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Wintriss Shadow VI User Manual

Safety light curtain
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Shadow VI
®
Safety Light Curtain
1107200
Rev. E
July 2010
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone (800) 586-8324
Fax (978) 263-2048
PRINTED IN USA
DA46072
Tech Support Hotline
800-586-8324
8-5 EST
www.wintriss.com
®

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Summary of Contents for Wintriss Shadow VI

  • Page 1 ® Safety Light Curtain 1107200 Rev. E July 2010 Tech Support Hotline 800-586-8324 8-5 EST ® Wintriss Controls Group, LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone (800) 586-8324 Fax (978) 263-2048 www.wintriss.com PRINTED IN USA DA46072...
  • Page 2 Requirements You Must Meet When Installing and Using Shadow Safety Light Curtains DANGER FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID- STROKE OR MID-CYCLE • DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped at any point in its stroke or cycle.
  • Page 3 44) , and, as a result, all references to the button have been removed from the manual. • AC power is now grounded to the set screw terminal on the Shadow VI enclosure rather than to pin #3 on TB 1 (see page 51).
  • Page 4 Wintriss Product. We appreciate your business and want to do whatever we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are backed by an ironclad guarantee, international standards approvals, and unbeatable support. Whenever you need assistance or service, we back all our products with excellent spare parts inventories, training programs, and prompt repair service.

  • Page 5: Table Of Contents

    Using Mirrors with Shadows ......................36 Using Weld Shields.........................39 Mounting Shadow Light Curtains Upside Down................39 Avoiding Cross Talk When Mounting 2 Sets of Shadows .............39 Loosely Mounting Shadow VI Transmitter and Receiver ................40 Mounting the Control ..........................42 Shadow VI User Manual 1107200...
  • Page 6 S1 settings ............................60 S4 Settings ............................60 J12 Setting............................61 Plug in Connector and Replace Cover ....................61 Aligning and Tightening Down Shadow VI Components................61 Alignment Procedure ...........................62 Diagnostic Steps to Perform Before Using Shadow................63 No Power to Unit ..........................63 The Light Curtain Is in a "Reset Required" Condition..............63 If the Transmitter Has No Power or Is Not Functioning ..............63...
  • Page 7 Standard Enclosure Versus Optional Panel Mount ................115 Preparation for Mounting Shadow Using Your Enclosure..............115 About Shadow VI Panel Mount Labels .....................116 Appendix C – Installation of Shadow VI-WPC Control Board ..... 119 Mounting Dimensions and Required Clearance ..................119 About Shadow VI-WPC Control Board Labels.................120 Wiring Shadow VI optic heads to the board ..................124...
  • Page 8 Figure 2-3. Brackets for Shadow Light Curtains....................29 Figure 2-4. Shadow VI Optic Heads Mounting Dimensions................31 Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts) ............32 Figure 2-6. Transmitter and Receiver Properly Aligned ..................34 Figure 2-7. Using Laser Alignment Tool to Properly Align Shadow..............34 Figure 2-8.
  • Page 9 Figure 7. Wintriss Clutch/Brake Control Dual Shadow Wiring Figure 8. Wintriss Clutch/Brake Control Integrated Shadow VI Wiring Figure 9. Older Model Wintriss Clutch/Brake Control Shadow VI Wiring Figure 10. WPC 1000 Shadow VI and Cam Output Wiring Table of Contents...
  • Page 10 Appendix B, Shadow VI Panel Mount explains how to install Shadow VI as a panel mount. Mounting and "cutout" dimensions are provided. Appendix C, Installation of Shadow VI-WPC Control Board explains how to install, wire, and operate the optional Shadow VI-WPC control board assembly in conjunction with your Wintriss Clutch/Brake Control (WPC).
  • Page 11 Shadow VI User Manual 1107200 Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: DANGER A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
  • Page 12 Wintriss Controls freight prepaid, and which are, after examination, disclosed to the satisfaction of Wintriss to be defective. This warranty shall not apply to any equipment which has been subjected to improper installation, misuse, misapplication, negligence, accident, or unauthorized modification.

  • Page 13: Chapter 1 - Introduction To Shadow

    NOTICE USE EXCERPTS FROM SAFETY STANDARDS FOR REFERENCE ONLY Refer to the latest versions of the documents from which Wintriss has provided excerpts for your convenience. An excerpt from OSHA regulation 1910.217 appears in the appendix of this manual. Excerpts from the American National Standards Institute (ANSI) standards for safety devices are also included in Appendix A.

  • Page 14: Osha And Ansi Compliance

    Shadow safety light curtains provide excellent protection. Once properly installed, Shadow VI does not require additional adjustment, and no maintenance is required. You do not have to worry about personnel forgetting to close gates or replace barriers.

  • Page 15: Figure 1-1. Illustration Of Shadow Transmitter And Receiver

    Shadow VI User Manual 1107200 The cables join the control with the transmitter and receiver and are interchangeable between each optic head. These cables have connectors that plug into the optic head end and screw terminations that connect at the control end. They come in various lengths.

  • Page 16: How Shadow Works

    1107200 Shadow VI User Manual LED Indicators for cover latches curtain clear, floating window enabled, curtain blocked and reset required CURTAIN FLOATING STOP RESET CLEAR WINDOW SIGNAL REQUIRED enclosure keylock OPERATE RESET reset keyswitch (key pointed toward "operate" during normal...

  • Page 17: Figure 1-3. Showing Light Beams With Shadow Light Curtain

    Figure 1-3. Showing Light Beams with Shadow Light Curtain Shadow's transmitter and receiver are not "matched sets". In other words, a Shadow VI transmitter will work with any same-sized Shadow VI receiver. You mount the units on the machinery on either side of the hazardous area.

  • Page 18: Shadow And Control Reliability

    1107200 Shadow VI User Manual Because the receiver only accepts infrared light pulses of a certain duration in proper sequence, Shadow cannot be affected or fooled by other light sources. All other continuous light sources and even pulsed light sources are "tuned out." Therefore, the light curtain is not affected by normal lighting near the light curtain.

  • Page 19: Description Of Shadow Vi Indicators

    It is highly unlikely that the relay contacts will fail simultaneously. Description of Shadow VI indicators Shadow includes several indicators. Figure 1-1 shows the indicators on the transmitter and receiver, and Figure 1-2 illustrates the control.

  • Page 20: At The Control

    1107200 Shadow VI User Manual At the Control Four indicators appear on the front cover of the control and are clearly labeled. The green "curtain clear" indicator means that the light curtain is unobstructed and the machinery will be allowed to operate (the control relay contacts are held closed or in the unobstructed/ energized state).

  • Page 21: Shadows Are Easy To Maintain

    Shadow VI User Manual 1107200 Shadows Are Easy to Maintain No adjustment or maintenance is required. It continues working silently. You only need to replace fuses or relays as needed (described in Chapter 4). You should, however, clean the lens window(s) periodically if the working environment is particularly dusty, dirty, oily or smoky.

  • Page 22: Shadow Vi Features And Options

    1107200 Shadow VI User Manual Shadow VI Features and Options Shadow is designed for uncompromising safety and durability under real world conditions. The light curtain includes various features and options. Some of these are described next. The floating window feature provides a means for the random bypass of only one beam of the light curtain.

  • Page 23: Weld Shield Kit

    Shadow VI User Manual 1107200 alignment easier. By rotating the brackets 90° with respect to the head, they provide additional flexibility when mounting. Installing the universal mounts is covered in Chapter 2. Weld Shield Kit Shadow's operation is not affected by smoke, dirt, or oil found in a typical industrial environment.

  • Page 24: Table 1-1. Shadow Vi Specifications

    1107200 Shadow VI User Manual Table 1-1. Shadow VI Specifications WARNING INDICATOR OUTPUTS NOT SUITABLE FOR SAFETY USE • DO NOT use the indicator outputs listed in the specifications table for personnel protection. They cannot be used to stop the machinery.
  • Page 25 Shadow VI User Manual 1107200 Shock testing 50g, 11ms pulse per MIL-STD-810 C, Method 516, Procedure I (applies to all three axes). Operating Temperature - 4° F to 122° F (-20° to 50° C). Inputs Power 115-230 VAC (DC available) 50-60 Hz;...

  • Page 26: Table 1-2. Shadow Options And Functions

    Laser Alignment Tool For optimum alignment; uses 3V Lithium battery. Interchangeability Transmitter and receiver are not matched sets; Shadow VI transmitter can be used with Shadow VI receiver of same. page 14 Chapter 1 Introduction to Shadow VI Safety Light Curtain...

  • Page 27: Chapter 2 - Installation And Checkout

    Failure to comply with these instructions will result in death or serious injury. Installing Shadow is a straightforward procedure. You must proceed carefully, however, since the Shadow VI light curtain is a safety device which protects press operators and other personnel.

  • Page 28: Installation Overview

    NEMA 4/IP65 enclosure, suitably rated conduit hubs must be used on all unused holes in the control enclosure to maintain proper NEMA 4/IP65 rating. Ensuring that the Shadow light curtains are working properly Perform the checkout sequence after installation to ensure that Shadow VI is working properly. page 16...

  • Page 29: Installation Procedure

    • Connecting stop circuits to the control • Making settings inside the control • Aligning and tightening down Shadow VI components • Diagnostic steps to perform before Shadow operation • Final checkout sequence It is a good idea to read over the complete installation procedure before starting. This will guide you about the materials and techniques required for making and positioning mounting brackets and aligning Shadow VI heads.

  • Page 30: Calculating The Safety Distance

    1107200 Shadow VI User Manual Calculating the Safety Distance DANGER INCORRECT SAFETY DISTANCE • Calculate the safety distance carefully according to the instructions below, and mount your light curtain heads at least this distance from the hazardous area. • Mount your light curtain heads at least 7.5” (191 mm) from the hazardous area, regardless of the calculated safety distance.

  • Page 31: Osha And Ansi Requirements

    It must be calculated using a precise formula. This ensures that Shadow VI can send the stop signal to the press, and the press will stop, before the operator's hand reaches the hazardous area.

  • Page 32: The Osha Safety Distance Formula

    Failure to comply with these instructions will result in death or serious injury. The OSHA safety distance formula as specified in OSHA regulation 1910.217 is explained below. As noted earlier, Wintriss recommends you use the American National Standards Institute formula for calculating safety distance because it contains more factors that allow you to calculate the safety distance more precisely.

  • Page 33: The Ansi Safety Distance Formula

    Next we will add in Shadow VI response time and the braking percentage factor. Let's say our brakes are new. Then we will add 20% additional time to the stop time measurement (.20 x .190 = .038). We also add response time of the 60”...
  • Page 34 T r is the response time of the light curtain. Response time for the Shadow VI is 30 to 40 ms (30 ms for 6" to 24” models, 35 for 30” to 48” models and 40 ms for the 60” model).
  • Page 35 D pf is related to the object sensitivity. Object sensitivity is the smallest diameter object that Shadow VI will detect anywhere in its field. Object sensitivity (S) for Shadow VI is 1.25" (3.2 cm), with beam centers of "...

  • Page 36: Perimeter Guarding

    Remember, the minimum size that Shadow VI can sense is an object 1.25" (3.17 cm) in diameter. Anything smaller might fit between two light beams. This diameter (1.25") is called the object sensitivity of the light curtain.

  • Page 37: Pass-Through Protection

    A recommendation would be to install a second set of light curtains at waist height mounted horizontally between the vertical light curtain and the hazard. See the illustration below. With Shadow VI, two sets of optic heads can be wired to the same control box. pinch point...

  • Page 38: Height Considerations

    Once you have determined the correct safety distance, you must select the proper curtain height. Shadow VI comes in sizes ranging from 6" to 60". Shadow must be installed so it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the press without being detected.

  • Page 39: Mounting Location Requirements

    When choosing the mounting location, you must make sure the location meets these requirements: 1. Shadow VI heads must always be installed so that it is impossible for anyone to reach over, under, or around the light curtain and into the hazardous area of the press without being detected.

  • Page 40: How To Design And Mount Brackets Or Floor Stands

    Shadow light curtains from the bed or platform of the press. On gap frame presses, do not attach the top Shadow VI bracket to the press frame and the bottom bracket to the bolster. The upper portion of the press will deflect (pull away) from the bolster during the work portion of the stroke.

  • Page 41: Figure 2-3. Brackets For Shadow Light Curtains

    Shadow VI User Manual 1107200 L-shaped brackets with side supports for rigidity Box type brackets Long angle iron type of bracket. Here one unit mounts right on one large bracket. Wedge-shaped bracket good for mounting units to bed or wall of machinery Figure 2-3.

  • Page 42: Table 2-1. Light Curtain Dimensions: Inches (Cm)

    1107200 Shadow VI User Manual Table 2-1. Light Curtain Dimensions: inches (cm) * see Figure 2-4 Size 6 (15) 7.75 (19.7) 9.5 (24.1) 11 (27.9) 12 (30) 13.75 (34.9) 15.5 (39.4) 17 (43.2) 18 (45) 19.75 (50.2) 21.5 (54.6) 23 (58.4) 24 (61) 25.75 (65.4)

  • Page 43: Figure 2-4. Shadow Vi Optic Heads Mounting Dimensions

    .5 (1.3) (3.8) location beam blanking window 2.34 (1.9) (5.9) Table 3 (7.6) (min. req'd heads cable allowance) ** Use 1/4-20 bolts for mounting (3.8) Figure 2-4. Shadow VI Optic Heads Mounting Dimensions Installation and Checkout Chapter 2 page 31...

  • Page 44: Figure 2-5. Top Views Of Shadow Vi Optic Heads (Universal Mounts)

    Shadow VI User Manual 3.25 30° (82,6) (38,1) 30 ° 2.55 (64,8) (38,1) 1.05 (26,7) Dimensions: inches 2.10 (53,3) (mm) 2.75 (69,9) Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts) page 32 Chapter 2 Installation and Checkout...

  • Page 45: Alignment Considerations

    Shadow optic heads must be attached at both ends so that vibration does not cause the units to go out of alignment. It is all right to mount Shadow VI brackets to your press at one end only (to the bolster of a press, for instance). However, the bracket must be designed so that the shock mounts supplied with your heads can be placed between the head and the bracket.

  • Page 46: Figure 2-6. Transmitter And Receiver Properly Aligned

    1107200 Shadow VI User Manual If PT is in funnel-shaped light path, Shadow is in funnel- alignment, even if optic shaped heads are not phototransistor light path (PT) perfectly aligned. receiver transmitter light beams plane of alignment Figure 2-6. Transmitter and Receiver Properly Aligned...

  • Page 47: Maximum Openings For Side Guards

    When mounting your brackets you can draw a leveling line using the center of the bracket holes as the end points (see the next illustration). When you mount the Shadow VI flanges onto the bracket holes, the Shadow light curtains will be aligned (or at least very close).

  • Page 48: Using Mirrors With Shadows

    Figure 2-10. You do not have to arrange the Shadow light curtains and mirrors in a rectangle as shown, however. You can adjust the mirrors to reflect light from the Shadow VI transmitter at other angles besides right angles. Shadow VI aligns in the same way using mirrors as without them. Even...

  • Page 49: Figure 2-9. Shadow Vi Mirror Dimensions

    21.38 23.88 24.64 24” 27.38 29.88 30.64 30” 33.38 35.88 36.64 36” 39.38 41.88 42.64 42” 45.38 47.88 48.64 48” 51.38 53.88 54.64 60” 63.38 65.88 66.64 Figure 2-9. Shadow VI Mirror Dimensions Installation and Checkout Chapter 2 page 37...

  • Page 50: Figure 2-10. Representation Of Shadow With Mirrors For Three-Sided Guarding

    1107200 Shadow VI User Manual corner receiver mirror light beams corner transmitter mirror Figure 2-10. Representation of Shadow with Mirrors for Three-sided Guarding Use of Laser Alignment Tool Is Useful During Mirror Installation page 38 Chapter 2 Installation and Checkout...

  • Page 51: Using Weld Shields

    1107200 Using Weld Shields The operation of Shadow VI is not affected by smoke, dirt, or oil found in a typical industrial environment. In a more severe environment, you may need to install clear plastic shields that provide protection from weld splatter and other hazards.

  • Page 52: Loosely Mounting Shadow Vi Transmitter And Receiver

    Leave the Shadow VI heads loose on their mounting brackets so that you can properly determine wiring length and conduit required. You will align and tighten the heads later. Shock mounts are provided to help protect the optic heads of your Shadow VI from damage due to shock or vibration.

  • Page 53: Figure 2-12. Mounting An Optic Head With Shock Mounts

    Shadow VI User Manual 1107200 Lock washer Shock mount (4 places) (4 places) (4 places) Universal mounting bracket Optic head (transmitter or receiver) Mounting surface Figure 2-12. Mounting an Optic Head with Shock Mounts Installation and Checkout Chapter 2 page 41...

  • Page 54: Mounting The Control

    1107200 Shadow VI User Manual Mounting the Control DANGER CONTROL AFFECTS LIGHT CURTAIN OPERATION Install the light curtain control in a location where access to it will not affect the operation of the light curtain. Failure to comply with these instructions will result in death or serious injury.

  • Page 55: Figure 2-13. Shadow Vi Control Enclosure Mounting Dimensions

    4 places CURTAIN FLOATING STOP RESET CLEAR WINDOW SIGNAL REQUIRED 9.00 (22.86) 9.75 (24.76) OPERATE RESET LIGHT CURTAIN 5.00 (12.7) typical, 2 places 7.00 (17.78) Figure 2-13. Shadow VI Control Enclosure Mounting Dimensions Installation and Checkout Chapter 2 page 43...

  • Page 56: Figure 2-14. Location Of Components, Shadow Vi Control

    MPCE2 LED TRANSMITTER 2 JUMPER RESET DISABLE MPCE1 LED RESET ON RESET ON INTERRUPT TRANSMITTER FLOATING WINDOW ACTIVE STAT=GRN OPTIONS Figure 2-14. Location of Components, Shadow VI Control (Important components shown and labeled) page 44 Chapter 2 Installation and Checkout...

  • Page 57: Wiring The Transmitter And Receiver To The Control

    Shadow VI User Manual 1107200 Wiring the Transmitter and Receiver to the Control DANGER FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID-STROKE OR MID-CYCLE • DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped at any point in its stroke or cycle.

  • Page 58: Terminating Shields Of The Head Cables

    1107200 Shadow VI User Manual The instructions below describe how to wire the Shadow transmitter and receiver to the control. Terminating Shields of the Head Cables, next section Connecting the Head Cables to the Control, page 47 If You Have a Second Set of Shadow Optic Heads, page 49 Terminating Shields of the Head Cables The shields of the head cables must be terminated close to their entry into the control box.

  • Page 59: Connecting The Head Cables To The Control

    2. Run the cables through separate " flexible, liquid-tight conduits from the Shadow VI transmitter and receiver to the knockouts at the bottom of the control (receiver should go into right front knockout and transmitter into the center). Because the control enclosure is rated NEMA 2/IP52, you must use conduit of the same rating and make proper connections to ensure suitable protection with the enclosure.

  • Page 60: Table 2-3. Connecting Light Curtain Receiver Head To Tb2 In Controller

    1107200 Shadow VI User Manual To connect a wire, find the correct terminal and loosen the screw over it by turning it counterclockwise. Strip the correct wire for this terminal 1/4" (6.4 mm) from end. Insert bare wire into the terminal 90% of the way. Tighten the screw. The metal tooth inside the terminal will clamp down on the bare wire for a tight connection.

  • Page 61: If You Have A Second Set Of Shadow Optic Heads

    Shadow VI User Manual 1107200 Table 2-4. Connecting Light Curtain Receiver Head to TB3 in Controller Set #1 Heads to Upper Level; Set #2 Heads to Lower Level XMTR TB3 Wire color Terminal signal Pin #1 orange Pin #2 blue...

  • Page 62: Connecting Ac Wiring To The Control

    Wiring is a straightforward and simple procedure. The control is wired to a 115 VAC 50-60 Hz single phase power source. (Note: Shadow VI can also be used with 230 VAC, 50 Hz. Step 4 below explains how to switch to 230 VAC.) Follow these wiring guidelines: •...

  • Page 63: Figure 2-17. Setting Voltage Selector Switch S2

    Shadow VI User Manual 1107200 3. Locate the 115V-230V voltage selector switch (S2) on the control board. It is located just below TB1. If your AC power is 115V, check to see that "115V" is displayed in the switch cavity. If your AC power is 230V, push the handle down.

  • Page 64: Connecting Stop Circuits To The Control

    1107200 Shadow VI User Manual 7. Leave a service loop at the control to allow for later adjustment of the conduit. Cut the wires as necessary. Proceed to the next section "Connecting Stop Circuits to the Control". Do not connect wires to AC power source until you are done with all other installation procedures.
  • Page 65 Shadow VI User Manual 1107200 NOTICE LOCKOUT MAY NOT BE REQUIRED If light curtains are installed so they are active in all press operating modes, it may not be necessary to lock out the press during routine die changes. Refer to the relevant safety standards for more details.

  • Page 66: Figure 2-19. Relays Wired To Emergency Stop Circuit, Typical

    Figure 2-19. Relays Wired to Emergency Stop Circuit, Typical active in all modes of operation When wiring Shadow VI into the press circuit, you should ensure that it is active in all modes of operation. This would include inch, single stroke, and continuous. Following this practice will provide safety for setup personnel as well as the operator.

  • Page 67: Wiring Shadow To The Wpc (One Or Two Control Boxes)

    If you have an older-model WPC, refer to Figure 9 at the end of the manual. Once you make connections, proceed to the next section "Making settings inside the control". If you have the optional Shadow VI-WPC control board, refer to Appendix C and Figure 8 for specific instructions. Installation and Checkout...

  • Page 68: Wiring Shadow To A Plc

    (or more) independent logic systems should be used to control the press's stop circuit. Wintriss does not provide specific step-by-step instructions for connecting Shadows to PLCs. This is because of the variety of PLCs and the various programming techniques used.

  • Page 69: Optional Wiring

    PLC can inhibit the press from further operation until the PLC inputs have been checked out. Optional Wiring This section provides instructions to wire various optional Shadow VI features, including remote reset, indicator outputs, and MPCE monitor input. Indicator Outputs...

  • Page 70: Mpce Monitor Inputs

    See the figure below for an example of how to wire the MPCE inputs. Use normally closed contacts only. To monitor external MPCEs, place jumpers J14 and J15 in the EXT (external) position. See Figure 2-23. Call Wintriss Tech Support for further information. Light Curtain...

  • Page 71: Making Settings Inside The Control

    Shadow VI User Manual 1107200 115 V For “Internal” place jumper For “External” place on left-hand two pins. jumper on right-hand two pins. GRN AMB RED YEL V-OUT Set MPCE2 at JP15 TRANSMITTER 1 RECEIVER 1 1 SET FSD1 FSD2...

  • Page 72: S1 Settings

    It is useful to keep the setting at "off". This is a reminder for you to ensure that the daily tests on Shadow are performed as soon as the “reset required” condition has been cleared. If your the Shadow is wired to the resolver-based Wintriss Clutch/Brake Control (WPC), disable this functionality because WPC already has this feature.

  • Page 73: J12 Setting

    Connect 115 VAC wires from the control to the 115 VAC source. Make sure power is off before making connections. Now go on to the next step—aligning and tightening down your Shadow VI heads. Aligning and Tightening Down Shadow VI...

  • Page 74: Alignment Procedure

    You have wired and loosely mounted your Shadow transmitter and receiver as directed in the section "Loosely mounting Shadow VI transmitter and receiver". Now you need to test and align them. Once that is done you can tighten them using the appropriate adjustment method to keep them in alignment (such as rotating the universal mounts discussed at the beginning of this chapter).

  • Page 75: Diagnostic Steps To Perform Before Using Shadow

    Failure to comply with these instructions will result in death or serious injury. If your Shadow light curtain does not operate correctly, use the following diagnostic steps to troubleshoot and correct problems. If you need help, call Wintriss Tech Support. No Power to Unit If your light curtain has no power, check the power fuse F1.

  • Page 76: Check Lens Window

    1107200 Shadow VI User Manual means that either transmitter, receiver, or both may not be receiving power. If this is the case, run a few tests. First check that the power connections at the control have been performed correctly. (See location of components at Figure 2-14.) If DS4 is off, test the transmitter.

  • Page 77: No Green Light

    No Green Light If you did not get a green light even after bringing the Shadows close together, your Shadows probably have an internal problem. Call Wintriss Tech Support to discuss the problem. If You Have Two Sets of Shadow Heads If you have two sets of Shadow heads, you should already have completed the necessary wiring explained in "Wiring Shadow heads to the control."...

  • Page 78: Final Checkout Sequence

    1107200 Shadow VI User Manual Final Checkout Sequence DANGER FAILURE TO PERFORM SAFETY SYSTEM TESTS • Perform the final checkout sequence below when you have completed installation of your light curtain, before operating the equipment it is connected to. • Operate your machinery only after your safety system meets all the requirements of the checkout sequence.
  • Page 79 Shadow VI User Manual 1107200 Have ready 1-1/4" (32 mm) and 1/8” (3.2 mm) opaque test bars. If your light curtain has floating window, also have ready a 2” (50.8 mm) opaque test bar. Turn on power to Shadow safety light curtain and to the machine.
  • Page 80 See "Chapter 4. Troubleshooting Shadow Safety Light Curtains" to see if you can solve the problem by making some simple checks described in that chapter. If the safety system still does not work properly, contact Wintriss Tech Support for assistance. page 68...

  • Page 81: Chapter 3 - Fixed And Floating Blanking

    Instructions for installing and/or enabling both of these features are covered in this chapter. Shadow VI User Manual 1107200 Fixed and Floating Blanking...

  • Page 82: Blanking Windows Affect Safety Distance

    1107200 Shadow VI User Manual Blanking Windows Affect Safety Distance DANGER INCORRECT SAFETY DISTANCE Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

  • Page 83: Adding To Safety Distance For Fixed Blanking

    Shadow VI User Manual 1107200 Adding to Safety Distance for Fixed Blanking DANGER INCORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS • Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

  • Page 84: Installing Blanking Windows

    1107200 Shadow VI User Manual Installing Blanking Windows Blanking windows are easy to install. If you are blanking more than one beam, you attach the master blanking window first and connect "slave" blanking windows above it. This increases the blanked area. The maximum number of beams that can be blanked is 5.

  • Page 85: Figure 3-1. Connecting Master Blanking Window

    Shadow VI User Manual 1107200 intend to blank more than 1 beam, install the master blanking window on the lowest blanked beam at this time. (The next section explains how to install the slave.) 3. Position the master blanking window over the front of the receiver. Loosen the thumbscrew on the right side.

  • Page 86: Figure 3-2. Close-Up - Installing Blanking Window

    1107200 Shadow VI User Manual plastic coverings have been removed to allow stacked windows cut-away representing top of receiver grooves on window helps fit part of one on top of the other master cable shown thumbscrew (no cable with slave)

  • Page 87: Installing Slave Windows

    Shadow VI User Manual 1107200 9. Notice the 2 tiny plastic coverings on the top of the master blanking window. These should remain in place unless you plan to add more slave blanking windows (next section). 10. You are done connecting the master blanking window. The beam you selected has been physically disabled.
  • Page 88 1107200 Shadow VI User Manual 5. Press down firmly on the slave blanking window so that it lines up between the alignment indicators on either side of the receiver. Make sure that the pins in the slave blanking window fit properly into the mating connector holes on the top of the master. If you need to adjust the blanking window back up, press down on the top of the receiver end cap as you push the slave upward.

  • Page 89: Floating Window

    Shadow VI User Manual 1107200 Floating Window DANGER INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW • Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

  • Page 90: Adding To Safety Distance For Floating Window

    1107200 Shadow VI User Manual Adding to Safety Distance for Floating Window DANGER INCORRECT SAFETY DISTANCE WHEN USING FLOATING WINDOW • Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Chapter 2 for detailed information on object sensitivity, depth penetration factor and calculating the safety distance.

  • Page 91: Chapter 4 - Troubleshooting Shadow Vi

    Two charts found at the beginning can be used as quick troubleshooting reference guides. Start with Table 4-1. This chart is useful if your Shadow VI comes with either 1 or 2 sets of optic heads. The first column provides common symptoms. The next columns identify how the indicators will or will not light up when the symptoms occur.

  • Page 92: Description Of Shadow Vi Indicators

    However, once you know which unit is bad, you may be able to substitute another unit for the faulty one until the repairs are made. Description of Shadow VI Indicators Shadow includes several indicators. Figure 1-1 in Chapter 1 shows the indicators on the transmitter and receiver, and Figure 1-2 illustrates the control.

  • Page 93: Inside The Control

    Shadow VI User Manual 1107200 Inside the Control There are eight LED indicators on the circuit board inside the control (refer to Figure 2-14 in Chapter 2 for location of components). DS1 and DS2 are located just above the TB2 receiver connectors at the lower right-hand corner of the board, and do not light up under normal conditions.

  • Page 94: Table 4-1. Shadow Troubleshooting Guide For 1 Or 2 Sets

    1107200 Shadow VI User Manual Table 4-1. Shadow troubleshooting guide for 1 or 2 sets Control Action No power to unit. 7 Off 1. Check power fuse F1. 8 Off 2. Check power connection. Optic heads are 3 Grn 7 Off 1.
  • Page 95 1. Check reset key to see if it is stuck in the “Reset” (Scenario 2) 4 Grn 8 Grn position. If it is, contact Wintriss Tech Support. 2. Check your external reset circuit to see if it is stuck “on.” If it is, repair it. NOTICE You cannot clear a “reset required”...
  • Page 96 1107200 Shadow VI User Manual Table 4-1. Shadow troubleshooting guide for 1 or 2 sets (cont.) Control Action Red 3 Off Receiver head is 7 Off 1. Unplug receiver connector at receiver. not getting power. 4 Grn 8 Grn If DS3 turns ON, receiver is defective.

  • Page 97: External Mpce Monitoring: Checking Ds5 And Ds6

    Shadow VI User Manual 1107200 External MPCE Monitoring: Checking DS5 and DS6 These LEDs help diagnose problems relating to external MPCE monitoring. If you are using external MPCE monitoring do the following: 1. Block the light curtain and look at LEDs DS5 and DS6 (see Figure 2-14 for location).

  • Page 98: Shadow Vi Optic Head Connector

    1107200 Shadow VI User Manual Shadow VI Optic Head Connector CAUTION MAKING OR BREAKING CONNECTIONS WITH POWER ON Power down Shadow before connection or disconnecting any connections at the control, transmitter or receiver. Failure to comply with these instructions could result in property damage.

  • Page 99: Checking And Cleaning Lens Window(S)

    LEDs send the light from the transmitter to the phototransistors at the receiver. If they are weak, they cannot generate enough light at greater distances. If you suspect a bad LED or phototransistor, contact Wintriss Tech Support immediately to discuss return of the unit.

  • Page 100: Checking And Replacing Fuses

    1107200 Shadow VI User Manual Checking and Replacing Fuses WARNING ELECTRIC SHOCK HAZARD • Ensure that the power source is off before checking or replacing fuses. • Disconnect power from the machinery it is connected to before making any wiring connections.

  • Page 101: Checking And Replacing Control Relays

    Shadow will not allow relay operation if a relay failure occurs. Even the contacts of the good relay will be open and all voltages will be zero. You must replace the Shadow VI control board (see Replacing Safety Relays, page 91).

  • Page 102: Checking Relays With A Voltmeter

    Therefore, the press will not operate even though the Shadow relay contacts are closed and the indicator light is green. If you find a bad control relay, replace the Shadow VI Control board (see next section). To obtain a new Control board, contact Wintriss Tech Support.

  • Page 103: Replacing Safety Relays

    2. Making sure that you are grounded, open the Shadow VI enclosure (see Figure 2-13, page 43). 3. Identify all cables with inputs on the Shadow VI Control board by the terminal block to which they connect (see Figure 2-14, page 44) and attach identifying labels.

  • Page 104: Checking And Correcting Cross Talk

    1107200 Shadow VI User Manual 8. Set switches S1, S2, and S4 and jumpers J12, J14, and J15 on the new Shadow VI Control board in the positions they were in on the old board. (Instructions for setting switches and jumpers are provided on page 51 (S2) and pages 57-61.) 9.

  • Page 105: Appendix A - Extracts From Osha Regulations And Ansi Standards

    PMA are shown in the right-hand column. Wintriss makes no claim for the accuracy or effectiveness of the PMA interpretations, and persons making use of this material do so at their own risk. PMA interpretations should not be relied upon for use in any specific application.
  • Page 106 1107200 Shadow VI User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c). TABLE 0-10 Distance of opening Maximum width of (c) Safeguarding the point of operation. from point of operation opening (inches) (1) General requirements.
  • Page 107 Shadow VI User Manual 1107200 Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation (d) Muting (bypassing of the protective Top of stroke is the point at which muting shall function) of such device, during the cease as it is not possible to set a point on the...
  • Page 108 1107200 Shadow VI User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c) (3) (5) (cont) (i) The employer shall use a control system and brake monitor which comply with paragraphs (b) (13) and (14) of this section.

  • Page 109: Extracts From Ansi Standards For Presence-Sensing Devices

    Shadow VI User Manual 1107200 Extracts from ANSI Standards for Presence-sensing Devices WARNING REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS The following extracts from OSHA and ANSI documents are provided for the user’s convenience only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI standards to ensure that you have the most up-to-date information.
  • Page 110 1107200 Shadow VI User Manual Extracts from ANSI B11.1-2009 8.6.2.1 Standards Requirements Explanatory Information 8.6.2.1.7 Each operator’s hand controls shall E8.6.2.1.7 The total stopping time of the press be located at a distance from the point-of- should include the total response time of the...
  • Page 111 Shadow VI User Manual 1107200 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3 Presence-sensing safeguarding device 8.6.3.1 A presence-sensing device, when used E8.6.3.1 Various presence-sensing devices for safeguarding, shall protect the operator as employ different sensing and adjustment specified in E8.6.1 (a).
  • Page 112 1107200 Shadow VI User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.6 Muting of the device shall be permitted E8.6.3.6 Muting is typically accomplished by only during the non-hazardous portion of the interface circuits or auxiliary controls.
  • Page 113 Shadow VI User Manual 1107200 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.11 The device shall be provided with a E8.6.3.11 Red and green indicators or other means that visibly indicates when it is means that can be easily seen by the operator functioning properly.
  • Page 114 1107200 Shadow VI User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.13 The device shall conform to the requirements of 6.11 and 8.8. In the event of a power failure to the device, the device shall initiate a stop command to the press control system.
  • Page 115 Shadow VI User Manual 1107200 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information NOTE - T s + T c is usually measured by a stop 8.6.3.16 (cont) time measuring device. See also ANSI B11.19, Annex C and D.
  • Page 116 1107200 Shadow VI User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.18 The device shall not be affected by E8.6.3.18 Examples of ambient light are ambient light or by light-source decay so that the associated with windows, light fixtures, skylights, increase in response time or object sensitivity is bay doors, or die lights.
  • Page 117 Shadow VI User Manual 1107200 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3 Electro-Optical, RF, and area scanning presence-sensing safeguarding devices 8.3.1 Design and Construction 8.3.1.1 The presence-sensing device shall be E8.3.1.1 The device should be designed and...
  • Page 118 1107200 Shadow VI User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.1.5 The presence-sensing device shall E8.3.1.5 Indicators (usually red and green), incorporate visual means to indicate that the displays or meters should be provided to device is detecting an individual within the indicate the status of the device.
  • Page 119 Shadow VI User Manual 1107200 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.1.10 The area scanning device shall E8.3.1.10 These devices typically operate on provide a means or operating mode to verify the principle of “diffuse reflectance," which is a...
  • Page 120 1107200 Shadow VI User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.2 Installation, operation, and maintenance 8.3.2.1 Exposure to the hazard(s) shall not be E8.3.2.1 The user should select a presence- possible by reaching over, under or around the sensing device adequate to prevent individuals sensing field of the device.
  • Page 121 Shadow VI User Manual 1107200 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information The device shall be installed such that it does Some installation hazards include, but are not not create additional hazards. limited to: pinch point hazards created by interference between the device and moving members of the machine;...
  • Page 122 1107200 Shadow VI User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.2.3 The presence-sensing device shall protect individuals from hazards by initiating an immediate stop command to the machine control system when the sensing field of the device is interrupted during the hazardous portion of the machine cycle.
  • Page 123 Shadow VI User Manual 1107200 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information Annex C for further information. If the machine has reversing capability where a One method of meeting this requirement is by muting hazard is possible, the control system...
  • Page 124 1107200 Shadow VI User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.2.8 The total tolerance in the range E8.3.2.8 When the device is horizontally measurement of an area scanning device shall mounted, the detection area or zone should be be included in determining the distance from visibly marked on the floor.

  • Page 125: Daily Tests In English

    Shadow VI User Manual 1107200 Daily Tests in English Perform these tests daily to make sure the light curtain and the machine's control systems work properly. Also perform these tests after any modification or maintenance to the light curtain or the machine.

  • Page 126: Tests Quotidiens Du Rideau De Lumiere

    1107200 Shadow VI User Manual Tests Quotidiens du Rideau de Lumiere Daily Tests in French Effectuer ces tests quotidiennement pour s'assurer que le rideau de lumière et le système de commande de la machine fonctionnent comme if faut. Effectuer également ces tests après toute modification ou tout entretien du rideau de lumière ou de la machine.

  • Page 127: Appendix B - Shadow Vi Panel Mount

    Standard Enclosure Versus Optional Panel Mount Shadow VI is available either with an enclosure or as a panel mount. The panel mount can be mounted from the inside or outside. Be sure to allow at least 8" (20.3 cm) of clearance behind the panel mounting plane to allow enough room for the electronics.

  • Page 128: About Shadow Vi Panel Mount Labels

    1107200 Shadow VI User Manual About Shadow VI Panel Mount Labels DANGER DAILY TESTS LABEL INACCESSIBLE Affix the Daily Tests label where operators can clearly read the instructions. The daily tests are critical to operator safety and must be run every day before operating the press.

  • Page 129: Figure B-1. Daily Tests Label (Left) And Operator Instructions Label (Right)

    Shadow VI User Manual 1107200 CAUTION Perform these tests daily to ensure the Light Curtain and the machine's control system work properly. These tests should also be performed after any modification or maintenance to the Light Curtain or the machine.

  • Page 130: Figure B-2. Shadow Vi Panel Mount Control Dimensions

    Final assembly Once the final checkout has been confirmed and Shadow is working satisfactorily while it has been sitting outside the enclosure, you are ready to completely install the Shadow VI panel mount into your enclosure. Remember earlier you had cut out a hole in your panel enclosure. Mount the Shadow panel assembly into this cavity using the ten 1/4-20 screws.

  • Page 131: Appendix C - Installation Of Shadow Vi-Wpc Control Board

    This control board replaces the standard Shadow VI control box. The Shadow VI-WPC control board can only be used with Shadow VI Light Curtains (all sizes) and Wintriss Clutch/Brake Control. It cannot be used with any other press control or any other model of light curtain.

  • Page 132: About Shadow Vi-Wpc Control Board Labels

    With your panel mount assembly you should have received the three labels shown below: "Daily tests,” “Shadow VI” and “Warning.” Place these labels where they are clearly visible. page 120 Appendix C...

  • Page 133: Figure C-1. Shadow Vi - Wpc Labels

    C L U T C H MACHINES. C42254 Rev Figure C-1. Shadow VI - WPC Labels "Daily tests" label (left), "Shadow VI" label showing response time (upper right), “Warning” label (lower right) Installation of Shadow VI-WPC Control Board Appendix C...

  • Page 134: Figure C-2. Mounting Dimensions And Required Space For Control Board

    6.00 around (15.24) 3.25 (8.26) 8 standoffs (size 6-32, 1/2" long) are provided with processor board 2.75 (6.99) 3.25 (8.26) Figure C-2. Mounting Dimensions and Required Space for Control Board page 122 Appendix C Installation of Shadow VI-WPC Control Board...

  • Page 135: Figure C-3. Important Components - Shadow Vi-Wpc Control Board

    2SET / 1 SET Jumpers TRANSMITTER(S) RECEIVER(S) upper - Set 1 upper - Set 1 lower - Set 2 lower - Set 2 Figure C-3. Important Components - Shadow VI-WPC Control board Installation of Shadow VI-WPC Control Board Appendix C page 123...

  • Page 136: Wiring Shadow Vi Optic Heads To The Board

    • Figure 8 (Shadow VI-WPC wiring schematic) at the end of the manual • Figure 10 (Shadow VI-WPC 1000 wiring schematic) at the end of the manual Run the cables through separate " flexible, liquid-tight conduits from the Shadow VI transmitter and receiver to the knockouts at the bottom of the WPC enclosure.

  • Page 137: Connecting Ac Wiring To Wpc

    (115 VAC 50-60 Hz single phase power source), consult in the manual: • Table C-3 TB1 Wiring table • Figure 8 (Shadow VI-WPC wiring diagram) at the end of the manual The following is an illustration of this terminal. #1 HI #2 NEU...

  • Page 138: Connecting Stop Circuits To Wpc

    The setting on this board must match the voltage setting at WPC. The default setting is 115V ("115V" displays in the switch cavity). If the WPC is set for 230V AC power, push down on the handle for the Shadow VI control board to display "230V".

  • Page 139: Making Settings On The Control Board

    Pin #27 (LIGHT CURTAIN 1 ENABLE) Making settings on the control board These are the settings to make on the Shadow VI-WPC board. Floating window setting The floating window feature provides a means for the random bypass of only one beam of the light curtain (refer to Chapters 1 and 3 of this manual for more detail).

  • Page 140: J12 Setting

    Figure C-7. Jumper Position for "1 SET" and "2 SETS" You also need to perform some diagnostics to verify this setting. To do this, refer to the section, "Aligning and tightening down Shadow VI components" in Chapter 2. page 128...

  • Page 141: Reset Button

    References throughout the manual to "reset keyswitch" are applicable to this Reset button. Rather than turning the reset keyswitch, which is standard on the Shadow VI control box, you will press the Reset button, which is located on the Shadow VI-WPC control board.

  • Page 142: Shadow Vi User Manual

    1107200 Shadow VI User Manual page 130 Appendix C Installation of Shadow VI-WPC Control Board...

  • Page 143: Appendix D - Replacement Parts

    (order one set for each head or control box) Master blanking window (6” - 24”) 4280602 Master blanking window (30” - 48”) 4280603 Master blanking window (60” - 72”) 4280604 Slave blanking window 4280601 Shadow VI User Manual 1107200 Replacement Parts Appendix D page 131...
  • Page 144 1107200 Shadow VI User Manual page 132 Appendix D Replacement Parts...

  • Page 145: Index

    Shadow VI - WPC, 122 checking, 87 location of components, 44 American National Standards Institute (ANSI), 1, location of components, Shadow VI - WPC, 2, 6, 19, 22, 97 extracts from B11.1-2009, 98 control relays, 90 extracts from B11.19-2003, 105 control reliability, 6 standard B11.1-2009, 1...
  • Page 146 8, 10, 13 master blanking window, 72 control, 8, 80 matched sets, 5 heads, 80 mirror on control board, Shadow VI - WPC, 123 dimensions, 37 installation, 17 using, 36 aligning and tightening down Shadow, 62 mirrors, 14 blanking window(s), 72...
  • Page 147 13 S1 and S4, 59 reset button status follows stop outputs (S1), 59 Shadow VI - WPC control board, 122, 127, voltage selector (S2), 51 T bm , stop time adjustment for brake wear, 102 reset keyswitch, 2...
  • Page 148 Shadow to a PLC, 56 wiring to, 55, 119 Shadow to WPC, 55 wiring. See also installation WPC. See Wintriss WPC Clutch/Brake Control optic heads (Shadow VI-WPC), 124 WPC 1000. See Wintriss WPC 1000 Clutch/Brake Control optic heads, standard control, 46 page 136 Index...

  • Page 149: Wintriss Manuals

    DA71420 DA71443 Servofeed Interface – Waddington/Wintriss DA71419 DA71443 Shadow V Safety Light Curtain DA71433 DA71449 Shadow VI Safety Light Curtain DA71422 DA71445 Shadow VII Safety Light Curtain N. A. * 1129400 * Shadow 8 Safety Light Curtain N. A. * 1139300 * SmartPAC (w/ DiProPAC &...

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