flashing yellow LED indicates sensor alignment. The faster the flash rate, the
more beams are "made", and the fewer beams are blocked or "not made". This
feature is very helpful for emitter/receiver alignment (Section 6.1). When alignment
is correct, the GREEN light will come "on" (to join YELLOW) and the RED light
will go "off" when the obstruction is removed. If alignment is not correct, the
GREEN light will remain "off" when the obstruction is removed.
GREEN** and YELLOW "on" steadily: the MINI-SCREEN System has been
reset and is in the RUN mode, the defined area is clear of obstructions, and the
emitter and receiver are properly aligned. All output relays are closed.
Indicator
On steadily Flashing
GREEN
RED
YELLOW
Clear
Blocked
Reset
RED (only) "on" and flashing: a lockout condition due to an internal MINISCREEN System problem exists. SSD, FSD1, FSD2, and Auxiliary Monitor
contacts are all open (de-energized).
Blanking
Lockout
Alignment
(Three sides of receiver)
See also Figure 5, page 10.
YELLOW (only) "on" and double-flashing: a double-flashing YELLOW LED
indicates a power-up or power interrupt lockout condition. These lockouts occur in
the normal course of powering up the MINI-SCREEN System or upon an interruption of power to the System (unless Auto Power-up is "on"; see Fig. 5). SSD, FSD1,
FSD2, and Auxiliary Monitor contacts are open (de-energized).
Figure 3. Status Indicator LEDs
(Receiver)
Diagnostic Indicators
Red
Green
YELLOW (only) "on" steadily: the key switch has been
switched to the RESET position at power-up. FSD1,
FSD2, and Auxiliary Monitor contacts are open (deenergized). SSD contacts are closed (energized).
Yellow
E
N
N
A
B
R
E
IN
G
N
E
G
IN
R
E
P
R
O
C
N
IO
T
A
R
O
*If the TEST INPUT terminals are shorted, the YELLOW
LED will be "on" steadily if the defined area is clear (see
Section 3.5.7).
**A flashing GREEN LED indicates the blanking is "on".
Figure 4. Control Box Indicator LEDs
9
System Overview
Operation Mode
Power Up
Normal Operation
Apply power to
Control Box
LOCKOUT STATE
Turn key to
"RESET" position
Indicator Status
"BLOCKED" "CLEAR"
Red
Green
Red
Green
Relay Status
"RESET"
Yellow
FSD1
FSD2
SSD
Aux. Monitor
Yellow
FSD1
FSD2
SSD
Aux. Monitor
Key Reset
Turn key to
"RUN" position
Defined
area
is clear
Run
Symbol Definitions
Indicator "OFF"
Indicator "ON"
steadily
Indicator
"single-flashing"
Defined
area
is blocked
(TRIP)
Internal
System
fault
(LOCKOUT)
If Auto Power-up is ON when power is applied to the MINISCREEN System, the controller will perform an automatic RESET
after passing an internal system checkout (key RESET not needed).
Auto Power-up is discussed in Section 3.4. NOTE: A key RESET is
always required to recover from a LOCKOUT condition.
Red
Green*
Yellow
FSD1
FSD2
SSD
Aux. Monitor
Yellow**
FSD1
FSD2
SSD
Aux. Monitor
**Yellow LED will be "off" if the
system is powered up without
alignment
Red
Green
Yellow
FSD1
FSD2
SSD
Aux. Monitor
*Green light will flash
if blanking is "on".
Red
Green
Indicator
"double-flashing"
Figure 5. Operating Status Conditions
2.5 Diagnostic Indicator LEDs
There are four Diagnostic Indicator LEDs located on the edge of the controller
module assembly. They are visible through a transparent window in the control box
cover. Refer to Figure 4 (page 9).
The purpose of the Diagnostic Indicator LEDs is to assist in troubleshooting by
indicating the possible causes of internal MINI-SCREEN System problems (lockouts) that are discovered as a result of the controller's self-checking function.
The green diagnostic indicator LED is always "on", as long as power is applied to
the controller, except when a controller microprocessor has failed. The message of
the four diagnostic indicator LEDs is interpreted using the table in Figure 24
(page 35).
10
System Overview
2.6 Output Relay Operation
The MINI-SCREEN System control box has three output relays plus an Auxiliary
Monitor Relay. Refer to Figure 6, below. The three output relays are labeled
"FSD1", "FSD2", and "SSD". The contacts of the Final Switching Device (FSD)
relays (FSD1 and FSD2) are connected to the Machine Primary Control Elements
(MPCEs) of the guarded machine. An MPCE is an electrically powered element of
the guarded machine that directly controls the machine's normal operating motion in
such a way that it is last (in time) to operate when motion is either initiated or
arrested. The Secondary Switching Device (SSD) relay contacts are connected to
the guarded machine's Machine Secondary Control Element (MSCE), an electrically
powered element of the guarded machine (independent of both MPCEs) that is
capable of removing power from the prime mover of the dangerous part of the
machine in the event of a system fault. The two MPCEs must each (alone) be
capable of stopping the motion of the guarded machine in an emergency. The
opening of any FSD1, FSD2, or SSD relay contact results in the removal of power to
either an MPCE or MSCE (or both), which will stop the motion in the guarded
machine.
Any object that blocks one or more unblanked beams will be detected, and will
cause a trip condition: output relays FSD1 and FSD2 (but not SSD) in the control
box open their contacts. All three output relays (FSD1, FSD2, and SSD) will open
their contacts in response to any one or more of seven lockout conditions, including
component failure within the MINI-SCREEN System itself (see Control Reliability,
Section 2.7). The MINI-SCREEN System automatically resets itself from a trip
condition when the object that caused the trip is removed, but recovery from a
lockout condition requires a key reset (Section 2.3). NOTE: See warning regarding
use of the MINI-SCREEN for perimeter guarding on page 13.
The Auxiliary Monitor Relay is a separate relay which follows the action of output
relays FSD1 and FSD2. It is intended for non safety-related purposes, and is
typically used to signal a programmable logic controller (PLC) when output relay
contacts FSD1 and FSD2 open or close.
Figure 6. Banner MINI-SCREEN System Functional Schematic
11
System Overview
2.7 Control Reliability: Redundancy & Self-checking
MINI-SCREEN Systems meet certain U.S. and international control reliability
standards for safety. Banner MINI-SCREEN Systems must reliably send a "stop"
signal to a guarded machine as follows:
1) The MINI-SCREEN System must provide a "stop" signal to the guarded
machine, within 48, 60, or 72 milliseconds*, whenever the defined area is
interrupted, and
2) The MINI-SCREEN System must provide a "stop" signal to the guarded
machine when internal component failures have occurred which compromise
the integrity of the MINI-SCREEN System itself.
Regarding the first situation: In order for the machinery guarded by the MINISCREEN System to be stopped as described, the guarded machine must be capable
of stopping at any point in its machine cycle. This means that the MINI-SCREEN
System cannot be used with certain types of machinery, such as single stroke (also
known as “full-revolution” clutched) machinery, or any machine with inconsistent
machine response time and stopping performance. If there is any doubt about
whether or not your machinery is compatible, contact the Banner Factory
Application Engineers.
Regarding the second situation: This type of component failure includes any
internal MINI-SCREEN System failure which could prevent or delay the output
relays of the MINI-SCREEN System from going to a trip condition or a lockout
condition in response to a situation which, in normal operation, would cause them to
do so. The ability of the MINI-SCREEN System to send a "stop" signal even when
such a component failure has occurred depends upon the design principle of
redundancy.
Redundancy requires that MINI-SCREEN System circuit components be "backed
up" to the extent that, if the failure of any single component will prevent effective
stopping action when needed, that component must have a redundant counterpart
which will perform the same function.
The microprocessor-controlled MINI-SCREEN System is designed with diverse
redundancy. Diverse redundant components are of different designs, and microprocessor programs used by them run from different instruction sets written by different
programmers.
Redundancy must be maintained for as long as the MINI-SCREEN System is in
operation. Since a redundant system is no longer redundant once a component has
failed, MINI-SCREEN Systems are designed to be continuously self-checking. A
component failure detected by or within the self-checking system causes a "stop"
signal to be sent to the guarded machine and puts the MINI-SCREEN System into a
lockout condition.
Recovery from this type of lockout condition requires replacement of the failed
component (to restore redundancy) and a key reset. Possible causes of lockout
conditions are listed in Section 2.3. The Diagnostic Indicator LEDs are used to
diagnose internal causes of a lockout condition (Section 5.1).
*Depending upon sensor length: see Specifications, page 52.
12
Installation & Alignment
3. System Installation & Alignment
CAUTION . . .
!
In order for the machinery
guarded by the MINISCREEN System to be stopped as
described, that machinery must be capable
of stopping at any point in its machine
cycle. This means that the MINISCREEN System cannot be used with
certain types of machinery (see listing, at
right). If there is any doubt about
whether or not your machinery is
compatible with the MINI-SCREEN
System, contact Banner's Application
Engineers at the factory.
3.1 Appropriate Application
The MINI-SCREEN System may only be used to guard machinery that is
capable of stopping motion immediately upon receiving a stop signal and at any
point in its machine cycle.
The MINI-SCREEN System may not be used with single stroke (also called "full
revolution") clutched machinery, as this type of machinery is incapable of
stopping immediately.
MINI-SCREEN Systems also may not be used on certain other types of
machinery. This includes any machine with inadequate or inconsistent stopping
response time, and any machine that ejects materials or component parts through
the defined area.
MINI-SCREEN Systems may not be used in any environment that is likely to
adversely affect the efficiency of a photoelectric sensing system. For example,
corrosive chemicals or fluids or unusually severe levels of smoke or dust, if not
controlled, may degrade the efficiency of the MINI-SCREEN System.
MINI-SCREENs may not be used as tripping devices to initiate machine motion
(PSDI applications) on mechanical power presses, per OSHA regulation 29 CFR
1910.217.
WARNING . . .
The Banner MINI-SCREEN System is a point-of-operation machine guarding device. Its ability to perform this
function depends upon the appropriateness of the application and upon the MINI-SCREEN System's proper mechanical
and electrical installation and interfacing to the machine to be guarded. If all mounting, installation, interfacing, and
checkout procedures are not followed properly, the MINI-SCREEN System cannot provide the protection for which it was designed.
The user has the responsibility to ensure that all local, state, and national laws, rules, codes, or regulations relating to the installation and
use of this control system in any particular application are satisfied. Extreme care should be taken to ensure that all legal requirements
have been met and that all technical installation and maintenance instructions contained in this manual are followed. Read Section 3 of
this manual carefully before installing the system. Failure to follow the instructions in Section 3 (and its subsections) could result in
serious bodily injury or death.
!
The user has the sole responsibility to ensure that the Banner MINI-SCREEN System is installed and interfaced to the guarded machine
by qualified persons in accordance with this manual and applicable safety regulations. A "qualified person" is defined as "a person or
persons who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training, and
experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work"
(ANSI/ASME B30.2-1983).
WARNING. . .
!
Use of MINI-SCREEN Systems for Perimeter Guarding
If a MINI-SCREEN System is installed for use as a perimeter guarding system, the Machine Primary Control Elements
(MPCEs) of the guarded machine must be wired such that any interruption of the defined area will cause immediate arrest
of the dangerous motion of the guarded machine. Following any interruption, the dangerous machine motion must be able to be initiated
only by actuation of a reset switch. This reset switch must be located outside of the area of dangerous motion, and must be positioned so
that the area of dangerous motion may be observed by the switch operator during the reset operation. Failure to observe this warning
could result in serious bodily injury or death.
13
Installation & Alignment
3.2 Mechanical Installation Considerations
The two factors that influence the layout of the MINI-SCREEN System's
mechanical installation the most are:
• separation distance, and
• hard guarding.
3.2.1 Separation Distance
The MINI-SCREEN System must be able to react fast enough, when a hand or
other object is inserted into the defined area, to send a stop signal to the guarded
machine before the object or hand reaches the closest reachable hazard point on
the machine. The separation distance is the minimum distance that is required
between the midpoint of the defined area and the closest reachable hazard point.
The actual separation distance required depends upon several factors, including
the speed of the hand (or object), the total system stopping time (of which there
are several response time components), and the depth penetration factor. The
formula used to calculate the separation distance is:
Ds = K x (Ts + Tr ) + Dpf
Ds
K
Ts
Tr
where:
= the separation distance;
= the OSHA-recommended hand speed constant of 63 inches per second
(NOTE 1, below);
= the overall stop time of the machine measured from the application of
the "stop" signal to the final ceasing of all motion (including stop
times of all relevant control elements, and measured at maximum
machine velocity). See the WARNINGs (right), NOTE 2 (below),
and the NOTICE regarding MPCEs (page 29).
= the response time of the MINI-SCREEN System:
.048 sec. for 4.5 in. to 16 in. emitter/receiver
.060 sec. for 20 in. to 32 in. emitter/receiver
.072 sec. for 36 in. to 48 in. emitter/receiver
Dpf = the added distance due to depth penetration factor,
as prescribed in OSHA 1910.217 and ANSI B11 standards:
Dpf = 1.6 inches with floating blanking off
Dpf = 5 inches with floating blanking on.
1) The OSHA-recommended hand-speed constant K has been determined by various studies, and
although these studies indicate speeds of 63 in/sec to over 100 in/sec, they are not conclusive
determinations. The employer should consider all factors, including the physical ability of the
operator, when determining the value of K to be used.
2) Ts is usually measured by a stop-time measuring device. If the specified machine stop time is
used, we recommend that at least 20% be added as a safety factor to account for clutch/brake
system deterioration.
3) Use of floating blanking will always cause the required Ds to increase.
14
WARNING. . .
!
Banner MINI-SCREEN
System emitters and receivers
must be mounted at a distance
from moving machine parts that is determined by OSHA standards found in Section
1910.217 (c)(3)(iii)(e). Failure to establish
and maintain the required separation
distance exactly as described in Section 3.2
of the MINI-SCREEN manual could result
in serious bodily injury or death.
!
WARNING . . .
The measurement of stop
time (Ts ) must include the
response time of all devices
or controls that react to stop the machine.
If all devices are not included, the
calculated safety distance (Ds ) will be too
short. This can lead to serious bodily
injury or death. Be sure to include the
stop time of all relevant devices and
controls in your calculations.
CAUTION . . .
!
Floating blanking increases Dpf.
You must increase the penetration factor (Dpf = 5 inches) to
calculate the separation distance whenever
floating blanking is used.
Always turn floating blanking "off" when the
larger minimum object detection size is not
required.
Installation & Alignment
Figure 7. Separation Distance
Example: Separation Distance (Ds) Calculation
The following is an example showing how to use the formula from page 14 to
calculate the safety distance (Ds ). We will use these numbers for the variables
in the formula:
K = 63 inches per second (the hand speed constant set by OSHA)
Ts = .250 second (the total stop time of the example machine, specified
by machine manufacturer)
Tr = .048, .060, or .072 second (the specified response time of the MINISCREEN System; see Specifications, page 52 or page 14.)
Our example uses floating blanking, so we use a Dpf of 5 inches (page 14).
Response time for this example is .060 second. Substitute the numbers into the
formula as follows:
Ds = K x (Ts + Tr) + Dpf
Ds = 63 x (.250 x 1.2* + .060) + 5 = 28 inches
Therefore, in this example, the MINI-SCREEN emitter and receiver must be
mounted such that no part of the defined area will be closer than 28 inches to the
closest reachable hazard point on the guarded machine.
*20% safety factor (see NOTE 2, on page 14)
15
Installation & Alignment
3.2.2 Hard Guarding
ANSI B11.1-1988, E6.3.2 (14) requires that "all areas of entry to the point of
operation not protected by the presence-sensing device shall be otherwise
safeguarded". The hazard point must be accessible only through the defined
area. This means that mechanical barriers (screens, bars, etc.), or supplemental
presence sensing devices (supplemental guarding) must be installed, wherever
needed, to prevent any person from reaching around, under, or over the
defined area and into the hazard point, and to prevent any person from
standing between the defined area and the hazard point (see OSHA
1910.212). The use of mechanical barriers for this purpose is called "hard
guarding" (see the WARNING on the right and the hard guarding
example, below).
There must be no gaps between the hard guarding and the edges of the defined
area. Also, OSHA specifies a relationship between the distance of the hard guard
barrier from the point of operation and the maximum allowable size of openings
in that barrier (see OSHA 1910.217, Table O-10). Openings in the hard guard
material must meet OSHA criteria.
Figure 8. Example of "Hard Guarding"
16
WARNING. . .
!
The point of operation must be
accessible only through the
defined area. Mechanical
barriers (screens, bars, etc.), or supplemental
presence sensing devices (supplemental
guarding) must be installed, wherever needed,
to prevent any person from reaching around,
under, or over the defined area and into the
point of operation, and also to prevent any
person from entering the space between the
defined area and the point of operation. (See
OSHA 1910.212). The use of mechanical
barriers for this purpose is called "hard
guarding". There must be no gaps between the
hard guarding and the edges of the defined
area. Openings in the hard guard material
must meet OSHA criteria (see OSHA
1910.217, Table O-10).
Supplemental presence sensing devices,
such as safety mats, must be used if the
space between the defined area and the
nearest danger point is large enough to
allow a person to stand undetected by the
MINI-SCREEN System.
Installation & Alignment
3.2.3 Emitter and Receiver Orientation
WARNING. . .
!
The emitters and receivers of
the MINI-SCREEN System
must be installed with their
corresponding ends (either cabled ends or
non-cabled ends) pointing in the same
direction (i.e. both cabled ends "up", both
cabled ends "down", etc.). Failure to do
this will impair the performance of the
MINI-SCREEN System and result in
incomplete guarding. See Figure 10a.
Failure to observe this warning could
result in serious bodily injury or death.
It is absolutely necessary that the emitter and receiver are mounted such that
they are perfectly parallel to each other and aligned in a common plane with
both cable ends pointing in the same direction. Never mount the emitter with
its cable end oriented opposite to the cable end of the receiver. If the emitter
and receiver cable ends are oriented opposite to each other, there will be voids
in the light curtain through which objects can pass undetected (see Figure 10a).
The emitter and receiver may be oriented in a horizontal plane, or at any
angle between horizontal and vertical. However, the cable ends must always
point in the same direction. Always be certain that the light screen completely
covers all access to the hazard point which is not already protected by
hardguarding or another means of supplemental guarding.
a.) Both cable ends down
b.) Both cable ends up
c.) Orientated parallel to
floor with both cable
ends pointing in the
same direction
Figure 9. Examples of Correct Emitter and Receiver Orientation
a.) Cable ends pointing in
opposite directions.
Problem: Voids in
defined area.
b.) Emitter and receiver not
parallel to each other.
Problem: Reduced
excess gain
Figure 10. Examples of Incorrect Emitter and Receiver Orientation
17
Installation & Alignment
3.2.4 Adjacent Reflective Surfaces
A reflective surface located adjacent to the defined area may deflect one or
more beams of the light curtain around an object which is in the defined area.
In the worst case, an object may pass through the defined area undetected.
A reflective surface may be a part of the machine or the workpiece and may
include shiny metal or plastic or surfaces with glossy paint. Where possible,
reflective surfaces which are adjacent to the defined area should be roughened
or covered with a dull material. Where this is not possible (as with a reflective
workpiece), the sensor mounting should include a means of restricting the
field of view of the receiver or the spread of the light from the emitter
(see Figure 8).
Beams deflected by reflective surfaces are discovered during the initial
checkout procedure (Section 3.5.3), the final alignment and checkout
procedure (Section 6.1), and also by the periodic checkout procedures
(Sections 6.2, 6.3, and 6.4).
3.2.5 Use of Corner Mirrors
MINI-SCREEN sensors may be used with one or more corner mirrors. The
use of corner mirrors somewhat reduces the maximum specified emitter/
receiver separation of 30 feet. Corner mirrors and stands are available from
Banner. Contact the factory Applications Enginineering Department for
information.
WARNING. . .
!
It may be possible for a
highly reflective surface
(such as a shiny machine
surface or a shiny workpiece) to reflect
sensing light around an object in the
defined area, thus preventing that object
from being detected. This potentially
dangerous condition is discovered using
the "trip test" as described in the Initial
Checkout Procedure (Section 3.5.3), the
Alignment Procedure (Section 6.1), and
the periodic checkout procedures
(Sections 6.2, 6.3, and 6.4).
When this condition is discovered,
eliminate the problem reflection(s). If
possible, relocate the sensors to move the
curtain of light beams away from the
reflective surface(s). If relocating the
sensors, be careful to retain at least the
required separation distance (Section
3.2.1). Otherwise, paint, mask, or
roughen the interfering shiny surface to
reduce its reflectivity. Use the trip test to
verify that these changes have eliminated
the problem reflection(s).
NOTE: If the workpiece is especially
reflective and comes close to the curtain,
perform the trip test with the shiny
workpiece in place.
WARNING. . .
The MINI-SCREEN System
is not designed for use in a
retroreflective mode where
the sensors are mounted adjacent to each
other and the light from the emitter is
bounced back directly to the receiver by a
mirror or other reflective surface. Never
use MINI-SCREEN sensors in a retroreflective mode, as illustrated in
Figure 11. Sensing is unreliable in this
mode and could result in serious injury
or death.
!
Figure 11. Never use the MINI-SCREEN
Sensors in a retroreflective mode.
18
Installation & Alignment
3.2.6 Installation of Multiple MINI-SCREEN Systems
Whenever the emitter and receiver pairs of two or more MINI-SCREEN
Systems are adjacent to one another, there is potential for optical crosstalk to
take place between systems. To minimize optical crosstalk, it is recommended
to alternate emitters and receivers, as shown in Figure 12.
a.) Two systems in a
horizontal plane.
b.) Two systems stacked.
c.) Two systems at right angles.
Figure 12. Installation of Multiple MINI-SCREEN systems. Alternate Emitters
and Receivers to Avoid Optical Crosstalk.
When three or more systems are installed in a horizontal plane, (as shown for
two pairs in Figure 12a.), optical crosstalk may occur between those sensor
pairs which have their emitter and receiver lenses orientated in the same
direction. In this situation, optical crosstalk may be controlled by mounting
these sensor pairs exactly in line with each other within the same plane, or by
adding a mechanical light barrier between the pairs.
19
Installation & Alignment
3.3 Mounting Procedure
Sensor Mounting
Banner MINI-SCREEN System emitters and
receivers are small, lightweight, and easy to handle
during mounting. The mounting brackets (supplied)
allow ±30 degrees rotation.
From a common point of reference, make measurements to locate the emitter and receiver in the same
plane with their midpoints directly opposite each
other. Important: The connector ends of both
sensors must point in the same direction (see
drawings and WARNING, page 17). Mount the
emitter and receiver brackets using the vibration
isolators and M4 Keps nuts (all supplied). See
Figure 13. Standard #8-32 bolts may be substituted
(and the vibration isolators eliminated) in situations
where the emitter and receiver are not subjected to
shock or vibration forces. While the internal
circuits of the emitter and receiver are able to
withstand heavy impulse forces, the vibration
isolators dampen impulse forces and prevent
possible damage due to resonant vibration of the
emitter or receiver assembly.
Mount the emitter and receiver in their brackets
and position the red lenses of the two units directly
facing each other. Measure from one or more
reference planes (e.g. the building floor) to the
same point(s) on the emitter and receiver to verify
their mechanical alignment. If the units are positioned exactly vertical or horizontal to the floor, a
carpenter's level is useful for checking alignment.
A straightedge or a string extended between the
sensors also helps with positioning. Also check
"by eye" for line-of-sight alignment. Make any
necessary final mechanical adjustments, and handtighten the bracket hardware. A detailed alignment
procedure is given in Section 6.1.
M4 x 10 mm
Slotted Hex Head
with Compression
Washer (2)
Mounting
Surface
Mounting
Bracket
M4 Keps
Nut (8)
Emitter or
receiver
Anti-Vibration
Mount (4)
Studs:
M4 x 0.7
9.5 mm (0.38 in) long
Mounting
Bracket
Washer
Nut
Figure 13. Emitter and Receiver Mounting Hardware
Figure 14. Emitter and Receiver Mounting Bracket Dimensions.
20
Installation & Alignment
a.) With mounting bracket flanges "out"
b.) With mounting bracket flanges "in"
Figure 15. Emitter and Receiver Mounting Dimensions and Location of Defined Area.
Models
Housing Length
L1
(inch) (mm)
Distance Between Bracket Holes
L2
L3
(inch) (mm)
(inch)
(mm)
Defined Area
X
Y
(inch)
(mm)
(inch)
(mm)
MSE424 emitter
MSR424 receiver
6.0
153
7.4
188
5.1
130
1.1
28
4.5
114
MSE824 emitter
MSR824 receiver
10.0
254
11.3
287
9.1
231
1.1
28
8.5
215
MSE1224 emitter
MSR1224 receiver
14.0
356
15.3
389
13.1
333
1.2
30
12
305
MSE1624 emitter
MSR1624 receiver
18.0
457
19.3
490
17.1
434
1.2
30
16
406
MSE2024 emitter
MSR2024 receiver
22.0
558
23.3
592
21.1
536
1.2
30
20
508
MSE2424 emitter
MSR2424 receiver
26.0
659
27.3
693
25.1
637
1.2
30
24
610
MSE2824 emitter
MSR2824 receiver
30.0
761
31.3
795
29.1
739
1.3
33
28
711
MSE3224 emitter
MSR3224 receiver
33.9
862
35.3
896
33.0
838
1.3
33
32
813
MSE3624 emitter
MSR3624 receiver
37.9
963
39.3
998
37.0
940
1.3
33
36
914
MSE4024 emitter
MSR4024 receiver
41.9
1064
43.3
1100
41.0
1041
1.3
33
40
1016
MSE4424 emitter
MSR4424 receiver
45.9
1166
47.3
1201
45.0
1143
1.3
33
44
1118
MSE4824 emitter
MSR4824 receiver
49.9
1267
51.2
1300
49.0
1245
1.3
33
48
1219
21
Installation & Alignment
Connect the shielded cables to the emitter and receiver and route them (per local
wiring code for low-voltage dc control cables) to the control box mounting
location. (NOTE: Emitter and receiver cables must be routed to the control box
knockouts closest to terminal barrier TB3; see Figures 19 and 20.) The same
cable type is used for both emitter and receiver (two cables required per system).
Cables may be cut to length at the time of installation. Emitter and receiver cable
lengths may not exceed 50 feet (each). Do not trim the cables until you are
certain that you have routed all cables properly (see Figures 19 and 20). The
cable braid at the control box connection points may be either removed or twisted
together with the drain wire for attachment to the wiring block.
Control Box Mounting
Mount the MINI-SCREEN System control box in a convenient location that is
free from heavy impulse force and high-amplitude vibration. The control box
must be mounted at a location which provides an unobstructed view of
the defined area. Mounting hole information is given in Figure 17 (below).
The MINI-SCREEN Controller module must be configured before initial
checkout and use. Controller configuration is done at the row of DIP
switches along the edge of the controller module (Figure 18). The controller
will automatically sense the length of the emitter and receiver, and set its
response time accordingly.
Figure 16. Quick Disconnect Cable
Clearance Dimensions.
.31"
(7.9 mm) (4)
BANNER ENGINEERING CORPORATION
8.75"
(222.3 mm)
8.3"
(210 mm)
9.6"
(244 mm)
6.00"
(152.4 mm)
8.3"
(210 mm)
Figure 17. Control Box Mounting Hole Locations.
22
3.3"
(84 mm)
Installation & Alignment
3.4 Controller Module Configuration
Controller Module
Configuration Switches and LED Identification
1 - Floating Blanking
2 - Auto Power-up
Because it has redundant microprocessors, the controller module has two
identical DIP switch banks (bank A and bank B) which must be set identically.
Failure to set both banks identically will cause a lockout condition when
power is applied to the control box. Power to the MINI-SCREEN System
must always be "off" when changing switch settings. Changing switch
settings with power "on" will cause a lockout condition. A switch pushed to
the left is "on"; a switch pushed to the right is "off". Set the configuration
switches as follows:
Bank
"A"
Diagnostic
LEDs
Steady / Flashing
Red - Blocked/Lockout
Green - Clear/Blanking
Yellow - Reset/Alignment
1 - Floating Blanking
2 - Auto Power-up
The parameters to be manually configured are:
• Floating blanking "on" or "off".
• Auto Power-up "on" or "off".
NOTE: The factory setting for both parameters is "off".
Status
LEDs
Bank
"B"
Figure 18. Controller Configuration
Switches
Floating Blanking ON or OFF
Locate the floating blanking (FB) configuration switch in bank A (switch
#1). Set the switches identically at banks A and B. Be aware of the difference in minimum object sensitivity, penetration factor, and required light
screen separation distance between the "on" and "off" settings (refer to
Sections 2.1 and 3.2.1). Floating blanking causes the MINI-SCREEN
System to ignore multiple objects of up to 0.8 inch in cross section.
Auto Power-up feature ON or OFF
Locate the Auto Power-up (AP) configuration switch (switch #2) in bank A.
If Auto Power-up is "on" (switches pushed to the left) when power is applied
to the MINI-SCREEN System, the controller will automatically reset after
conducting and passing an internal system checkout. If the switch is "off"
(pushed to the right), this initial reset is manual (via the key reset switch on
the front panel). Regardless of the setting of this switch, a key reset is
always necessary to recover from an internal lockout condition. To select
Auto Power-up, remove the protective coating on switch #2 and push the
switch to the left ("on") position. The switches must be set identically at
banks A and B.
23
Installation & Alignment
3.5 Electrical Hookup and Checkouts
Make the electrical connections in the order that they are presented in
Sections 3.5.1 through 3.5.7. Exercise care when removing control box
knockouts, so as to not damage the contents of the control box.
The following wiring connections are located inside the control box:
Emitter and receiver cables,
System power,
Output relay connections (FSD1, FSD2, and SSD),
Auxiliary Monitor Relay, and
Remote devices (key switch and test input).
Several conduit knockouts are provided around the sides of the control box.
As you complete the wiring in the following sections, select knockout
locations that are closest to the internal control box connection points that
you want to access. Refer to Figures 19 and 20. NOTE: Except for emitter
and receiver cable entries (for which cable glands are supplied), it is the
user's responsibility to maintain NEMA 13 sealing at all cable entries into the
control box.
WARNING. . .
Electrical hookup must be
made by a qualified electrician,
and must comply with NEC
(National Electrical Code) and local
standards. Also, make no more connections
to the MINI-SCREEN System than are
described in Sections 3.5.1 through 3.5.7.
Connection of other wiring or equipment
to the MINI-SCREEN System could result
in serious bodily injury or death.
!
Note that the wiring barriers inside the control box can accept conductors no
larger than #14 AWG. Also, the wires used should have an insulation
temperature rating of at least 90°C (194°F).
R
E
N
N
A
B
G
IN
R
E
E
IN
G
N
E
N
IO
T
A
R
O
P
R
O
C
1.15"
(29.2 mm)
N
E
R
E
A
B
N
N
2.00"
(50.8 mm)
G
IN
E
E
R
IN
G
C
O
R
P
O
R
T
A
IO
N
1.13"
(28.7 mm)
0.75"
(19.0 mm)
1.00"
(25.4 mm)
1.75"
(44.5 mm)
1.75"
(44.5 mm)
1.63"
(41.4 mm)
1.00"
(25.4 mm)
1.75"
(44.5 mm)
2.63"
(66.8 mm)
1.00"
(25.4 mm)
1.26"
(32.0 mm)
0.88"
(22.4 mm)
1.00"
(25.4 mm)
NOTE:
All knockouts measure ø0.875" for 1/2"
conduit fittings.
Figure 19. MINI-SCREEN Control Box Knockout Locations.
24
Installation & Alignment
TB4
Auxilliary Monitor
Connection
Relay Module
TB1
Output
Connections
TB2
Remote Input
Connections
TB1
Power Input
Connections
Controller
Module
Fuse
TB3
Emitter and Receiver
Connections
Figure 20. MINI-SCREEN System Electrical Connections
Emitter and Receiver Cable
Preparation
Trim braided shield flush
with cable, or twist together
with drain wire
Trim foil shield flush
with cable
NOTE:
The "drain wire"
is the uninsulated
stranded wire which runs between the
braided shield and the foil shield. The foil
shield should be removed at the point
where the wires exit the cable. The
braided shield may be either removed or
twisted together with the drain wire for
connection to wiring barrier TB3.
Uninsulated
drain wire
3.5.1 Emitter and Receiver Hookup
The emitter and receiver cables require two control box knockouts. Two cable
gland strain relief fittings are supplied with each control box for the entrance of
emitter and receiver cables into the control box. Emitter and receiver cables both
connect to wiring barrier TB3 (Figure 20, above). Route the cables through the
knockouts nearest to barrier TB3. Only the use of Banner QDC Series cables (see
page 54) can ensure reliable communication of data between the controller and
the sensors. Match the color-coded terminals of wiring barrier TB3 to colors of the
wires in each 5-conductor cable. Double-check your wiring. Incorrect wiring can
lead to component damage. There are no user adjustments or connections inside
the MINI-SCREEN sensors themselves.
25
Installation & Alignment
3.5.2 System Power (temporary connection)
As shown in Figure 23 (page 30), the ac lines to the control box connect through
the MPCE monitor contacts of the guarded machine. However, do not wire to
the MPCEs at this time. Instead, temporarily connect power directly at the
L and N terminals of control box wiring barrier TB1. Connect earth ground at
the terminal provided. This will allow the MINI-SCREEN System to be
checked out, by itself, before permanent power connections through the guarded
machine's monitor contacts are made. Permanent power connection will be
made after MINI-SCREEN System initial checkout, and is covered in
Section 3.5.5.
3.5.3 MINI-SCREEN System Initial Checkout
This initial checkout procedure must be performed by a qualified person (see
WARNING, page 13). It must be done after connecting the emitter and receiver
(Section 3.5.1) and temporary power (Section 3.5.2) to the MINI-SCREEN
control box, but before the MINI-SCREEN System is connected to the machine
to be controlled.
This initial checkout procedure is done when the MINI-SCREEN System is first
installed, and must also be performed by a qualified person whenever any
maintenance or modification is performed on the MINI-SCREEN System or on
the machinery guarded by the MINI-SCREEN System. A schedule of required
checkouts is given in Section 4.2.
Operation Mode
Power Up
Normal Operation
Apply power to
Control Box
LOCKOUT STATE
Turn key to
"RESET" position
Key Reset
Turn key to
"RUN" position
Run
Defined
area
is clear
Symbol Definitions
Indicator "OFF"
Indicator "ON"
steadily
Indicator
"single-flashing"
Indicator
"double-flashing"
Defined
area
is blocked
(TRIP)
Internal
System
fault
(LOCKOUT)
Indicator Status
"BLOCKED" "CLEAR"
Red
Green
Red
Green
"RESET"
Yellow
Yellow
If Auto Power-up is ON when
power is applied to the MINISCREEN System, the controller
will perform an automatic RESET
after passing an internal system
checkout (key RESET not needed).
Auto Power-up is discussed in
Section 3.4.
Red
Green*
Yellow
*Green light will flash
if blanking is "on".
Red
Green
Yellow**
**Yellow LED will be "off" if the
system is powered up without
alignment
Red
Green
Yellow
NOTE:
A key RESET is always required to recover from a LOCKOUT condition.
Figure 21. Operating Status LED Conditions
26
Note: If the key is
inadvertently turned to
RESET while the
system is operating
normally, the MINISCREEN System will go
into a LOCKOUT
condition and the RED
(only) status indicator
LED will flash. To return
the MINI-SCREEN
System to the RUN
condition, the key must
again be turned to
RESET, and then back
to RUN.
CAUTION. . .
Electrical shock hazard exists
when the MINI-SCREEN
System has power applied to
it and the control box door is open. Close
the hinged control box cover and secure
the latches before running this checkout
procedure.
Installation & Alignment
INITIAL CHECKOUT PROCEDURE:
The MINI-SCREEN System has three operating modes: POWER UP, KEY
RESET, and RUN. Monitor the three status LEDs (red, yellow, and green,
on the control box front panel or the receiver) and refer to Figure 21.
1) Enter the POWER UP mode by applying power to the control box (see
CAUTION, page 26). With Auto Power-up "off" the System will
"power up" in a lockout condition (yellow LED only will double-flash).
With Auto Power-up "on", the System will automatically enter the RUN
mode (step 3).
2) Enter the key RESET mode by turning the key to the RESET position.
The yellow panel LED will glow steadily.
NOTE: Hold the switch in the RESET position for at least one-half
second. This allows time for the microprocessors to run a startup diagnostic check routine.
3) Enter the RUN mode by turning the key from the RESET position to
the RUN position.
If the red LED (only) lights and flashes when the system is placed in the
RUN mode, an internal lockout condition exists. Refer to Section 5.1 to
determine the cause of the lockout.
If the red and yellow LEDs come "on", the defined area is not clear (one
or more light beams are obstructed) or the system may be out of alignment. This is a trip condition. If this occurs, check the defined area for
obstruction(s). The red LED will be "on" steadily. The yellow LED will
be flashing to indicate the relative number of made (cleared) light
beams; the faster the flash rate, the more beams are "made".
If the MINI-SCREEN System is properly aligned and the blanking is
properly set and all obstructing objects are removed from the defined
area, the green and yellow LEDs should come "on" after step #3 has been
performed (the green LED will flash if blanking is "on", but the yellow
LED should be "on" steadily). If you are setting up the MINISCREEN System for the first time, or if the green and yellow LEDs
do not come "on" in step #3, perform the alignment procedure in
Section 6.1. When you are certain that the emitter and receiver are
aligned properly, tighten the emitter and receiver mounting hardware in
position and repeat steps #1-3, above.
27
Installation & Alignment
Figure 22. MINI-SCREEN System Trip Test
4) Next, "trip test" the MINI-SCREEN for object detection capability
using the specified test pieces supplied with the control box. To perform
the trip test, the key switch must be in the RUN position, the yellow LED
must be "on" steadily, and the green LED must either be on steadily (to
indicate blanking "off") or flashing (to indicate blanking "on").
a) If floating blanking is "off" (green LED "on" steadily), use the
smaller (0.75" dia.) test piece, model STP-2, in step c.
b) If floating blanking is "on" (green LED flashing), use the larger
(1.75" dia.) test piece, model STP-3, in step c.
c) Pass the specified test piece, very slowly, down the length of the
defined area in three paths: close to the emitter unit, close to the
receiver unit, and midway between the emitter and receiver units.
The red and yellow LEDs must come "on" when the test piece enters
the defined area, and must remain "on" for as long as the test piece
remains in the defined area. When the test piece is removed from the
defined area, the green and yellow (only) LEDs must come "on"
steadily (if floating blanking is "on", the green LED will be flashing).
If the MINI-SCREEN System passes all of the checks in Section 3.5.3, go on
to Section 3.5.4. If the MINI-SCREEN System fails any of these checks, do
not attempt to use it until the reason for the failure(s) is identified and the
failures are corrected.
28
Installation & Alignment
CAUTION. . .
Electrical shock hazard
exists when the
MINI-SCREEN System
has power applied to it and the
control box door is open. Use
extreme caution to avoid electrical
shock at all times when the control box
door is open. Always disconnect all
power from the MINI-SCREEN
System and the guarded machine
before making any connections or
replacing any component.
WARNING. . .
The output relays of the
MINI-SCREEN System must
be the final switching devices
for the machinery being guarded. Never
wire an intermediate device (for
example, a programmable logic
controller - PLC), other than a safety
relay, between either FSD and the
machine control element is switches
(Reference ANSI B11.1-1988. Appendix
B4). To do so could result in serious
bodily injury or death.
!
3.5.4 Output Relay Connections
Output relay connections are made at the FSD1 (Final Switching Device 1),
FSD2 (Final Switching Device 2), and SSD (Secondary Switching Device)
terminals on wiring barrier TB1. These relays are energized (contacts
closed) in normal operation with no obstructions in the defined area. All
relays become de-energized (their contacts open) in a lockout condition.
Relays FSD1 and FSD2 (only) de-energize in a trip condition. Before
continuing, read NOTICE regarding MPCEs, below, left.
The FSD1 output relay connects to Machine Primary Control Element #1
(MPCE 1) on the guarded machine. MPCE 1 is an electrically powered
element of the guarded machine that directly controls the normal operating
motion of the machine in such a way that it is last (in time) to operate when
motion is either initiated or arrested. The output contact of relay FSD1 must
be connected, as shown in Figure 23, to control power to Machine Primary
Control Element #1. The switching capacity of relay FSD1 is 250V ac
max., 4 amps max. (resistive load).
Connection of the output relays to the
guarded machine must be direct and
must produce immediate stopping
action.
The FSD2 output relay connects to Machine Primary Control Element #2
(MPCE 2) on the guarded machine. MPCE 2 is an electrically powered
element of the guarded machine (in a different control path than MPCE 1)
that directly controls the normal operating motion of the guarded machine in
such a way that it is last (in time) to operate when machine motion is either
initiated or arrested. The output contact of relay FSD2 must be connected, as
shown in Figure 23, to control power to Machine Primary Control Element
#2. The switching capacity of relay FSD2 is 250V ac max., 4 amps max.
(resistive load).
NOTICE regarding
MPCEs
Many different types of mechanisms are used to arrest dangerous machine
motion. Examples include mechanical braking systems, clutch mechanisms,
and combinations of brakes and clutches. Additionally, control of the
arresting scheme may be hydraulic or pneumatic.
Each of the two Machine Primary
Control Elements (MPCE 1 and
MPCE 2) must be capable of immediately stopping the dangerous machine
motion, irrespective of the state of the
other. These two channels of machine
control need not be identical, but the
stop time performance of the machine
(Ts, used to calculate the separation
distance) must take into account the
slower of the two channels.
Some machines offer only one
primary control element. For such
machines, it is necessary to duplicate
the circuit of the single MPCE to add a
second machine primary control
element. Refer to Figure 23 (page 30)
or consult the machine manufacturer
for additional information.
As a result, MPCEs may be of several control types, including a wide variety
of contactors and electromechanical valves. If your machine documentation
leaves any doubt about the proper connection points for the MINI-SCREEN
System output relay contacts, do not make any connections. Contact the
machine builder for clarification regarding connections to the MPCEs and
MSCE.
The SSD output relay connects to the Machine Secondary Control Element
(MSCE) on the guarded machine. The MSCE is an electrically powered
element of the guarded machine (independent of the MPCEs) that is capable
of removing power from the prime mover of the dangerous part of the
machine in the event of an emergency. The output contacts of the SSD relay
must be connected, as shown in Figure 23, to the Machine Secondary Control
Element such that, if a lockout condition occurs, the motive power will be
removed from the machine. The switching capacity of the SSD relay is
250V ac max., 4 amps max. (resistive load).
29
Installation & Alignment
Figure 23 (below) shows output relay connections in a generic
interfacing situation. The connections between the MINI-SCREEN System
outputs and the machine primary and secondary control elements must be
direct, and arranged so that any single line fault or earth fault will not result
in a circuit failure to a potentially dangerous state.
*L (V AC)
or
+ (V DC)
*N (V AC)
or
– (V DC)
Model MSCA-1 Control Box: 115V AC 50/60 Hz
Model MSCB-1 Control Box: 230 V AC 50/60 Hz
Model MSCT-1 Control Box: 24V dc
Machine Secondary
Control Element
Secondary Switching
Device
SSD
MSCE
TB1
Machine
Control
Circuit
Arc Suppression
(see warning)
Machine Primary
Control Element #2
Final Switching
Device #2
FSD 2
MPCE
2
TB1
Arc Suppression
(see warning)
Machine Primary
Control Element #1
Final Switching
Device #1
FSD 1
MPCE 1 MPCE 2
Earth
Ground
MPCE
1
TB1
MPCE
Monitor
Contacts
Arc Suppression
(see warning)
*L (V AC) or + (V DC)
MPCE 1 MPCE 2
*N (V AC) or – (V DC)
TB1
MINI-SCREEN
Control Box
*WIRING NOTE:
In USA and Canadian 115V ac and European 230V ac supply
systems, L is ac "hot" and N is ac "neutral". In USA and
Canadian 230V ac systems, L and N are both ac "hot".
WARNING. . .
If arc suppressors are used, they MUST BE INSTALLED AS SHOWN
ACROSS THE COILS OF THE MACHINE CONTROL ELEMENTS.
NEVER INSTALL SUPPRESSORS DIRECTLY ACROSS THE
CONTACTS OF THE MINI-SCREEN SWITCHING DEVICES! It is possible for
suppressors to fail as a short circuit. If installed directly across the contacts of a
MINI-SCREEN switching device, a short-circuited suppressor will create an unsafe
condition.
!
WARNING. . .
All MINI-SCREEN System output contacts (FSD1, FSD2, and SSD)
must be used. The generalized wiring configuration, shown here, is
provided only to illustrate the importance of proper installation. The
actual details of wiring of the MINI-SCREEN system to any particular machine is
solely the responsibility of the installer and end user.
!
Figure 23. Generic Machine Interface, MINI-SCREEN System
30
WARNING. . .
!
Use of MINI-SCREEN
Systems for Perimeter
Guarding
If a MINI-SCREEN System is installed
for use as a perimeter guarding system, the
Machine Primary Control Elements
(MPCEs) of the guarded machine must be
wired such that any interruption of the
defined area will cause immediate arrest
of the dangerous motion of the guarded
machine. Following any interruption, the
dangerous machine motion must be able
to be initiated only by actuation of a reset
switch. This reset switch must be located
outside of the area of dangerous motion,
and must be positioned so that the area of
dangerous motion may be observed by the
switch operator during the reset operation.
Failure to observe this warning could
result in serious bodily injury or death.
Installation & Alignment
3.5.5 System Power (permanent connection)
NOTICE regarding
MPCE Monitoring
Hookup
It is strongly recommended that one
normally open and one normally closed
auxiliary contact of each MPCE be
wired (as shown in Figure 23, page 30)
as MPCE monitor contacts. If this is
done, any inconsistency of action
between the two MPCEs will remove
power from the MINI-SCREEN
System, causing a lockout condition.
The use of MPCE auxiliary contacts
as MPCE monitor contacts is necessary in order to maintain redundancy.
MPCE auxiliary contacts used for this
purpose must be rated at 55 VA
minimum.
In order to maintain redundancy, the
MPCE monitor contacts must be
wired as described in section 3.5.5
and Figure 23, page 30.
After the initial checkout of Section 3.5.3 has been successfully completed,
the power lines to the MINI-SCREEN System must be re-routed to their
permanent hookup through the MPCE monitor contacts of the guarded
machine. This is important: it ensures that any inconsistency in action
between the two MPCEs will remove power from the system. (This is
discussed in the NOTICE regarding MPCE Monitoring Hookup, left).
Connection of system power is at the L and N (or + and -) terminals of
control box wiring barrier TB1. The MINI-SCREEN System requires 115V
ac, 50/60Hz when using control box MSCA-1, 230V ac when using model
MSCB-1, or 24V dc when using model MSCT-1. Three-wire connection (ac
"hot", ac "neutral", and earth ground) to ac power mains must be done
according to NEC and local wiring codes. Do not operate the MINI-SCREEN
System without an earth ground connection.
After power has been connected to the MINI-SCREEN System and the
output relay contacts have been connected to the machine to be controlled,
the operation of the MINI-SCREEN System with the guarded machine must
be verified before the combined system may be put into service. To do this, a
qualified person must perform the Commissioning Checkout Procedure
given in Section 6.2 on page 42.
3.5.6 Auxiliary Monitor Relay
The action of the Auxiliary Monitor Relay contact "follows" the action of
output relays FSD1 and FSD2. The Auxiliary Monitor Relay contact is a
light-duty contact used for control functions that are not safety-related. A
typical use is to communicate with a programmable logic controller (PLC).
The switching capacity of the Auxiliary Monitor Relay is 125V ac or dc
max., 500mA max. Connection to the Auxiliary Monitor Relay contact is
made at wiring barrier TB4.
3.5.7 Accessory Connections at Terminal Strip TB2
Terminal Barrier TB2 at the upper left corner of the control box allows
connection of remote inputs including the following:
Optional (see page 55) MGA-KSO-1 Remote Key Switch connects across the
KEY 1 and KEY 2 terminals of TB2. It is functionally equivalent to the
control box key switch. The MGA-KSO-1 must be positioned at a location
that provides the switch operator with an unobstructed view of the entire
defined area. We recommend use of shielded cable or separate wiring in a
grounded conduit. See Section 5.2.
Remote Test Input connects to the TEST 1 and TEST 2 terminals of TB2 (see
Figure 20, page 25). When connected together (shorted) for a minimum of
50 milliseconds, these terminals provide the MINI-SCREEN System with the
equivalent of a BLOCKED beam condition, for testing purposes. The switch
or switching device used to short the TEST contacts must be capable of
switching 15 to 50V dc at 20 to 100 mA dc.
31
Operating Instructions
4. Operating Instructions
4.1 Security Protocol
The MINI-SCREEN control box has a lockable cover and a key-operated
front-panel RESET switch.
In order to prevent access by unauthorized personnel, and to ensure that all
lockout conditions come to the attention of a person qualified to deal with
them, a lock must be inserted in the lockable cover and the key (or combination)
to this lock must be kept in the possession of a qualified person as defined in
ANSI/ASME B30.2-1983 (see Glossary Section). Qualified persons only
should have access to the interior of the MINI-SCREEN System control box.
The key to the front-panel RESET switch should be available to a designated
person or persons. A designated person is one who is identified and
designated in writing, by the employer, as being appropriately trained and
qualified to perform a specified checkout procedure. If the machine operator
meets these requirements, he/she may be a designated person.
4.2 Periodic Checkout Requirements
In addition to the checkouts that are performed by a qualified person or
persons at the time that the MINI-SCREEN System is installed and put into
service, the functioning of the MINI-SCREEN System and the guarded
machine must be verified on a regular periodic basis to ensure proper
operation. This is absolutely vital and necessary. Failure to ensure
proper operation can lead to serious injury or death.
Checkouts must be performed as follows:
1) By a designated person at every power-up of the MINI-SCREEN System
(use checkout procedure 6.3, page 44),
2) By a qualified person following the correction of every lockout condition
(use checkout procedure 6.3, page 44),
3) By a designated person at every shift change or machine setup change (use
checkout procedure 6.3, page 44),
4) By a qualified person semi-annually (every 6 months) following installation
of the MINI-SCREEN System (use checkout procedure 6.4, page 45).
32
WARNING. . .
The Banner MINI-SCREEN
System can do the job for
which it was designed only if
it and the guarded machine are operating
properly, both separately and together. It
is your responsibility to verify this, on a
regular basis, as instructed in Section
4.2 and Section 6.
!
If the MINI-SCREEN System and the
guarded machine do not perform exactly
as outlined in the checkout procedures, the
cause of the problem must be found and
corrected before the system is put back
into service. Failure to correct such
problems can result in serious bodily
injury or death.
Operating Instructions
4.3 Normal Operation
Power-up
If the Auto Power-up feature is "on" when ac power is applied to the System,
the controller performs a system checkout and resets itself, without the need
for a key reset. If the Auto Power-up feature is "off" when ac power is
applied to the MINI-SCREEN System, it is normal for it to "power up" into
a lockout condition. To prepare the MINI-SCREEN System for operation
after a "power-up" lockout, the designated person must perform a key reset:
a) Turn the key to the RESET position (yellow LED goes "on" steadily).
Wait at least one-half second, then
b) Turn the key to the RUN position.
If the defined area is clear, the green* and yellow LEDs will go "on" (red
LED goes "off").
If the emitter and receiver are misaligned, the red LED will come "on". The
yellow LED will single-flash at a rate that indicates the relative number of
light beams established.
If the defined area is blocked and the emitter and receiver are in alignment,
the red LED will come "on", and the yellow LED will single-flash at a rate
that indicates the relative number of light beams established.
The green and yellow LEDs should be "on" steadily*. Now perform checkout procedure 6.2 on page 42.
Floating Blanking Operation
With floating blanking "on", objects of up to 0.8 inch (20 mm) in cross
section may enter the defined area at any point without causing a "trip"
condition (see Section 2.1). With floating blanking "on", the minimum
object sensitivity is increased to 1.75 inches (44 mm).
The use of floating blanking increases the Penetration Depth Factor (Dpf)
and also, therefore, the separation distance required between the defined area
and the closest machine danger point. If the separation distance was calculated on the basis of no floating blanking and you later begin to use floating
blanking, OSHA regulations require the separation distance to be increased
accordingly. See Section 3.2.1.
Upon power-up (and also at every shift change or machine setup change),
checkout procedure 6.3 on page 44 must be performed.
* If floating blanking is "on", the green LED will be flashing.
33
Troubleshooting & Maintenance
5. Troubleshooting and Maintenance
5.1 Troubleshooting Lockout Conditions
A MINI-SCREEN System lockout condition occurs:
1) Routinely upon MINI-SCREEN System "power-up" (unless Auto Powerup is "on", see Section 4.3),
2) If power to the MINI-SCREEN System is interrupted, unless Auto
Power-up is "on",
3) If the control box key switch is in the RESET position, at power-up
(with auto power-up "on"), or if the key switch is switched to RESET
while the system is in the RUN mode,
4) If an FSD (Final Switching Device) relay does not "drop out" within its
specified time,
5) If the SSD (Secondary Switching Device) relay has de-energized,
6) If the controller module switch settings are inconsistent with each other
or are changed while the system is in RUN mode,
7) If the self-checking circuits of the microprocessor detect a component
failure within the MINI-SCREEN System itself.
A lockout condition causes all output relays (FSD1, FSD2, and SSD) plus the
auxiliary monitor relay to open, shutting down the MPCEs and MSCE of the
guarded machine. A lockout condition resulting from an internal system
fault is indicated by the red status LED (only) flashing.
Power-up/power interrupt lockouts (Auto Power-up "off", conditions #1 or 2
above, yellow LED only double-flashing) are normal and require a key reset
for operation to continue.
Use the following procedure to resume operation after a power interruption
(condition #2):
a) Turn the key to the RESET position (yellow Status Indicator LED
should light) and wait at least one-half second, then
b) Turn the key to the RUN position:
If defined area is clear and the emitter and receiver are properly
aligned, the green and yellow LEDs will light.
If the lockout condition was due to a momentary power interruption that has
been corrected, the MINI-SCREEN System will now operate normally.
Upon recovery from a power interruption, checkout procedure 6.3 on page
44 must be performed.
34
WARNING. . .
Power failures or other
MINI-SCREEN System
lockout conditions should
always be investigated immediately
by a qualified person. With the
exception of lockout conditions #1
and #2 (left), lockout is a positive
indication of a problem and should be
investigated at once. Attempts to
operate machinery by bypassing the
MINI-SCREEN System are dangerous
and could result in serious bodily
injury or death.
!
CAUTION. . .
Dangerous voltages are
present inside the MINISCREEN System control
box whenever ac power to the system
and/or machine control elements is "on".
Exercise extreme caution whenever
the control box cover is open and ac
voltage is or may be present!
Troubleshooting & Maintenance
If the Status Indicator LEDs will not operate, the lockout condition is due
to another cause (conditions #3-7). In this case, the qualified person must
note the state of the Diagnostic Indicator LEDs (refer to Fig. 24, below). If
one or more of the red Diagnostic Indicator LEDs is "on", the cause of the
lockout condition is within the MINI-SCREEN System. The MINI-SCREEN
System will not operate if its self-checking circuits have detected an internal
problem. Take the corrective measure(s) shown in Figure 24 for the listed
Error Number and related Problem. If further assistance is required, contact
your Banner field service engineer or the factory Applications Engineering
Department.
If no Diagnostic Indicator LEDs are "on", power to the system may have
been lost. The green LED on the power supply board (see Figure 20, page
25) indicates the presence (LED "on") or absence (LED "off") of dc power
at the power supply board. It is possible for power to be present at the
input of the power supply even if the dc power LED is "off". Exercise care.
A shock hazard may exist under these conditions.
Very carefully check for voltage across the L and N (or + and -)
terminals of wiring barrier TB1. If voltage is not present at L and N,
power to the MINI-SCREEN System has been lost, and the cause is outside
the system. Check for 12V dc at connector block TB3. If 12V dc is not
present there, turn off the power to the control box and check the fuse. If the
fuse is bad, replace it (Section 5.3.1). If the fuse is good, and 12V dc is still
not present at TB3, a power supply failure has occurred.
Error No.
0
SYSTEM IS O.K.
1
RELAY SIGNAL ERROR
• Replace Relay Module
• Replace Controller
• Replace Power Supply
2
KEY INPUT ERROR
• Check Key Position
• Invalid Key Reset
• Replace Key Switch
3
CONTROLLER ERROR
• Replace Controller
4
RECEIVER ERROR
• Check Receiver Cable
• Replace Receiver
5
EMITTER ERROR
• Check Emitter Cable
• Replace Emitter
2
4
6
COMMUNICATION ERROR
• Check Cable Connections
• Observe Noise Indicator
• Replace Emitter/Receiver
1
2
4
7
DIP SWITCH ERROR
• Check Switch Settings
• Replace Controller
Diagnostic Indicator LEDs
Controller Module Assembly
1
Binary
Value
Red
Red
Red
Green
1
2
4
2
1
2
Notes:
Intermittently flashing #4 red
LED indicates presence of
optical or electrical "noise".
4
Green LED indicator is
always "ON" except when a
CPU failure is detected.
1
4
See Section 5.2 for further
information about electrical
and optical "noise".
ERROR TYPE / Action
8*
CPU ERROR
• Replace Controller
* Green LED off
Figure 24. Interpretation of Diagnostic Indicator LEDs
35
Troubleshooting & Maintenance
5.2 Effects of Electrical and Optical Noise
The MINI-SCREEN System is designed and manufactured to be highly
resistant to "noise" and to operate reliably in industrial settings. However,
serious electrical and/or optical "noise" may cause a random "trip" condition.
In very extreme cases, a "lockout" is possible. In order to minimize the
effects of transitory noise, the MINI-SCREEN System will respond to noise
only if the noise is detected on multiple consecutive scans. Red Diagnostic
Indicator LED #4 will flash to indicate the presence of electrical or optical
noise. This LED can be used to track down particularly offensive noise
sources (see sidebar). Simply observe the LED while shutting down or
isolating the suspected sources.
Whenever a remote accessory (such as the MGA-KSO-1 Remote Key
Switch) is used with the MINI-SCREEN System, use of shielded cable or a
separate grounded conduit is recommended.
Electrical and Optical Noise
Check the following if red Diagnostic
Indicator LED #4 is flashing:
• Poor connection between control box
and earth ground
• Drain wire of emitter and/or receiver
not connected to TB3 (see Figure 20)
• Sensor wires or output wires routed
too close to "noisy" wiring
• Optical interference from adjacent
light curtains or other photoelectrics
5.3 Servicing and Maintenance
WARNING. . .
5.3.1 Fuse Test and Replacement
Turn off ac power to the control box before proceding.
The MINI-SCREEN System control box fuse is located in a fuseholder on
the power supply board (see Figure 20, page 25). Remove the fuse from the
holder. Visually inspect the fuse and/or test its conductivity using an ohm
meter or a continuity tester. The fuse is a 3AG or 5x20 mm slow-blow type
(see specifications, page 53).
5.3.2 Controller Module and Relay Replacement
MINI-SCREEN Systems are designed for reliability. While replacement of
the controller module and relays is not normally required, these components
have been designed to be easily replaceable as a convenience to the customer.
To maintain control reliability, use only Banner-supplied replacement
relays with forced-guided contacts.
The controller module may be removed from the control box by gently
"rocking" the board to loosen it and then sliding the board out of the box. To
re-install the controller module, slide the board into place until snug, then
push it into place.
Servicing the MINISCREEN System while the
hazardous machinery is
operational could result in serious bodily
injury or death. You may be working
close to the hazardous area of your
machinery while servicing the MINISCREEN System. The machinery that
the MINI-SCREEN System is connected to must not be operating at any
time during this procedure.
!
CAUTION. . .
Electrical shock hazard
exists when the MINISCREEN System has power
applied to it and/or the machine control
elements and the control box door is open.
Use extreme caution to avoid electrical
shock during installation or servicing or
when the control box door is open to change
programming or observe the diagnostic
indicators. Always disconnect all power
from the MINI-SCREEN System and the
guarded machine before making any
wire connections or before replacing any
component.
The control box should be opened and/or
serviced only by a qualified person (see
Section 4.1).
36
Troubleshooting & Maintenance
WARNING. . .
!
If replacement parts are ever
required, always use only
genuine Banner-supplied
replacement parts (see page 55). Do not
attempt to substitute parts from another
manufacturer. To do so could impair the
operation of the MINI-SCREEN System
and could result in serious bodily injury
or death.
The output relays are configured on one module (see Figure 20, page 25). To
remove the module, remove the 3/8" nylon hex nuts and gently slide the
module out of the control box to disconnect it from the mother board. To
reinstall, press the module firmly and evenly onto its connector pins and
replace the hex nuts. Use care to avoid overtightening.
NOTE: Do not open the emitter or receiver housing. The emitter and
receiver contain no field-replaceable components. If repair is necessary,
return the unit to the factory. Do not attempt to repair an emitter or receiver
yourself.
If it ever becomes necessary to return any MINI-SCREEN
component to the factory, pack it carefully.
Damage that occurs in return shipping is not covered by warranty.
5.3.3 Cleaning
The MINI-SCREEN System control box is constructed of welded steel
with a black polyester paint finish, and is rated NEMA 13 (IP 64). It may be
cleaned using mild detergent or window cleaner and a soft cloth.
The MINI-SCREEN System emitter and receiver units are constructed of
aluminum with a black anodized finish and are rated NEMA 4, 13 (IP65).
Lens covers are acrylic. Emitters and receivers are best cleaned using mild
detergent or window cleaner and a soft cloth. Avoid cleaners containing
alcohol, as they may damage the acrylic lens covers.
37
Alignment and Checkout
6. Alignment and Checkout Procedures
Study each procedure from beginning to end to make sure that you
understand each step before you start. Refer all questions to the Banner
Applications Engineering Department (address, telephone, and FAX
information on page 2).
Section 6.1 is a procedure for optically aligning a MINI-SCREEN System.
Sections 6.2, 6.3, and 6.4 are periodic performance checkout procedures for
the MINI-SCREEN System, and are performed according to the schedule
given in Section 4.2.
WARNING. . .
6.1 MINI-SCREEN System Alignment
This alignment procedure begins with the assumption that the MINISCREEN System has been mechanically aligned as described in Section 3.3.
Follow the measures outlined below to maximize MINI-SCREEN System
excess gain. If there are reflective surfaces near the defined area, read
alignment step #5 (page 40) before proceding further, to prevent possible
reflection problems.
Only a qualified person may align the MINI-SCREEN System, as follows:
1) Turn off power to the MINI-SCREEN System and to the guarded machine. Leave power to the guarded machine "off",
Operation Mode
and power-up the MINI-SCREEN System only.
2) The MINI-SCREEN will power up into a powerup lockout condition (unless Auto Power-up is
"on"). Remove all obstructions from the defined
area and reset the MINI-SCREEN System as
follows:
a. Turn the control box front-panel key reset
switch to the RESET position,
b. Leave the key in the RESET position for at
least 1/2 second to allow time for internal
system checks, and
c. Turn the key switch to the RUN position.
Power Up
You may be working close to
the hazardous area of your
machinery while aligning the
MINI-SCREEN System. Aligning the
MINI-SCREEN System while the
hazardous machinery is operational could
result in serious bodily injury. The
machinery that the MINI-SCREEN
System is connected to must not be
operating at any time during the
alignment procedure of Section 6.1.
!
Normal Operation
Apply power to
Control Box
LOCKOUT STATE
Turn key to
"RESET" position
Key Reset
Turn key to
"RUN" position
Run
Defined
area
is clear
Symbol Definitions
Indicator "OFF"
Indicator "ON"
steadily
Indicator
"single-flashing"
Indicator
"double-flashing"
Defined
area
is blocked
(TRIP)
Internal
System
fault
(LOCKOUT)
Indicator Status
"BLOCKED" "CLEAR"
Red
Green
Red
Green
"RESET"
Yellow
Yellow
If Auto Power-up is ON when
power is applied to the MINISCREEN System, the controller
will perform an automatic RESET
after passing an internal system
checkout (key RESET not needed).
Auto Power-up is discussed in
Section 3.4.
Red
Green*
Yellow
*Green light will flash
if blanking is "on".
Red
Green
Yellow**
**Yellow LED will be "off" if the
system is powered up without
alignment
Red
Green
Yellow
NOTE:
A key RESET is always required to recover from a LOCKOUT condition.
Figure 25. Operating Status LED Conditions
38
Alignment and Checkout
3) Upon completion of the key RESET (step #2), the MINI-SCREEN will
indicate either a BLOCKED or a CLEAR condition:
a) A BLOCKED condition is indicated by the RED LED “on” steadily
and the YELLOW LED flashing at a rate which is proportional to the
number of beams which are aligned and unblocked. Go to step #4.
b) A CLEAR condition is indicated by the RED LED “off’, and the
GREEN and YELLOW LEDs “on” steadily. Further alignment is not
necessary.
4) A BLOCKED condition after RESET indicates that one or more of the
beams is misaligned or interrupted. When this occurs:
a) Check carefully for any obstructions in the path of the beams within
the defined area (the limits of which are indicated by yellow arrows
on the front face of the emitter and receiver - see Figure 15).
b) If the defined area is completely clear of obstructions, loosen the two
slotted hex head M4 bolts and the M30 nut on the cable end which
fasten the receiver to its mounting brackets. Slowly rotate the receiver first to the right and then to the left while watching the LED
indicators at the base of the receiver.
c) If the GREEN LED does not come “on”, regardless of angular
position of the receiver, then loosen the emitter and rotate both
relative to each other until the green LED comes “on”. Secure the
emitter and receiver in the center of the area of rotation where the
YELLOW and GREEN LEDs are “on” steadily.
d) If the GREEN LED still fails to come “on”, then re-check the sensor
mounting per the procedure in Section 3.3, and then re-align per this
alignment procedure.
5) "Trip test" the MINI-SCREEN System for object detection capability
using the test piece(s) supplied with the control box. To perform this
test, the key switch must be in the RUN position and the GREEN and
YELLOW LEDs (only) must be "on". Reset the system (key reset), if
necessary, to attain this condition.
Use the .75-inch diameter specified test piece, model STP-2, if the floating
blanking feature is “off”.
Use the 1.75-inch diameter specified test piece, model STP-3, if the floating
blanking feature is “on”. Both specified test pieces are supplied with the
control box.
39
Alignment and Checkout
Perform the trip test as follows:
Pass the appropriate specified test piece downward through the defined area at
three points (see Figure 26):
a) close to the receiver,
b) close to the emitter, and
c) midway between the emitter and receiver.
In each case, the RED and YELLOW indicators must come “on” and remain
“on” for as long as the test piece is within the defined area.
The GREEN and the YELLOW indicators must come “on” only when the test
piece is withdrawn from the defined area. If the GREEN indicator comes “on” at
any time when the test piece is within the defined area, the cause may be from
light reflected from the emitter to the receiver by a nearby reflective surface (see
Caution on page 18). If a reflective surface can be identified, move either the
defined area (i. e. - move the sensors) or the reflective surface. Be sure to
maintain at least the minimum required separation distance (see Section 3.2.1).
Alternately, take measures to reduce the reflectivity of the interfering surface
(i. e. by angling, painting, masking, etc.).
Figure 26. MINI-SCREEN Trip Test.
40
WARNING. . .
!
If the MINI-SCREEN
System does not respond
properly to the trip test, do
not attempt to use the System. If the
MINI-SCREEN System does not respond
properly to the trip test, it cannot be relied
upon to stop dangerous machine motion
when a person or object enters the defined
area. Serious bodily injury or death could
result.
Alignment and Checkout
41
Alignment and Checkout
6.2 Commissioning Checkout to be Performed at Time of Installation
This commissioning checkout must be done by a qualified person who possesses all of the manufacturer-provided information on
the MINI-SCREEN™ System and guarded machine and who, by possession of a recognized degree or certificate of professional
training or who, by extensive knowledge, training, or experience, has successfully demonstrated the ability to solve problems
relating to the installation, operation, and maintenance of optoelectronic machine guards.
A copy of checkout results should be kept in the employer's files: see OSHA 1910.217(e)(1).
The qualified person must:
1) Examine the guarded machine to verify that it is of a type and design that is compatible with the MINI-SCREEN System. See
page 2 for a list of misapplications.
2) Verify that the minimum separation distance from the closest danger point of the guarded machine to the defined area is not
less than the calculated distance (see figure 27, below).
3) Verify that access to the dangerous parts of the guarded machine is not possible from any direction not protected by the MINISCREEN System, hard guarding, or supplemental guarding, and verify that all supplemental guarding devices and hard
guarding are in place and operating properly.
4) Verify that it is not possible for a person to stand between the defined area and the dangerous parts of the guarded machine.
5) Examine the electrical wiring connections between the MINI-SCREEN output relays
and the guarded machine's control elements to verify that the requirements stated in Section 3.5.4.
WARNING. . .
A shock hazard exists while the control box door is open. Before continuing, verify that the control
box door is closed and latched.
The formula used to calculate the separation distance is:
Ds = K x (Ts + Tr ) + Dpf
!
where:
Ds = the separation distance;
K = the OSHA-recommended hand speed constant of 63 inches per second
(NOTE 1, below);
Ts = the overall stop time of the machine measured from the application of the
"stop" signal to the final ceasing of all motion (including stop times of all
relevant control elements, and measured at maximum machine velocity).
See NOTE 2, below.
Tr = the response time of the MINI-SCREEN System:
.048 seconds for 4.5 to 16 inch emitter/receiver,
.060 seconds for 20 to 32 inch emitter/receiver
.072 seconds for 36 to 48 inch emitter/receiver
Dpf=
WARNING. . .
Calculate the separation distance carefully. Failure to
maintain appropriate separation distance can result in
serious bodily injury or death.
the added distance due to depth penetration factor, as prescribed in OSHA
1910.217 and ANSI B11 standards:
Dpf = 1.6 inches with floating blanking off
Dpf = 5 inches with floating blanking on.
NOTES:
1) The OSHA-recommended hand-speed constant K has been determined by various
studies, and although these studies indicate speeds of 63 in/sec to over 100 in/sec, they are
not conclusive determinations. The employer should consider all factors, including the
physical ability of the operator, when determining the value of K to be used.
2) Ts is usually measured by a stop-time measuring device. If the specified machine stop time is used, we
recommend that at least 20% be added as a safety factor to account for clutch/brake system deterioration.
3) Use of floating blanking will always cause the required Ds to increase.
Figure 27. Caculation of DS
42
Alignment and Checkout
6) Test the effectiveness of the MINI-SCREEN System with power "on", as described in steps (a) through (d),
below. If floating blanking is NOT in use, use the 0.75" dia. test piece, model STP-2. If floating blanking is in
use, use the 1.75" dia. test piece, model STP-3.
a) Verify that the MINI-SCREEN System is in the RUN mode (green and yellow Status Indicator LEDs "on").
b) With the guarded machine at rest, pass the specified test piece (supplied with the control box) downward
through the defined area at three
points: close to the receiver
column, close to the emitter
column, and midway between
the emitter and receiver columns
(figure 28). In each case, the red
and yellow indicators (only)
should come "on" and remain
"on" for as long as the test piece
is within the defined area. When
the test piece is withdrawn from
the defined area, the green and
yellow indicators (only) should
come "on". If the green indicator comes "on" at any time when
the test piece is within the
defined area, check for reflective
surfaces, and do not continue
until the cause is discovered and
the situation is resolved.
c) Initiate machine motion of the
Figure 28. Use of Test Piece
guarded machine and, during
motion, insert the specified test
piece into the defined area (at right angles to the defined area). Do not attempt to insert the test piece into the
dangerous parts of the machine. Upon insertion of the test piece into the defined area at any time during
machine motion, the dangerous parts of the machine should come to a stop with no apparent delay. Upon
removal of the test piece from the defined area, verify that the machine does not automatically restart, and
that the initiation devices must be engaged to restart the machine.
d) With the guarded machine at rest, insert the specified test piece into the defined area and verify that it is
not possible for the guarded machine to be put into motion while the specified test piece is within the
defined area.
7) Remove electrical power to the MINI-SCREEN System. All output relays should immediately de-energize, and should
not be capable of being reactivated until power is re-applied and a key RESET is performed (unless the auto power-up
feature is "on").
8) Test the machine stopping response time using an instrument designed for that purpose to verify that it is the same or
less than the overall system response time specified by the machine manufacturer. (NOTE: Banner's Applications
Engineering Department can recommend a suitable instrument.)
WARNING. . .
!
If all of the above checks cannot be verified, the MINI-SCREEN System/guarded machine should not be used until the defect
or problem has been corrected (see Section 5). Attempts to use the guarded machine under such conditions could result in
serious bodily injury or death.
43
Alignment and Checkout - Periodic System Checks
6.3 To Be Performed at Every Power-up, Shift Change, and Machine Setup Change
Daily checkout and checkouts after tooling and machine changes must be performed by a designated person
appointed and identified in writing by the employer. During continuous machine run periods, this checkout must
be performed at intervals not to exceed 24 hours. A copy of checkout results should be kept on or near the machine: see OSHA 1910.217(e)(1).
The designated person must:
1) Verify that access to the dangerous parts of the guarded machine is not possible from any direction not
protected by the MINI-SCREEN System, hard guarding, or supplemental guarding, and verify that all
supplemental guarding devices and hard guarding are in place and operating properly.
2) Verify that the minimum separation distance from the closest danger point of the guarded machine to the
defined area is not less than the calculated distance. See Section 3.2.1.
3) Ensure that it is not possible for a person to stand between the defined area and the dangerous parts of the
guarded machine.
4) Verify that the MINI-SCREEN control box is latched and locked. The key or combination to the control box
latch lock should be in the possession of a qualified person.
WARNING. . .
A shock hazard exists while the control box door is open. Before continuing, verify that the control
box door is closed and latched.
5) Test the effectiveness of the MINI-SCREEN with power "on", as described in steps (a) through (d), below.
If floating blanking is in use, use the 1.75" dia. test piece, model STP-3; if floating blanking is NOT in use, use
the 0.75" dia. test piece, STP-2.
a) Verify that the MINI-SCREEN System is in the RUN mode (green and yellow Status Indicator LEDs "on").
See Section 4.3 for RESET procedure. Refer to Figure 28.
b) With the guarded machine at rest, pass the diameter specified test piece downward through the defined area at three
points: close to the receiver column, close to the emitter column, and midway between the emitter and receiver
columns. In each case, the red and yellow indicators (only) should come "on" and remain "on" for as long as the
test piece is within the defined area. When the test piece is withdrawn from the defined area, the green and yellow
indicators (only) should come on. If the green indicator comes "on" at any time when the test piece is within the
defined area, check for reflective surfaces (see Caution, page 45).
c) Initiate machine motion of the guarded machine and, during motion, insert the specified test piece into the defined
area (at right angles to the defined area). Do not attempt to insert the test piece into the dangerous parts of the
machine. Upon insertion of the test piece into the defined area at any time during machine motion, the dangerous
parts of the machine should come to a stop with no apparent delay. Upon removal of the test piece from the
defined area, verify that the machine does not automatically restart, and that the initiation devices must be engaged
to restart the machine.
d) With the guarded machine at rest, insert the specified test piece into the defined area and verify that it is not possible
for the guarded machine to be put into motion while the specified test piece is within the defined area.
6) Check carefully for external signs of damage to the MINI-SCREEN System, the guarded machine, and their electrical
wiring. Any damage found should be immediately reported to management.
44
Alignment and Checkout - Periodic System Checks
6.4 To Be Performed at Six Month Intervals (Semi-annually)
This semi-annual checkout must be done by a qualified person. A copy of test results should be kept on or near the machine.
WARNING. . .
A shock hazard exists while the control box door is open. Before continuing, verify that the control
box door is closed and latched.
The qualified person must:
1) Perform the Commissioning Checkout Procedure (Section 6.2). If any decrease in machine braking ability has
occurred, make the necessary clutch/brake repairs, readjust Ds appropriately, and re-perform the checkout
sequence of Section 6.2.
2) Examine and test the machine primary control elements (MPCEs) to ensure that they are functioning correctly
and are not in need of maintenance or replacement.
3) Inspect the guarded machine to ensure that there are no other mechanical or structural problems that would
prevent the machine from stopping or assuming an otherwise safe condition when signalled to do so by the
MINI-SCREEN System.
4) Examine and inspect the machine controls and connections to the MINI-SCREEN System to ensure that no
modifications have been made which adversely affect the system.
WARNING. . .
!
If all of the above checks cannot be verified, the MINI-SCREEN System/guarded machine should not be used until the defect
or problem has been corrected (see Section 5 ). Attempts to use the guarded machine under such conditions could result in
serious bodily injury or death.
WARNING – Reflective Surfaces. . .
!
It may be possible for a highly reflective surface (such as a shiny machine surface or a shiny workpiece) to reflect sensing
light around an object in the defined area, thus preventing that object from being detected. This potentially dangerous
condition is discovered using the "trip test" as described in the Initial Checkout Procedure (Section 3.5.3), the Alignment
Procedure (Section 6.1), and the periodic checkout procedures (Sections 6.2, 6.3, and 6.4).
When this condition is discovered, eliminate the problem reflection(s). If possible, relocate the sensors to move the curtain of light beams
away from the reflective surface(s). If relocating the sensors, be careful to retain at least the required separation distance (Section 3.2.1).
Otherwise, paint, mask, or roughen the interfering shiny surface to reduce its reflectivity. Use the trip test to verify that these changes
have eliminated the problem reflection(s).
NOTE: If the workpiece is especially reflective and comes close to the curtain, perform the trip test with the shiny workpiece in place.
45
Glossary
Glossary of Terms
Terms shown in italics in the definitions below are themselves defined elsewhere
in the glossary.
ANSI (American National Standards Institute): the American National
Standards Institute, is an association of industry representatives which
develops technical standards which include safety standards. These
standards comprise a consensus from a variety of industries on good practice
and design. ANSI standards relevant to application of the MINI-SCREEN
System include ANSI B11.1 (mechanical power presses), ANSI B11.2
(hydraulic power presses), and ANSI/RIA R15.06 (industrial robots and
robot systems). See page 56
Auxiliary monitor contact: a low load capacity, non safety-related relay
contact within the MINI-SCREEN System that follows the action of output
relays FSD1 and FSD2, and whose primary purpose is to communicate
system status to a PLC.
Auto Power-up: a feature of the MINI-SCREEN control box which, when
switched "on", enables the MINI-SCREEN to be powered up (and recover
from a power interruption) without the necessity of a key reset. When Auto
Power-up is "on", the MINI-SCREEN control box automatically begins
internal diagnostics upon power-up, and automatically resets the system if it
passes the diagnostic check. With Auto Power-up "off", a manual reset is
required.
Control reliability: A method of ensuring the integrity of performance of a
control system. Control circuits are designed and constructed so that a single
failure or fault within the system does not prevent the normal stopping action
from being applied to the machine when required, or does not create
unintended machine action, but does prevent initiation of successive machine
action until the failure is corrected.
Control box: contains the circuitry (internal to the MINI-SCREEN
System) that provides the proper voltages to the system, controls the
sensing units, receives and processes information from the sensing units and
the safety monitoring means, and provides outputs to the Final Switching
Devices (FSD1 and FSD2), the Secondary Switching Device (SSD), and the
Auxiliary Monitor Relay.
Controller module: a removeable printed circuit board, located within the
MINI-SCREEN System control box, which contains the microprocessors and
related electronic circuits.
46
Glossary
Defined area: the "curtain of light" generated by the MINI-SCREEN
System. When the defined area is interrupted by an opaque object of a
specified cross section, a trip condition results (see Figure 1).
Designated person: a person or persons identified and designated in
writing, by the employer, as being appropriately trained and qualified to
perform a specified checkout procedure.
Diverse redundancy: in diverse redundancy, the redundant components are
of different design, and any microprocessor programs used must run from
different instruction sets written by different programmers.
Emitter: the light-emitting component of the MINI-SCREEN System,
consisting of a row of synchronized modulated infrared LEDs. The emitter,
together with the receiver (placed opposite), creates a "curtain of light"
called the defined area.
Final switching device (FSD): the two output relays (FSD1 and FSD2) of
the MINI-SCREEN System which respond to an interruption of the defined
area by interrupting the circuit connecting them to the Machine Primary
Control Elements (MPCEs) of the guarded machine.
Floating blanking: a feature that allows the MINI-SCREEN System to be
programmed to produce an intentionally disabled light beam, within the
"curtain of light", which appears to move up and down ("float") in order to
allow the feeding of an object through the curtain (the defined area) at any
point along the length of the curtain without causing a trip condition.
The MINI-SCREEN System offers two-beam floating blanking which allows
multiple objects (usually workpiece material) up to 0.8 inch in cross section
to move through the defined area without tripping the final switching devices.
FMEA (Failure Mode and Effects Analysis): a testing procedure by
which potential failure modes in a system are analyzed to determine their
results or effects on the system. Component failure modes that produce
either no effect or a lockout condition are permitted; failures which cause an
unsafe condition (a failure to danger) are not. Banner MINI-SCREEN
Systems are extensively FMEA tested.
Forced-guided contacts: relay contacts that are mechanically linked
together, so that when the relay coil is energized or de-energized, all of the
linked contacts move together. If one set of contacts in the relay becomes
immobilized, no other contact of the same relay will be able to move. The
function of forced-guided contacts is to enable the safety circuit to check the
status of the relay. Forced-guided contacts are also known as "positiveguided contacts", "captive contacts", "locked contacts", or "safety relays".
MINI-SCREEN Systems use output relays with forced-guided contacts.
47
Glossary
Full-revolution devices: a method of machine drive arranged such that,
once started, the machine can only be stopped when the full cycle is
complete. Examples include positive key clutches and similar mechanisms.
Banner MINI-SCREEN Systems may not be used with full-revolution
devices.
Guarded machine: the machine whose point of operation is guarded by a
MINI-SCREEN System, and whose MPCEs and MSCE are connected to
relays FSD1, FSD2, and SSD of the MINI-SCREEN System.
Hard guarding: screens, bars, or other mechanical barriers that prevent a
person from reaching over, under, or around the defined area of an installed
MINI-SCREEN System and into the point of operation of the guarded
machine.
Internal lockout: a lockout condition that is due to an internal MINISCREEN System problem. Indicated by the red Status Indicator LED (only)
flashing. Requires the attention of a qualified person.
Key reset: a key-operated switch that is used to restore the Final Switching
Devices (FSDs) and Secondary Switching Device (SSD) to the ON state from
a lockout condition. Also refers to the act of using the switch to reset the
MINI-SCREEN System.
Lockout condition: a condition of the MINI-SCREEN System that is
automatically attained both: (1) when its ac supply mains are interrupted and
restored, and (2) in response to certain failure signals. When a lockout
condition occurs, the MINI-SCREEN System's FSD, SSD, and Auxiliary
Monitor Relay contacts open, and a key reset is required to return the system
to the RUN condition.
Machine primary control element (MPCE): an electrically powered
element, external to the MINI-SCREEN System, which directly controls the
machine's normal operating motion in such a way that it is last (in time) to
operate when motion is either initiated or arrested.
Machine response time: the time between the interruption by the Final
Switching Devices (FSDs) of the electrical supply to the Machine Primary
Control Element(s) (MPCEs) and the instant when the dangerous parts of the
machine reach a safe state by being brought to rest.
Machine secondary control element (MSCE): a machine control element
independent of the Machine Primary Control Element(s) (MPCEs), capable
of removing the source of power from the prime mover of the relevant
dangerous machine parts.
48
Glossary
Minimum object sensitivity: the minimum-diameter object that a light
curtain system can reliably detect. Objects of this diameter or greater will be
detected anywhere in the sensing field. A smaller object can pass undetected
through the curtain of light if it passes exactly midway between two adjacent
light beams. See also specified test piece.
MPCE monitor contacts: the normally open and normally closed contacts
of a guarded machine's MPCEs which are connected in series with the
power supply to the MINI-SCREEN System. Any inconsistency of action
between the two sets of monitor contacts will remove power from the
MINI-SCREEN System and cause a lockout condition. See Figure 23.
OFF state (of Final and Secondary Switching Devices): in the OFF state,
the output circuit is broken and interrupts the flow of current.
ON state (of Final and Secondary Switching Devices): in the ON state, the
output circuit is complete and permits the flow of current.
OSHA (Occupational Safety and Health Administration); OSHA CFR
1910.217: Occupational Safety and Health Administration (a US Federal
agency), Division of the US Department of Labor, that is responsible for the
regulation of workplace safety. OSHA regulations often follow ANSI
standards, including mechanical power press requirements (OSHA CFR
1910.217). These regulations become law when adopted by OSHA, and
must be followed. See page 56.
Output relays: the devices (within the MINI-SCREEN System) that are
used to initiate an emergency stop signal. The MINI-SCREEN System's
output relays (FSD1, FSD2, and SSD) use forced-guided contacts.
Point of operation: the area of the guarded machine where a workpiece is
positioned and a machine function (i.e. shearing, forming, punching,
assembling, welding, etc.) is performed upon it.
Power supply board: a removeable printed circuit board which contains the
power supply circuit and is located inside the MINI-SCREEN System
control box. A green LED on the power supply board lights whenever dc
power is present on the board.
Power-up/power interrupt lockout: a lockout condition of the
MINI-SCREEN System that, if Auto Power-up is "off", occurs when the
system is powered up (including upon power-up after a loss of power).
Indicated by the yellow Status Indicator LED (only) flashing. Requires a key
reset by a designated person.
49
Glossary
PSDI (Presence Sensing Device Initiation): an application in which a
presence sensing device is used to actually start the cycle of a machine. In a
typical situation, an operator manually positions a part in the machine for the
operation. When the operator moves out of the danger area, the presence
sensing device starts the machine (i.e. no start switch is used). The machine
cycle runs to completion, and the operator can then insert a new part and start
another cycle. The presence sensing device continually guards the machine.
Single break mode is used when the part is automatically ejected after the
machine operation. Double break mode is used when the part is both inserted
(to begin the operation) and removed (after the operation) by the operator.
PSDI is defined in OSHA CFR 1910.217. Banner MINI-SCREEN Systems
may not be used as PSDI devices on mechanical power presses, per OSHA
regulation 29 CFR 1910.217.
Qualified person: a person or persons who, by possession of a recognized
degree or certificate of professional training, or who, by extensive knowledge,
training, and experience, has successfully demonstrated the ability to solve
problems relating to the subject matter and work (ANSI B30.2-1983).
Receiver: the light-receiving component of the MINI-SCREEN System,
consisting of a row of synchronized phototransistors. The receiver, together
with the emitter (placed opposite), creates a "curtain of light" called the
defined area.
Secondary switching device (SSD): the output relay of the MINI-SCREEN
System which, in a lock-out condition, interrupts the circuit connecting it to
the Machine Secondary Control Element (MSCE).
Self-checking (circuitry): a circuit with the capability to electronically
verify that all of its own critical circuit components, along with their
redundant backups, are operating properly. Banner MINI-SCREEN Systems
are self-checking.
Separation distance: that distance, along the direction of approach,
between the outermost position at which the appropriate test piece will just
be detected and the nearest dangerous machine parts.
Single-stroke press: see full-revolution devices.
Specified test piece: an opaque object of the minimum cross section
required to place the MINI-SCREEN System into a trip condition when
inserted into any part of the defined area. The Banner-supplied specified test
pieces are .75" (19 mm) and 1.75" (44 mm) in diameter. See also minimum
object sensitivity.
50
Glossary
Supplemental guarding: additional electrosensitive safety device(s),
possibly employed along with hard guarding measures, used for the purpose
of preventing a person from reaching over, under, or around the defined area
of an installed MINI-SCREEN System and into the point of operation of the
guarded machine.
Trip condition: the response of the Final Switching Device (FSD) relays
when an object equal to or greater than the diameter of the specified test
piece enters the defined area. In a trip condition, FSD1 and FSD2
simultaneously de-energize and open their contacts. A trip condition clears
automatically when the object is removed from the defined area.
UL (Underwriters Laboratory): a third-party organization which tests a
manufacturer's products for compliance with appropriate Standards, electrical
and/or safety codes. Compliance is indicated by their listing mark on the
product.
51
Specifications
Product Specifications
Models
Defined Area
(inch) (mm)
Number of
Beams
Models
Defined Area
(inch)
(mm)
Number of
Beams
MSE424 emitter
MSE424 receiver
4.5
114
8
MSE2824 emitter
MSR2824 receiver
28
711
56
MSE824 emitter
MSR824 receiver
8.5
215
16
MSE3224 emitter
MSR3224 receiver
32
813
64
MSE1224 emitter
MSR1224 receiver
12
305
24
MSE3624 emitter
MSR3624 receiver
36
914
72
MSE1624 emitter
MSR1624 receiver
16
406
32
MSE4024 emitter
MSR4024 receiver
40
1016
80
MSE2024 emitter
MSR2024 receiver
20
508
40
MSE4424 emitter
MSR4424 receiver
44
1118
88
MSE2424 emitter
MSR2424 receiver
24
610
48
MSE4824 emitter
MSR4824 receiver
48
1219
96
Emitter/receiver separation:
6 inches (15 cm) to 30 feet (9 m).
Minimum object sensitivity:
0.75 inch (19 mm) with no floating blanking in use.
1.75 inches (44 mm) with floating blanking "on".
Response time
Less than 48 milliseconds using emitter/receiver with 4.5 to 16 inch defined area
Less than 60 milliseconds using emitter/receiver with 20 to 32 inch defined area
Less than 72 milliseconds using emitter/receiver with 36 to 48 inch defined area
Self-checking interval:
20 milliseconds
Ambient light immunity:
>10,000 lux at 5° angle of incidence
Strobe light immunity:
Totally immune to one Federal Signal Corp. "Fireball" model FB2PST
strobe.
Emitter elements:
Infrared LEDs; 880nm peak emission
Enclosures:
Emitter and receiver:
Size: see Figure 15, page 21
Material: Aluminum, with black anodized finish; acrylic lens cover
Rating: NEMA 4, 13 (IP 65)
Control box:
Size: see Figure 17, page 22
Material: Welded steel box with black polyester powder paint finish
Rating: NEMA 13 (IP 64)
Mounting hardware:
Emitter and receiver are each supplied with a pair of mounting brackets.
Mounting brackets are 11-gauge cold-rolled black zinc chromate finished
steel. A set of four vibration dampening mounts is also supplied.
Listed
Presence
Sensing
Device
10Y8
52
C
Specifications
Product Specifications
System power requirements:
Control box MSCA-1: 115V ac ±15% (50/60Hz), 55 VA;
Control box MSCB-1: 230V ac ±15% (50/60Hz), 55 VA;
Control box MSCT-1: 24V dc ±15%, 10% maximum ripple, 1.5 amps max.
Fuse rating:
Control box MSCA-1: 1/2 amp, 250V (3AG or 5x20 mm slow blow);
Control box MSCB-1: 1/4 amp, 250V (3AG or 5x20 mm slow blow);
Control box MSCT-1: 2 amp, 250V (3AG or 5x20 mm slow blow)
Status indicators:
(on control box and receiver)
Red
= BLOCKED
Green = CLEAR
Yellow = RESET
ALIGNMENT
Flashing red = LOCKOUT
Flashing green = BLANKING "on"
Double-flashing yellow = waiting for
power-up manual key reset
Single-flashing yellow = alignment indicator:
flash rate increases with the number of sensing
beams "made"; solid yellow when aligned and
defined area is clear.
Emitter has green LED to indicate power"on".
Diagnostic indicators:
Four LEDs indicate 8 system status conditions (see Fig. 24, page 35).
Diagnostic LEDs are visible through a window in the control box cover.
Controls and adjustments:
Keyed RESET of system lockout conditions
BLANKING selection switches
AUTO POWER UP on-off switches
Test input:
Terminals must be closed for a minimum of 0.05 seconds in order to
guarantee a test input signal. The switching device used must be capable of
switching 15-50V dc at 20 to 100 mA.
Auxiliary monitor relay:
Reed relay; 125V ac or dc max., 500 mA. max.
(10VA maximum, resistive load)
Output configuration:
(FSD1, FSD2, and SSD)
Forced-guided contact relays, 250V ac max., 4 amps max. (resistive load).
Mechanical life 10,000,000 operations (minimum). Electrical life (at
full rated load) 100,000 operations (typical). Arc suppression is
recommended when switching inductive loads. See Figure 23, page 30.
Operating temperature:
0 to +50°C (+32 to 122°F)
Relative humidity:
95% maximum (non-condensing)
FMEA tested:
(Failure Mode and Effects Analysis)
Per requirements of proposed first edition of UL 491 Standard and
BS6491.
Cables:
NOTE: Use only Banner cables, which incorporate a "twisted pair" for
noise immunity on RS485 data communication lines. Use of other cables
can result in "nuisance" lockouts. Emitter and receiver cables are ordered
separately. Banner 5-conductor shielded cables have a straight QD (Quick
Disconnect) connector molded onto the sensor end. Cables measure .32inch
(8,1 mm) in diameter, and are shielded and PVC-jacketed. Conductors are
20-gauge. Two liquid-tight cable gland/strain relief fittings are supplied
with each control box to admit the emitter and receiver cables through the
selected knockouts on the control box wall. Emitter and receiver cable
lengths may not exceed 50 feet (each). See Cables, page 54. See cable and
sensor drawing, page 22 .
53
Models and Accessories
Ordering Information
MINI-SCREEN Systems are sold as kits (below, right) which include a control box, an emitter and receiver of equal length, emitter and
receiver mounting hardware, and two quick-disconnect cables. Cables are interchangeable between the emitter and the receiver. Components are also available separately (below, left).
MINI-SCREEN Components
MINI-SCREEN System Kits
Emitter/receiver
Models
Height of
Defined Area
Number of
Light Beams
Part
Number
MSE424 emitter
MSR424 receiver
4.5 in. (114 mm)
8
37444
37445
MSE824 emitter
MSR824 receiver
8.5 in. (215 mm)
16
37446
37447
MSE1224 emitter
MSR1224 receiver
12 in. (305 mm)
24
37448
37449
MSE1624 emitter
MSR1624 receiver
16 in. (406 mm)
32
37450
37451
MSE2024 emitter
MSR2024 receiver
20 in. (508 mm)
40
37452
37453
MSE2424 emitter
MSR2424 receiver
24 in. (610 mm)
48
37454
37455
MSE2824 emitter
MSR2824 receiver
28 in. (711 mm)
56
37456
37457
MSE3224 emitter
MSR3224 receiver
32 in. (813 mm)
64
37458
37459
MSE3624 emitter
MSR3624 receiver
36 in. (914 mm)
72
37460
37461
MSE4024 emitter
MSR4024 receiver
40 in. (1016 mm)
80
37462
37463
MSE4424 emitter
MSR4424 receiver
44 in. (1118 mm)
88
37464
37465
MSE4824 emitter
MSR4824 receiver
48 in. (1219 mm)
96
37466
37467
Control Boxes
MSCA-1
MSCB-1
MSCT-1
115 V ac control box
(One per system)
230 V ac control box
(One per system)
24 V dc control box
(One per system)
P/N
w/(2) 25-ft
cables
P/N
w/(1) 15 &
(1) 25-ft cable
P/N
4.5”
8.5”
12”
16”
20”
24”
28”
32”
36”
40”
44”
48”
MSKA424C1
MSKA824C1
MSKA1224C1
MSKA1624C1
MSKA2024C1
MSKA2424C1
MSKA2824C1
MSKA3224C1
MSKA3624C1
MSKA4024C1
MSKA4424C1
MSKA4824C1
41100
41101
41102
41103
41104
41105
41106
41107
41108
41109
41110
41111
MSKA424C2
MSKA824C2
MSKA1224C2
MSKA1624C2
MSKA2024C2
MSKA2424C2
MSKA2824C2
MSKA3224C2
MSKA3624C2
MSKA4024C2
MSKA4424C2
MSKA4824C2
41112
41113
41114
41115
41116
41117
41118
41119
41120
41121
41122
41123
MSKA424C3
MSKA824C3
MSKA1224C3
MSKA1624C3
MSKA2024C3
MSKA2424C3
MSKA2824C3
MSKA3224C3
MSKA3624C3
MSKA4024C3
MSKA4424C3
MSKA4824C3
41124
41125
41126
41127
41128
41129
41130
41131
41132
41133
41134
41135
Kits with 230 V ac Control Box (model MSCB-1)
Array
Length
w/(2) 15-ft
cables
P/N
w/(2) 25-ft
cables
P/N
w/(1) 15 &
(1) 25-ft cable
P/N
4.5”
8.5”
12”
16”
20”
24”
28”
32”
36”
40”
44”
48”
MSKB424C1
MSKB824C1
MSKB1224C1
MSKB1624C1
MSKB2024C1
MSKB2424C1
MSKB2824C1
MSKB3224C1
MSKB3624C1
MSKB4024C1
MSKB4424C1
MSKB4824C1
41136
41137
41138
41139
41140
41141
41142
41143
41144
41145
41146
41147
MSKB424C2
MSKB824C2
MSKB1224C2
MSKB1624C2
MSKB2024C2
MSKB2424C2
MSKB2824C2
MSKB3224C2
MSKB3624C2
MSKB4024C2
MSKB4424C2
MSKB4824C2
41148
41149
41150
41151
41152
41153
41154
41155
41156
41157
41158
41159
MSKB424C3
MSKB824C3
MSKB1224C3
MSKB1624C3
MSKB2024C3
MSKB2424C3
MSKB2824C3
MSKB3224C3
MSKB3624C3
MSKB4024C3
MSKB4424C3
MSKB4824C3
41160
41161
41162
41163
41164
41165
41166
41167
41168
41169
41170
41171
Kits with 24 V dc Control Box (model MSCT-1)
37932
Array
Length
w/(2) 15-ft
cables
P/N
w/(2) 25-ft
cables
P/N
w/(1) 15 &
(1) 25-ft cable
P/N
43536
4.5”
8.5”
12”
16”
20”
24”
28”
32”
36”
40”
44”
48”
MSKT424C1
MSKT824C1
MSKT1224C1
MSKT1624C1
MSKT2024C1
MSKT2424C1
MSKT2824C1
MSKT3224C1
MSKT3624C1
MSKT4024C1
MSKT4424C1
MSKT4824C1
43300
43301
43302
43303
43304
43305
43306
43307
43308
43309
43310
43311
MSKT424C2
MSKT824C2
MSKT1224C2
MSKT1624C2
MSKT2024C2
MSKT2424C2
MSKT2824C2
MSKT3224C2
MSKT3624C2
MSKT4024C2
MSKT4424C2
MSKT4824C2
43312
43313
43314
43315
43316
43317
43318
43319
43320
43321
43322
43323
MSKT424C3
MSKT824C3
MSKT1224C3
MSKT1624C3
MSKT2024C3
MSKT2424C3
MSKT2824C3
MSKT3224C3
MSKT3624C3
MSKT4024C3
MSKT4424C3
MSKT4824C3
43324
43325
43326
43327
43328
43329
43330
43331
43332
43333
43334
43335
QDC-515C
15' cable, straight
QD connector.
One cable per sensor.
37442
QDC-525C
25' cable, straight
QD connector.
One cable per sensor.
50' cable*, straight
QD connector.
One cable per sensor.
37443
37498
* Contact factory Applications Department for information
on cable lengths greater than 50 feet.
54
w/(2) 15-ft
cables
37931
Cables (2 required per system)
QDC-550C
Kits with 115 V ac Control Box (model MSCA-1)
Array
Length
For Yellow Emitters and Receivers:
The models listed are for black emitters and receivers. To order yellow
emitters and receivers, add "Y" at the end of the model number (e.g.
MSE3624 becomes MSE3624Y).
Models and Accessories
Ordering Information
Documentation
The following documentation is supplied with each MINI-SCREEN System Control Box.
Additional copies are available at no charge.
Instruction Manual for MINI-SCREEN Systems: order p/n 39022.
Checkout Procedure Card (Daily): order p/n 39020
Checkout Procedure Card (Semi-annual): order p/n 39021
Replacement Parts, MINI-SCREEN Systems
27850
28513
30140
39023
39024
39025
39026
39911
39027
39028
43738
39029
40091
MGA-GSA-1
MGA-K-1
MGA-KSO-1
MSA-KS-1
MSA-MH-1
MSA-RM-1
STP-2
STP-3
MSA-PSA-1
MSA-PSB-1
MSA-PST-1
MSAB-1
BA2MB
Ground strap, control box door
Replacement key
Key switch, only (no wires)
Key switch, pre-wired
Control box mounting hardware
Relay module
Specified test piece (.75" dia.)
Specified test piece (1.75" dia,)
Replacement power supply board (115V ac)
Replacement power supply board (230V ac)
Replacement power supply board (24V dc)
Microprocessor control module
Mounting hardware kit for one emitter or receiver
Warranty: Banner Engineering Corporation warrants its products to be free from defects for a period of one
year. Banner Engineering Corporation will repair or replace, free of charge, any product of its manufacture
found to be defective at the time it is returned to the factory during the warranty period. This warranty is
necessarily limited to the quality of materials and workmanship in MINI-SCREEN Systems as they are supplied
to the original purchaser. Proper installation, operation, and maintenance of the MINI-SCREEN System
becomes the responsibility of the user upon receipt of the system. This warranty does not cover damage or
liability for the improper application of the MINI-SCREEN System. This warranty is in lieu of any other
warranty either expressed or implied.
See also warranty-related return shipping information, page 37.
55
Safety Standards
Standards Applicable to MINI-SCREEN Systems
U.S. Federal Regulations Applicable to Use
of Safety Light Curtains
OSHA 29 CFR 1910.212
General Requirements for (guarding of)
All Machines
OSHA 29 CFR 1910.217
(Guarding of) Mechanical Power Presses
Address:
Superintendent of Documents
Government Printing Office
Washington, D.C. 20402-9371
Telephone: 202-783-3238
Part of:
Code of Federal Regulations
Title 29, Parts 1900 to 1910
ANSI B11 Standards: Standards Applicable to Use
of Safety Light Curtains
ANSI B11.1-1988
Mechanical Power Presses
ANSI B11.16-1988
Metal Powder Compacting Presses
ANSI B11.2-1982
Hydraulic Power Presses
ANSI B11.17-1982
Horizontal Extrusion Presses
ANSI B11.3-1982
Power Press Brakes
ANSI B11.18-1992
Machinery and Machine Systems for the
Processing of Coiled Strip, Sheet, and Plate
ANSI B11.4-1993
Shears
ANSI B11.5-1988
Iron Workers
ANSI B11.6-1984
Lathes
ANSI B11.7-1995
Cold Headers and Cold Formers
ANSI B11.19-1990
Performance Criteria for the Design,
Construction, Care, and Operation of
Safeguarding when Referenced by the
Other B11 Machine Tool Safety Standards
ANSI B11.20-1991
Manufacturing Systems/Cells
ANSI B11.8-1983
Drilling, Milling, and Boring Machines
ANSI/RIA 15.06
Safety Requirements for Industrial Robots
and Robot Systems
ANSI B11.9-1975
Grinding Machines
ANSI B11 Documents
ANSI B11.10-1990
Metal Sawing Machines
ANSI B11.11-1985
Gear Cutting Machines
ANSI B11.12-1983
Roll Forming and Roll Bending Machines
ANSI B11.13-1992
Single- and Multiple-Spindle Automatic Bar
and Chucking Machines
ANSI B11.14-1983
Coil Slitting Machines/Systems
ANSI B11.15-1984
Pipe, Tube, and Shape Bending Machines
56
American National Standards Institute
11 West 42nd Street
New York, NY 10036
-orSafety Director
National Machine Tool Builders Assn.
7901 Westpark Drive
McLean, VA 22102-4269
ANSI/RIA Documents
Obtain from ANSI (above) or:
Robotic Industries Association
900 Victors Way, P.O Box 3724
Ann Arbor, MI 48106
Telephone: 313-994-6088
Standards Applicable to
Design of Safety Light
Curtains
UL 491
The Standard for Power-operated
Machine Controls and Systems
Address:
Underwriters Laboratories Inc.
333 Pfingsten Road
Northbrook, IL 60062-2096
Telephone: 708-272-8800
BS 6491
General Requirements for Electro-sensitive
Safety Systems for Industrial Machines
Address:
British Standards Association
2 Park Street
London W1A 2BS
England
Telephone: 011-44-908-1166
Notes
Application / Installation Notes
57
Notes
Application / Installation Notes
58
Notes
Application / Installation Notes
59
Banner Engineering Corp.
9714 10th Avenue No.
Minneapolis, MN 55441
Telephone: (612) 544-3164
FAX (applications): (612) 544-3573
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