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Wintriss Shadow 8 User Manual

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®
Shadow 8
®
Safety Light Curtain
1139300
Rev. K
March 2015
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

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  • Page 1 Shadow 8 ® Safety Light Curtain 1139300 Rev. K March 2015 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...
  • Page 2 Requirements You Must Meet When Installing and Using Shadow Safety Light Curtains DO NOT USE SHADOW LIGHT CURTAINS ON FULL-REVOLUTION POWER PRESSES • DO NOT use Shadow safety light curtains on full-revolution clutched machinery, which cannot be stopped in mid-stroke. •...
  • Page 3 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.

  • Page 4: Table Of Contents

    Shadow 8 and Control Reliability ........1-7...
  • Page 5 Wiring Shadow 8 in a Single Normally Open (N/O) Emergency Stop Circuit . . . 2-40 Wiring Shadow 8 to EDM Monitor Inputs ....... 2-41 Wiring Shadow 8 Optional Control Box to a PLC .
  • Page 6 Machine Run/Stop and Blanking Active LEDs Flash Simultaneously ..4-6 Shadow 8 Control Box or WPC Power LED Dims and Blinks....4-6 Checking and Cleaning Lens Windows .
  • Page 7 Figure 2-22. Shadow 8 AC Wiring Connections ................2-38 Figure 2-23. Relays Wired to Emergency Stop Circuit, N/O Configuration ........2-41 Figure 2-24. Shadow 8 Option Switches (Located in Main Receiver and Transmitter) ....2-46 Figure 2-25. Transmitter and Receiver Properly Aligned ............... 2-50 Figure 2-26.
  • Page 8 Shadow 8 Stand Height and Weight ........
  • Page 9 Chapter 1 provides an overview of Shadow 8 operation and features, including product specifications. Chapter 2 shows you how to install and wire Shadow 8, set Shadow 8 options, and perform checkout and test procedures. The chapter also provides instructions for calculating the safety distance for your light curtains.
  • Page 10 Shadow 8 User Manual 1139300 Important Highlighted Information Important danger, warning, caution and notice information is highlighted throughout the manual as follows: A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.
  • Page 11 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 12: Chapter 1. Introduction

    Receiver optic heads, which can be wired directly to a new Wintriss Clutch/Brake Control (WPC) or to an optional Shadow 8 control. Main heads are capable of supporting up to three additional pairs of Extension heads connected in series with two cables, as long as the total length of the heads does not exceed 202 in.

  • Page 13: Ul, Csa, Ce, Osha, And Ansi Compliance

    IEC 61508, EN ISO 13849-1, and 2002/95/EC – Restriction of the use of Certain Hazardous Substances - RoHS). Shadow 8 also complies with OSHA 1910.217, ANSI B11.1, ANSI B11.19, CSA Z142, and CSA Z432. These rules mandate that a single component failure cannot jeopardize operator safety.

  • Page 14: Figure 1-1. Shadow 8 Main Transmitter And Receiver

    Shadow 8 User Manual 1139300 Figure 1-1. Shadow 8 Main Transmitter and Receiver Introduction...

  • Page 15: Figure 1-2. Shadow 8 Main And Extension Heads

    TOP STOP ANGLE STOP TIME LIMIT AUTO CARRYUP MICRO-INCH cam on angle cam off angle BRAKE WARNING RESET/SELECT MUTE WPC SETTINGS WPC 2000 Honeywell Wintriss ® Clutch/Brake Control STROKE SELECT MODE SELECT MICRO-INCH Figure 1-2. Shadow 8 Main and Extension Heads Introduction...

  • Page 16: Figure 1-3. Shadow 8 Control

    An optional control enclosure (see Figure 1-3) is available for Main Receiver and Transmitter unless you are connecting Shadow 8 to a new Wintriss Clutch/Brake Control. The enclosure can accommodate any-sized receiver and transmitter. No special settings are required. The control contains a power supply and relay circuitry.

  • Page 17: Shadow 8 Operation

    Shadow 8’s transmitter and receiver are mounted on either side of the hazardous area. LEDs (light emitting diodes) in the transmitter emit harmless, invisible, infrared light pulses when electric current passes through them.

  • Page 18: Shadow 8 Object Sensitivity

    “on,” then “off” as the beam hits it and disappears. Each phototransistor must turn on, then off in sequence, or Shadow 8 will send a stop command to the guarded machinery. Between 7 and 9 consecutive beams on Main heads, depending on Shadow 8 model, and 2...
  • Page 19 WPC instantly de-energizes its relays, stopping the press. Shadow 8’s response time from loss of light to relay contacts open (or de-energized) is 23 to 59 milliseconds, depending on configuration (see Table 1-1, page 1-13). Even if one of Shadow’s control relay contacts fails closed (i.e., the contact welds shut), the second relay...

  • Page 20: Shadow 8 Led Displays

    1139300 Shadow 8 LED Displays Shadow 8 provides the following LED displays on the Main Receiver and Transmitter and on the optional control to provide information about light curtain operation. Three operating state LED indicators located on the pigtail end of the Main Receiver (see •...

  • Page 21: Shadow 8 Operating States

    (see Table 3-1, page 3-6). The Power LED on the optional Shadow 8 control, which is green, is illuminated when power is being applied to the unit. Illumination of the two green LEDs labelled “OSSD 1” and “OSSD 2”...

  • Page 22: Programmable Fixed Blanking

    Shadow 8 User Manual 1139300 Interlock state until the operator turns the key switch to the START position, and Shadow 8 switches to Curtains Unobstructed. Start/Restart Interlock operating mode is particularly useful in perimeter guarding applications when there is a walk-in hazard inside the guarded area.

  • Page 23: Other Shadow 8 Features And Options

    Figure 1-1, page 1-3). Mounting brackets, which can be rotated ±8°, are used to properly align the Shadow 8 heads during installation. An additional bracket can positioned at the light curtain’s midpoint with a T-slot mount to improve stability, and two brackets with T-slot mounts can be used instead of end brackets where mounting space is restricted.

  • Page 24: Specifications

    50 mS for up to 171 in. (4340 mm) combined length with extensions 59 mS for up to 202 in. (5120 mm) combined length with extensions If light curtains are wired to optional Shadow 8 control, add 10 mS to response time for N/O safety relay outputs, 20 mS for N/C output.
  • Page 25 1139300 Shadow 8 User Manual Table 1-1. Shadow 8 Specifications (Cont.) Operating 32° to 131° F (0° to 55° C) Temperature Inputs Heads Power 24 Vdc, 2.1 A max. Up to 4 sets (one Main and up to three Extensions) can be connected in series as long as total length of heads does not exceed 202 in.

  • Page 26: Chapter 2. Installation And Checkout

    Failure to comply with these instructions will result in death or serious injury. GUARD AGAINST ELECTRIC SHOCK HAZARD • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to, including the machine control and motor, before making any wiring connections.

  • Page 27: Calculating The Safety Distance

    Installing Shadow 8 is a straightforward procedure. However, you must install the unit with care since Shadow 8 is a safety device that protects press operators and other personnel. Before proceeding, make sure that you received the following items in your Shadow 8 order: Two optic heads (Main Transmitter and Main Receiver) •...

  • Page 28: Figure 2-1. Safety Distance: Distance Between Pinch Point And Light Curtain

    The “safety distance,” as shown in Figure 2-1, is the distance away from the pinch point (or hazardous area) of the press that the Shadow 8 heads must be mounted to allow enough time for Shadow 8 to react, and the press to stop, before the operator can penetrate the light curtain and reach the hazard.

  • Page 29: Osha And Ansi Requirements

    The safety distance is calculated using a formula that incorporates the stopping time of your press. You must mount your light curtains slightly beyond this calculated distance to ensure that Shadow 8 is able to stop the press before an operator’s hand reaches the hazardous area. OSHA and ANSI Requirements OSHA regulations, ANSI standards, and CSA mandate that all machine safeguarding devices, including Shadow 8, be located at the correct safety distance from the pinch point.
  • Page 30 Next we will add the Shadow 8 response time and the braking percentage factor. We will use a worst-case response time of .059 seconds for a Shadow 8 system with a protected length of between 172 in. and 202 in. We will assume that our brakes are new and add 20% to the stop time measurement (.20 x 0.190 = .038).

  • Page 31: Ansi Safety Distance Formula

    USE BRAKE MONITOR TO CHECK STOPPING TIME Use a brake monitor where a Shadow 8 light curtain is installed to protect operators whose hands are routinely exposed to a hazardous area, as required by OSHA 1910.217 (c) (3) (5). A brake monitor continually checks that the machine’s stopping time does not exceed a predetermined limit.
  • Page 32 Tc is the time it takes for the control to activate the press’s brake. The response time Tr for Shadow 8 is between 23 mS (for protected lengths up to 42 in.) and 59 mS (for lengths between 171 in. and 202 in.

  • Page 33: European Safety Distance Formulas

    1139300 Shadow 8 User Manual D pf = 3.07 Now let’s put our numbers into the formula: Ds = 63 x (0.190 + .059 + .038) + 3.07 Ds = (63 x .287) + 3.07 Ds = 18.08 + 3.07 Ds = 21.15 in.
  • Page 34 Shadow 8 User Manual 1139300 This formula applies for all minimum distances of up to and including 500 mm. The minimum value of cannot be less than 100 mm. is found to be greater than 500 mm, using the formula above, then the following formula can be used.

  • Page 35: Increasing Safety Distance For Perimeter Guarding

    ANSI safety distance formula. When blanking is inactive, Shadow 8 can sense an object 1.18 in. (30 mm) in diameter. The depth penetration factor (Dpf) with no beams blanked is 3.07 in. (78 mm).
  • Page 36 5.76 in. (146.3 mm), or a 2.69 in. (68.3 mm) safety distance increase for the one-beam floating blanking window. Since Shadow 8’s floating blanking window may be used in any segment in a multi-segment installation (see Setting a Floating Blanking Window, page 3-7), the safety distance for every segment must be increased by 2.69 in.

  • Page 37: Providing Pass-Through Protection Within The Safety Distance

    Figure 2-2. Plan View of Pass-through Protection With Shadow 8, two sets of optic heads can be wired to the same WPC press control or optional Shadow 8 control box, making this configuration easily implemented. All areas between the light curtains and pinch point that are not guarded by Shadow 8 must be protected by supplemental guarding (see Figure 2-3, page 2-13).

  • Page 38: Figure 2-3. Supplemental Guarding

    Shadow 8 User Manual 1139300 Supplemental Guarding Supplemental Guarding Mechanical Supplemental Example Guarding Barrier Supplementa Guarding Supplemental Guarding Figure 2-3. Supplemental Guarding Installation and Checkout 2-13...

  • Page 39: Height Considerations

    It is essential, therefore, to select light curtains of the right length combined with ancillary physical guards. Shadow 8 comes in sizes ranging from 9.4 in. to 59.9 in. Special Requirements for Presence Sensing Device Initiation (PSDI)

  • Page 40: Designing And Installing Mounts For Optic Heads

    Shadow 8 transmitter and receiver. Universal Mounting Brackets Universal mounting brackets are attached by screws to both ends of Shadow 8 transmitters and receivers (see Figure 2-7, page 2-20). By loosening the screws that secure them, you can rotate mounts ±8° to facilitate installation and alignment. If you need to pivot a bracket more than 8°, you must remove the screws, realign the mounting holes on the bracket with the...

  • Page 41: Designing And Installing Mounting Brackets And Floor Stands

    Designing and Installing Mounting Brackets and Floor Stands Shadow 8 light curtains can be mounted on floor stands or to brackets on your machinery, using the Shadow 8 universal mounting brackets on the top and bottom of each unit.

  • Page 42: Figure 2-4. Shadow 8 Stand Dimensions (Shown With Mounting Brackets For Heads)

    Figure 2-5, page 2-18 shows some examples of bracket designs. On gap-frame presses, do not attach the top Shadow 8 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 43: Figure 2-5. Light Curtain Mounting Bracket Types

    In applications where light curtains will be exposed to shock and vibration, it is recommended that you secure brackets at both ends where possible. You can mount the Shadow 8 heads directly to a vertical wall or column of the press if the location meets all mounting requirements, including safety distance.

  • Page 44: Figure 2-6. Shadow 8 Optic Heads: Mounting Dimensions

    Shadow 8 User Manual 1139300 Figure 2-6. Shadow 8 Optic Heads: Mounting Dimensions Table 2-2. Light Curtain Dimensions in Inches (Millimeters) (see Figure 2-6) Scanning B (Main) B (Extension) C (Main) C (Extension) Height 9.4 (240) 9.6 (244.6) 13.5 (341.9) 12.7 (323.3)

  • Page 45: Figure 2-7. Shadow 8 Universal Mounting Brackets: Dimensions And Rotation (Top View)

    1139300 Shadow 8 User Manual ° Figure 2-7. Shadow 8 Universal Mounting Brackets: Dimensions and Rotation (Top View) Universal bracket mounted in T-slot configuration Back view Side view Figure 2-8. Shadow 8 Universal Mounting Brackets: T-Slot Configuration 2-20 Installation and Checkout...

  • Page 46: Aligning Brackets

    Shadow 8s can be mounted with pigtails pointed up or down as long as both transmitter and receiver are oriented in the same direction. Shadow 8 heads can be mounted at any angle as long as they are in the same plane. Vertical mounting is easiest, however.

  • Page 47: Maximum Openings For Side Guards

    MIRRORS DECREASE SCANNING DISTANCE AND ANGLE OF DIVERGENCE • Allow for a reduction in scanning range of 10% for each mirror you use. Since Shadow 8 has a default scanning range of up to 65’ minimum (or up to 26’ minimum if option switch SWB 6 is set to ON–see page 2-48), you reduce the scanning range of the unit 6.5’...

  • Page 48: Figure 2-10. Shadow 8 With Mirrors For Three-Sided Guarding

    Figure 2-10. Shadow 8 with Mirrors for Three-sided Guarding The Shadow 8 light curtains and mirrors do not have to be arranged in a rectangle as shown in Figure 2-10. You can adjust the mirrors to reflect light from the Shadow 8 transmitter at other angles than right angles.

  • Page 49: Figure 2-11. Shadow 8 Mirror Dimensions

    1139300 Shadow 8 User Manual Figure 2-11. Shadow 8 Mirror Dimensions Table 2-4. Shadow 8 Mirror Dimensions (see Figure 2-11) Light Curtain Model A (in./mm) B (in./mm) 12.8 in. (320 mm) 13.5 (343) 15.18 (386) 17.5 in. (440 mm) 19.5 (495) 21.18 (538)

  • Page 50: Reflective Surface Interference

    2-26). The reflective surface may be part of the machine, mechanical guard or workpiece. Therefore, a minimum distance (d) must exist between the reflective object and the center line of the Shadow 8 sensing field. The Test Procedure (see Test Procedure, page 2-56) must be used to test for this condition.

  • Page 51: Figure 2-15. Minimum Distance: Worst Case Alignment Example

    1139300 Shadow 8 User Manual Sensing Field Interruption Reflection Transmitter Receiver Reflective Surface Perimter of danger area Figure 2-14. Unsafe Mounting, Example 2 Figure 2-15 and Figure 2-16 show the minimum distance from the reflective surface, d, to one side of the beam center line.

  • Page 52: Preventing Cross Talk Between Two Sets Of Shadow 8 Heads

    There are several ways to prevent cross talk: Insert a barrier of some type, such as a blind, between the two sets of Shadow 8 heads. • Make sure that the barrier runs all the way from the transmitter to the receiver.

  • Page 53: Loosely Mounting Shadow 8 Transmitter And Receiver

    Failure to comply with these instructions could result in property damage. When you initially install the Shadow 8 optic heads, you should leave the heads loose on their mounting brackets so that you can properly determine required conduit and wiring length.

  • Page 54: Mounting The Optional Control

    Figure 2-18. Follow the instructions in the next section to complete the installation. You will align and adjust the heads (see Aligning and Tightening Down Shadow 8 Heads, page 2-49) after you mount and wire the control. Mounting the Optional Control...

  • Page 55: Figure 2-19. Shadow 8 Control Box: Mounting Dimensions

    1139300 Shadow 8 User Manual Dimensions: inches (mm) 0.30 (7.6) 8 places Figure 2-19. Shadow 8 Control Box: Mounting Dimensions 2-30 Installation and Checkout...

  • Page 56: Wiring Main Optic Heads To The Control

    • DO NOT use Shadow 8 safety light curtains on full-revolution clutched machinery, which cannot be stopped in mid-stroke. • Use Shadow 8 safety light curtains only on machinery that can be stopped at any point in the stroke or cycle.

  • Page 57: Figure 2-20. Shadow 8 Main Board: Location Of Important Components

    N.C. (L) LINE (N) NEUT Figure 2-20. Shadow 8 Main Board: Location of Important Components When joining cables with quick-disconnect fittings, be sure to make the connections between the two cables as tight as you can make them by hand. Do not use tools such as wrenches or pliers to tighten quick-disconnects.

  • Page 58: Figure 2-21. Cable Being Threaded Through Top Of Gland Nut And Threaded Coupling

    Figure A at the end of the manual for a drawing and parts list. Open the control by pulling up on and turning the hinge to unlock the clasp. Locate terminal blocks TB2 (receiver) and TB20 (transmitter) on the Shadow 8 Main board (see Figure 2-20).

  • Page 59: Table 2-5. Main Receiver Wiring Connections

    Tighten the nut securely with a 1 1/16 in. (27 mm) wrench. Connect receiver wires to terminal block TB2 on the Shadow 8 Main board, as shown in Table 2-5, below, and Figure 1 at the end of the manual.

  • Page 60: Connecting Extension Heads

    Connecting Extension Heads Once you have wired the Main Receiver and Transmitter to the Shadow 8 control, you can connect up to three pairs of Extension light curtains to the Main heads. (Total protection length cannot exceed 202 in.

  • Page 61: Connecting Extension Heads Using Pigtails Only

    1139300 Shadow 8 User Manual It is easiest to connect extensions when power to the light curtains is off. Shadow 8 will only recognize the segments you have added when power to the press has been removed, then reapplied. Connecting Extension Heads Using Pigtails Only To connect a pair of Extension heads to the Main heads or to another pair of Extensions when the distance between the two receivers and the two transmitters is less than 7 in., do the...

  • Page 62: Connecting Ac Wiring To The Optional Control

    • Ensure that the power source is off before you make any wiring connections. • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to, including the machine control and motor, before making any wiring connections.

  • Page 63: Figure 2-22. Shadow 8 Ac Wiring Connections

    LINE terminal Figure 2-22. Shadow 8 AC Wiring Connections Determine how you will bring wiring from your 115 Vac power source (or 230 Vac source, if applicable) to the appropriate knockout at the bottom of the unit. These wires should be connected directly to the press control transformer.

  • Page 64: Connecting Stop Circuits To The Control

    • DO NOT use Shadow 8 safety light curtains on full-revolution clutched machinery, which cannot be stopped in mid-stroke. • Use Shadow 8 safety light curtains only on machinery that can be stopped at any point in the stroke or cycle.

  • Page 65: Wiring Shadow 8 In A Single Normally Open (N/O) Emergency Stop Circuit

    • Ensure that the power source is off before you make any wiring connections. • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to, including the machine control and motor, before making any wiring connections.

  • Page 66: Wiring Shadow 8 To Edm Monitor Inputs

    Connections for EDM monitoring are made at the terminals labelled “EDM” and “0 Vdc” on terminal block TB3 on the Main board in the optional Shadow 8 control box (see Figure 2-20, page 2-32). To enable EDM monitoring, you must set switches SWA 2 and SWB 2 on the Main Receiver to “ON”...

  • Page 67: Wiring Shadow 8 Optional Control Box To A Plc

    In order for the EDM function to monitor the performance of your relays, you must connect the Shadow 8 stop circuits to the interfacing relays (see figures 3 and 4 at the back of the manual) instead of connecting them in series with the machine’s immediate stop circuit or with control reliable safety relay modules.

  • Page 68: Wiring Shadow 8 Optional Control To A Wintriss Clutch/Brake Control

    1000, refer to Appendix A for detailed wiring instructions and to figures 11 (WPC 2000) and 12 (WPC 1000 “new-style”) at the back of the manual. If you want to connect Shadow 8 optic heads to an “old-style” WPC 1000, refer to Figure 13 for wiring schematics.

  • Page 69: Wiring Auxiliary Output(S)

    Wiring for Auxiliary Output 1 is connected to pins 1 and 2 on terminal block TB5 on the Shadow 8 Main board for N.O. output or to terminals 2 and 3 for N.C. output (see Figure 2-20, page 2-32 and Figure 10 at the back of the manual). The switch labelled “SW2 AUX”...

  • Page 70: Setting Option Switches

    With the exception of switch 6, both SWA and SWB switches must be set to the same position (i.e., OFF or ON) for each option. Otherwise, Shadow 8 generates a “23” fault code on the IBIs on the Main Receiver (see page 4-2).

  • Page 71: Setting Operating Mode (Receiver Switch 1)

    Figure 2-24. Shadow 8 Option Switches (Located in Main Receiver and Transmitter) Setting Operating Mode (Receiver Switch 1) Shadow 8 can be set to operate in either Automatic Start (Default) or Start/Restart Interlock operating mode (see Setting Operating Mode, page 3-3). Table 2-7 shows operating mode option switch settings.

  • Page 72: Enabling External Device Monitoring (Edm) (Receiver Switch 2)

    WHEN SHADOW 8 HEADS ARE WIRED DIRECTLY TO WPC, SET EDM TO “DISABLED” If you have wired your Shadow 8 Main Receiver and Transmitter to a WPC 1000 or WPC 2000 control, you must disable the EDM function on Receiver switch 2. Set the switch to “OFF” (see figures 11 through 13 at the back of the manual).

  • Page 73: Enabling Floating Blanking (Receiver Switch 4)

    Switch 6 allows you to select one of two scanning ranges for your Shadow 8 heads. The long range option, which is the default setting, is 65 ft. (20 m) minimum. The short range option is 26 ft.

  • Page 74: Connecting Ac Wiring To Power Source

    When Shadow 8 heads are out of alignment, one or more transmitter beams are not detected by the receiver, causing the Shadow 8 safety relays to open and stay open and your press to be emergency-stopped. Individual Beam Indicator LEDs (IBIs) on the misaligned segment illuminate when heads are out of alignment, and the Machine Run/Stop LED on the Main Receiver is illuminated red.

  • Page 75: Figure 2-25. Transmitter And Receiver Properly Aligned

    1139300 Shadow 8 User Manual If PT is funnel-shaped light path, Shadow is in alignment even if optic heads are not Phototransistor perfectly aligned. Funnel-shaped (PT) light path Receiver Transmitter Light beams Plane of alignment Figure 2-25. Transmitter and Receiver Properly Aligned Table 2-13.
  • Page 76 Individual Beam Indicator LEDs for guidance since alternate IBIs remain illuminated until power is cycled to the Shadow 8. You will have to make head adjustments without immediate IBI feedback, turning the Shadow 8 off, then back on after each adjustment to determine if alignment has been corrected.

  • Page 77: Diagnosing Problems Before Using Shadow 8

    Support. No Power to Unit If the optional Shadow 8 control has no power, check power fuse F1 on the Main board (see Figure 2-20, page 2-32) and replace if necessary. Also check that power connections have been made correctly (see Connecting AC Wiring to the Optional Control, page 2-37).

  • Page 78: Machine Run/Stop Led Not Illuminated Green

    • Ensure that the power source is off before checking or replacing fuses. • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to, including the machine control and motor, before making any wiring connections.

  • Page 79: Shadow 8 Control Box Or Wpc Power Led Dims And Blinks

    Shadow 8 Control Box or WPC Power LED Dims and Blinks If the Power LED on the Shadow 8 control box or WPC enclosure dims and blinks, a Receiver or Transmitter segment has shorted the 24 volt power internally. To determine the source of the problem, turn off power and unplug the Main Transmitter;...

  • Page 80: Performing Checkout And Test Procedures

    Appendix B for a form you can use to document the results of the checkout procedure.) Verify that the guarded machine is a type that may be used with the Shadow 8 system (see the Requirements page at the beginning of the manual).

  • Page 81: Test Procedure

    1139300 Shadow 8 User Manual Make sure the operator is not able to stand between the Shadow 8 sensing field and the machine danger point. Verify that the light curtain can only be reset from a position outside and within view of the hazardous machine area.

  • Page 82: Figure 2-26. Test Object Pattern

    Shadow 8 User Manual 1139300 Interrupt the Shadow 8 sensing field with the shank of a 1/8-in. (3.2 mm) screwdriver to check the unit’s alignment. Move the test object inside the perimeter (along the top, sides and bottom) of the sensing field and up and down through the center of the sensing field, as shown in Figure 2-26.
  • Page 83 1139300 Shadow 8 User Manual Start the machine. With the machine in motion, interrupt the sensing field with the test object. The machine should stop immediately. (Never insert the test object into the dangerous parts of the machine.) If muting is used, interrupting the light curtain during the non-hazardous portion of the stroke (upstroke) will not stop the machine.

  • Page 84: Adding And Removing Extension Heads

    Failure to comply with these instructions will result in death or serious injury. Adding Extension Heads You must cycle power to the light curtains after installing extensions; otherwise, Shadow 8 will not recognize the new heads. Failure to comply with these instructions will result in death or serious injury.

  • Page 85: Removing Extension Heads

    A “100” (Number of segments has been reduced) fault code displays. Power down Shadow 8, then while holding the Program/Run/Start key switch on the Shadow 8 control box to the START position, power up the unit, watching the three operating state LEDs on the Main Receiver.

  • Page 86: Chapter 3. Operation

    • Shadow 8 LED Displays Shadow 8 has LED displays on Main and Extension Receivers and on the optional control box to provide information about light curtain operation. There are four types of LED displays: Three operating state LEDs located on the pigtail end of the Main Receiver (see Figure 1-1, •...

  • Page 87: Shadow 8 Operating States

    “OSSD 2,” are illuminated when the safety relays are “closed,” or energized. When the safety relays are “open,” or de-energized, these two LEDs turn off. Shadow 8 Operating States Shadow 8 can be in one of five operating states, which are specified by the LED indicators on the Main Receiver: Machine Run •...

  • Page 88: Setting Operating Mode

    Program/Run/Start key switch to the START position and Shadow 8 switches to Curtains Unobstructed. If the key switch is turned to START when there is an object in the sensing field, Shadow 8 remains in Interlock.

  • Page 89: Programming A Fixed Blanking Window

    WINDOWS A method of supervisory control, such as use of a key switch, must be employed to limit access to Shadow 8’s programmable fixed blanking feature so that only a qualified person is able to program a fixed blanking window.

  • Page 90: Figure 3-1. Using Supplemental Guarding With Fixed Blanking Windows

    You program a blanking window at the Shadow 8 control or WPC press control for the area of the sensing field penetrated by the fixture, disabling the light beams that would normally detect the fixture.

  • Page 91: Table 3-1. Consecutive Beam Requirement For Programmable Blanking

    Extension Heads All models In order to prevent vibration from activating the light curtain unnecessarily, Shadow 8 has been designed to allow some flexibility in the area covered by programmable fixed blanking windows. Each fixed blanking window has a positional tolerance of ± 1 beam, allowing the object to move up or down by 1 beam without causing a Curtains Obstructed operating state.

  • Page 92: Setting A Floating Blanking Window

    Simply replace the object in the area defined by the illuminated Individual Beam Indicator LEDs. If Shadow 8 is in Start/Restart Interlock mode, you must reset the system after replacing the object by turning the Program/Run/Start key switch to START.

  • Page 93: Figure 3-2. Coil Stock Unwinding Using A One-Beam Floating Window

    1139300 Shadow 8 User Manual Shadow 8’s floating blanking feature allows you to disable one beam at any location along the length of the light curtain, letting any object 1 in. or smaller penetrate the sensing field in a random pattern without causing the light curtain to enter a Curtains Obstructed state. In multi-segment installations, the floating beam may be used in any segment.

  • Page 94: Enabling Both Blanking Options

    Shadow 8 User Manual 1139300 Enabling Both Blanking Options OBSERVE CORRECT SAFETY DISTANCE WHEN USING BLANKING WINDOWS • Ensure that the correct safety distance exists between the light curtain and the hazardous area. See Calculating the Safety Distance, page 2-2 for detailed information on object sensitivity, depth penetration factor, and OSHA and ANSI safety distance formulas.
  • Page 95 1139300 Shadow 8 User Manual 3-10 Operation...

  • Page 96: Chapter 4. Troubleshooting

    Failure to comply with these instructions could result in property damage. This chapter shows you how to respond to the fault codes that display on the Individual Beam Indicators (IBIs) on the Shadow 8 Main Receiver and test and repair a few Shadow 8 components.

  • Page 97: Table 4-1. Shadow 8 Fault Codes

    Code “30,” for example, is displayed as three flashing IBIs, code “100” as one flashing IBI, and code “101” as two flashing IBIs separated by an unlit IBI. Table 4-1 shows you how to correct the problem(s) associated with each fault code. Table 4-1. Shadow 8 Fault Codes Fault Code System Status...
  • Page 98 Shadow 8 User Manual 1139300 Table 4-1. Shadow 8 Fault Codes (Cont.) Fault Code System Status Corrective Action Safety Output (OSSD) Faults General safety output (OSSD) fault 1. Check wiring to see if OSSD 1 shorted to OSSD 2. Correct wiring if necessary.
  • Page 99 1139300 Shadow 8 User Manual Table 4-1. Shadow 8 Fault Codes (Cont.) Fault Code System Status Corrective Action Second segment firmware not Replace with compatible component or compatible with first segment return system to Wintriss for upgrade. Third segment firmware not compatible...

  • Page 100: Other Troubleshooting Steps

    Power down the control before connecting or disconnecting the wires to the heads. Make sure the lenses are pointed directly at one another and you have the Shadow 8 heads in the same plane.

  • Page 101: Machine Run/Stop Led Green But Press Won't Start

    • Ensure that the power source is off before checking or replacing fuses. • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to, including the machine control and motor, before making any wiring connections.

  • Page 102: Checking And Cleaning Lens Windows

    Make sure you avoid excessive rubbing. Checking Alignment Shadow 8 can go out of alignment if the universal mounting brackets have been bent, if a unit has been struck by another piece of equipment (e.g., die cart, forklift, etc.), or if mounting bolts have loosened, allowing the units to move slightly.

  • Page 103: Checking And Replacing The Ac Power Fuse In Optional Shadow

    Failure to comply with these instructions could result in death or serious injury. Whenever Shadow 8 loses power, first check the AC power fuse, F1, on the optional Shadow 8 control Main board (see Figure 2-20, page 2-32). F1 is a time-lag fuse rated at 1.25 A @ 250 Vac.

  • Page 104: Checking And Replacing Control Relays In Optional Shadow 8 Control Box

    GUARD AGAINST ELECTRIC SHOCK HAZARD WHEN CHANGING RELAYS • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to before checking relays or replacing the Relay board, unless the test requires power to be on.

  • Page 105: Performing A Resistance Test

    Carefully remove the wires connected to terminal block TB4 on the Relay board, and cap them to avoid an electric shock and prevent a short circuit on the Shadow 8 board. See Figure 2-20, page 2-32 for the location of the Relay board on the Shadow 8 Main board.

  • Page 106: Replacing The Relay Board

    Failure to comply with these instructions could result in death or serious injury. If one or both of the Shadow 8 safety relays fail, you should replace the entire Relay board (see Figure 2-20, page 2-32). You can order a new board from Wintriss Tech. Support. To replace the Relay board, do the following.
  • Page 107 1139300 Shadow 8 User Manual 4-12 Troubleshooting...

  • Page 108: Appendix A. Wiring Shadow 8 Heads Directly To Wpc

    • Ensure that the power source is off before you make any wiring connections. • Turn off and disconnect power from the Shadow 8 safety light curtain and from the machinery it is connected to, including the machine control and motor, before making any wiring connections.

  • Page 109: Table A-1. Shadow 8 Main Transmitter/Receiver Wiring Connections To Wpc

    Remove 3/16 to 1/4 in. of insulation from the end of each conductor, using a wire stripper. Connect wires as shown in Table A-1 and in figures 11 (WPC 2000) and 12 (WPC 1000 New Style) at the end of the manual. Table A-1. Shadow 8 Main Transmitter/Receiver Wiring Connections to WPC Optic Head Wire Color...

  • Page 110: Appendix B. Checkout Procedure Log

    Appendix B. Checkout Procedure Log The following checkout procedure must be performed by qualified personnel during initial Shadow 8 system installation and at least every three months after that. Perform the procedure more frequently if machine usage and company guidelines require.
  • Page 111 1139300 Shadow 8 User Manual Checkout Procedure Log...

  • Page 112: Appendix C. Test Procedure Log

    The following test procedure must be performed by qualified personnel during initial Shadow 8 installation, according to the employer’s regular inspection program, and after any maintenance, adjustment or modification to the Shadow 8 or the guarded machine. Testing ensures that the light curtain, safety system, and machine control system work together to properly stop the machine.
  • Page 113 1139300 Shadow 8 User Manual Test Procedure Log...

  • Page 114: Appendix D. Extracts From Osha Regulations And Ansi

    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 115 1139300 Shadow 8 User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c). TABLE 0-10 (c) SAFEGUARDING THE POINT OF Distance of opening Maximum width of OPERATION. – from point of operation opening (inches) hazard (inches) (1) General requirements.
  • Page 116 Shadow 8 User Manual 1139300 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 cease as it is not possible to set a point on the...
  • Page 117 1139300 Shadow 8 User Manual Extracts from OSHA Regulation 1910.217 OSHA Regulations PMA Interpretation OSHA 1910.217 (c) (3) (vii) (c) (c) The safety distance (Ds) between each two hand control device and the point of operation shall be greater than the distance...

  • Page 118: Extracts From Ansi Standards For Presence-Sensing Devices

    Shadow 8 User Manual 1139300 Extracts from ANSI Standards for Presence-sensing Devices 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 119 1139300 Shadow 8 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 be E8.6.2.1.7 The total stopping time of the press located at a distance from the point-of-operation should include the total response time of the...
  • Page 120 Shadow 8 User Manual 1139300 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 121 1139300 Shadow 8 User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.7 Muting of the device shall be E8.6.3.7 Muting is typically accomplished by accomplished in a manner that conforms to the interface circuits or auxiliary controls. The requirements of 6.11 and 8.8.
  • Page 122 Shadow 8 User Manual 1139300 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.11 (cont) Means of supplemental safeguarding can include completely filling the fixed blanked area to restrict access to the hazard, installing the device at a distance that accounts for the worse case object sensitivity (see 8.6.3.16), or...
  • Page 123 1139300 Shadow 8 User Manual Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.16 (cont) Tbm = the additional stopping time allowed by the stopping-performance monitor before it detects stop time deterioration. Dpf = the added distance due to the penetration factor as recommended in ANSI B11.19, Annex...
  • Page 124 Shadow 8 User Manual 1139300 Extracts from ANSI B11.1-2009 8.6.3 Standards Requirements Explanatory Information 8.6.3.17 If the position of the device will allow E8.6.3.17 Additional means may include the operator or others to place themselves manual reset outside of the sensing field of the...
  • Page 125 1139300 Shadow 8 User Manual 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 126 Shadow 8 User Manual 1139300 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information 8.3.1.6 The presence-sensing device shall have a maximum response time that shall not be affected by object sensitivity or environmental changes. The safeguarding supplier shall provide the maximum response time of the presence- sensing device.
  • Page 127 1139300 Shadow 8 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 EB.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 128 Shadow 8 User Manual 1139300 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 129 1139300 Shadow 8 User Manual Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information The reset device shall be located outside of the Key lock reset switches located at various safeguarded area such that it cannot be positions around the safeguarded area may be reached from within the safeguarded area.
  • Page 130 Shadow 8 User Manual 1139300 Extracts from ANSI B11.19-2003 8.3 Standards Requirements Explanatory Information When the device is bypassed, other When bypassed, the device's normal status safeguarding must be provided and used. indicators can be misleading if still active. One...
  • Page 131 1139300 Shadow 8 User Manual Extracts from ANSI B11.19-2003 Annex D Annex D - Safety Distance (Informative) The safeguarding devices listed below do not prevent an individual from reaching into a hazard area. In order for these devices to be effective, they must either prevent the start of, or stop hazardous motion (or situation) when an individual is exposed to the hazard.
  • Page 132 Shadow 8 User Manual 1139300 T includes portions of time that vary by machine type and by the safeguarding device applied. The following affect the total stopping time: a) Type of actuator; i. Full revolution clutch, or machines that cannot be stopped during a machine cycle.
  • Page 133 1139300 Shadow 8 User Manual drive system. This time should take into consideration both uncontrolled stops (category 0) and controlled stops (categories 1 and 2) including dynamic braking. See ANSI / NFPA 79. Note 5: The stopping time, Ts, of machines actuated or controlled by pneumatic or hydraulic valves must include the reaction time of the valve measured from the time that the valve is de- energized until motion is stopped.
  • Page 134 Shadow 8 User Manual 1139300 Equation 7 can be used to calculate the safety distance for the eight safeguarding devices listed in paragraph 2 by substituting the non-zero values or combination of values as determined above. NOTE ON THE FOLLOWING FIGURES: Figures D.1 through D.3 provide the reader with the means to find the value of Dpf they need to use in the safety distance formula.
  • Page 135 1139300 Shadow 8 User Manual D-22 Extracts from OSHA and ANSI...
  • Page 136 Shadow 8 User Manual 1139300 Extracts from OSHA and ANSI D-23...
  • Page 137 1139300 Shadow 8 User Manual D-24 Extracts from OSHA and ANSI...

  • Page 138: Glossary

    Stands for External Device Monitoring (EDM), a safety function that monitors the Shadow 8 interface to the guarded machine. EDM checks the interfacing relays to verify that they are responding correctly to the light curtain and that there is no inconsistency between the state of relays and that of the safety outputs.
  • Page 139 OSSD Stands for Output Signal Switching Device, a type of safety output. Shadow 8 has two OSSD outputs that can be connected to the guarded machine’s emergency stop circuit to stop the machine whenever the light curtain is obstructed.
  • Page 140 DIP switches. See option switches alignment aligning brackets , 2-21 –E– aligning optic heads , 2-49 emergency stop circuit, wiring Shadow 8 to , 2-39 checking optic head alignment , 4-7 extension optic heads American National Standards Institute (ANSI) adding...
  • Page 141 Programmable AC power Logic Controller (PLC) , 2-37 , 2-42 External Device Monitoring (EDM) wiring stop relay outputs to a Wintriss clutch/ , 2-41 main optic heads brake control , 2-31 , 2-43 –K–...
  • Page 142 –W– wiring to a Programmable Logic Controller (PLC) , 2-42 Wintriss clutch/brake control (WPC) wiring to a Wintriss clutch/brake control wiring Shadow 8 main optic heads directly (WPC) , 2-43 , A-1 stopping time wiring stop relays outputs to , 2-43...

  • Page 143: Index

    1139300 Shadow 8 User Manual Index...

  • Page 144: Wintriss Manuals

    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 & ProCamPAC) DA71439 DA71454 SmartPAC Hydraulic DA71435 DA71451 SmartPAC Run Mode (Spanish) N.

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