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Banner EZ-SCREEN Instruction Manual

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EZ-SCREEN Features
•
Non-contact safety device for perimeter and
access guarding from dangerous machinery
•
Diverse-redundant and self-checking design to
achieve control reliability and meet IEC 61496-1
type 4 requirements
•
Choose models with 2, 3, or 4 beams, beam
spacing from 300 to 584 mm (12" to 23")
•
Self-contained two-part system is optically
synchronized:
Needs no external controller
Needs no extra synchronization wire
Easy and economical to install
•
Operating range 0.8 to 20 m or 15 to 70 m
(2.6' to 65' or 49' to 230')
•
Selectable external device monitoring
•
Selectable trip or latch output
•
Fast 24 millisecond output response time for all
models
•
Easy-to-use removable terminal blocks or quick-
disconnect options speed and simplify wiring
•
Compact, robust housing
•
Multiple mounting options
•
Optional accessory interface module available
for ac or larger dc loads
•
Configuration settings accessible from the front,
with supplied tool. Sensor settings can be
changed while sensor remains mounted.
Printed in USA
EZ-SCREEN
Instruction Manual
Section 1
Section 2
Section 3
Section 4
Section 5
Section 6
09/01
Grid
™
Section Contents
Introduction Overview . . . . . . . . . . . . . . . . . .Page 4
System Components and Specifications . . . .Page 10
Installation and Alignment . . . . . . . . . . . . . .Page 16
System Operation . . . . . . . . . . . . . . . . . . . .Page 40
Troubleshooting and Maintenance . . . . . . . .Page 45
Periodic Checkout Procedures . . . . . . . . . . .Page 51
9714 10th Avenue North • Minneapolis, MN 55441
Phone: 763.544.3164 • http://www.bannerengineering.com
Email: sensors@bannerengineering.com
US
LISTED
P/N 68410

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Summary of Contents for Banner EZ-SCREEN

  • Page 1 EZ-SCREEN Grid ™ Instruction Manual EZ-SCREEN Features • Non-contact safety device for perimeter and access guarding from dangerous machinery • Diverse-redundant and self-checking design to achieve control reliability and meet IEC 61496-1 type 4 requirements • Choose models with 2, 3, or 4 beams, beam spacing from 300 to 584 mm (12"...
  • Page 2 They may be used with part-revolution clutched machines that have the applications ability to stop at any point in their stroke. Under no circumstances may the EZ-SCREEN System • To guard any machine that cannot be be used on full-revolution clutched machinery.

  • Page 3: Table Of Contents

    EZ-SCREEN Grid Table of Contents Instruction Manual Table of Contents 1. Introduction — Overview ..... page 4 5. Troubleshooting and Maintenance ....Page 45 1.1 System Description .

  • Page 4: Introduction - Overview

    The receiver has two solid-state safety outputs to control 24V dc loads. If an ac-powered MPCE or other load is required, an accessory interface module may be used to convert the EZ-SCREEN dc outputs to isolated, forced-guided relay contacts. (See Section 2.2 and Figures 3-17 and 3-18 for more information.)
  • Page 5 57-58. See Section 2.5 for cable specifications and Section 3.7 for wiring instructions. Banner EZ-SCREEN Grid components may be purchased individually or in kits. Kits include one emitter, one receiver, a keyed reset switch, and standard mounting hardware for both sensors.

  • Page 6: Applications And Limitations

    Instruction Manual 1.2 Applications and Limitations WARNING . . . Not for Point-of- The Banner EZ-SCREEN Grid System is designed for use in access-guarding and Operation or Area perimeter-guarding applications. It is designed to be mounted vertically, in order Guarding...
  • Page 7 Because the EZ-SCREEN Grid has a selectable (latch or trip) output, it must be installed and configured to prevent hazardous motion from occurring while personnel are within the guarded area.

  • Page 8: Control Reliability

    1.3 Control Reliability In addition to physical location requirements, safety standards require a safety system such as the EZ-SCREEN Grid to fulfill some internal requirements. For example, for an optical safety system to be used in a Safety Category 4 application (per ISO 13849-1/EN954-1), it must be third-party certified to the type 4 requirements of IEC 61496-1 and -2.
  • Page 9 The trip output will also automatically reset after all interruptions of one or more beams are cleared. If latch output is selected, the EZ-SCREEN requires a manual reset for the OSSD outputs to turn ON, after power is applied and all beams are clear (see Section 4.2.1).

  • Page 10: System Components And Specifications

    Proper Model 2.1 Models Available Selection Ensure proper Banner EZ-SCREEN Grid components may be purchased individually or in kits. selection of emitter models, Kits (as indicated below) include one emitter, one receiver, a keyed reset switch, with respect to range (operating...
  • Page 11 EZ-SCREEN Grid System Components Instruction Manual Lens Shields NOTE: The total range decreases by approximately 10% per shield. Part Model Number Fits EZ-SCREEN Models Length EZS-684 61949 SG..E/R2-500 684 mm EZS-768 61950 SG..E/R2-584 768 mm 984 mm EZS-984 61951 SG..E/R3-400...

  • Page 12: Replacement Parts

    EZ-SCREEN Grid System Components Instruction Manual MSA Series Stands Part Model Number Height To Fit Sensor Models To Fit Mirror Models MSA-S42-1 43175 42" SG..2-584, SG..2-500 SSM-550, SSM-675 SG..3-533, SG..3-400, Usable MSA-S66-1 43176 66" SSM-975, SSM-1175 Pole Stand SG..4-300 40 mm Height (1.58") Square...

  • Page 13: Specifications

    Two diverse-redundant solid-state 24V dc, 0.5 A max. sourcing OSSD (Output Signal Switching Device) safety outputs. (Use optional interface modules for ac or larger dc loads.) Capable of the Banner “Safety Handshake” (see Section 1.1). Outputs ON-State voltage: ≥Vin-1.5V dc (See Warnings on page 33.)
  • Page 14 Operating conditions Max. Relative Humidity: 95% maximum relative humidity (non-condensing) EZ-SCREEN systems have passed vibration and shock tests according to IEC 61496-1 and -2. Shock and Vibration This includes vibration (10 cycles) of 10-55 Hz at 0.35 mm (0.014") single amplitude (0.70 mm peak-to-peak) and shock of 10 g for 16 milliseconds (6,000 cycles).

  • Page 15: Dimensions

    (0.23") about other accessory brackets. (1.69") Figure 2-1. EZ-SCREEN dimensions (standard end-cap brackets shown) and EZA-MBK-1 mounting bracket dimensions 2.6 Dimensions Figure 2-1 shows the dimensions of the five basic configurations, including the placement of the individual beams. Note that beam spacing varies from model to model;...

  • Page 16: Installation And Alignment

    • Robotic work cells Read all of Section 3 of this manual carefully before installing The Banner EZ-SCREEN Grid System may not be used in the following types of the system. Failure to follow these applications: instructions could result in serious •...

  • Page 17: Security Protocol

    EZ-SCREEN Grid System and its integration with the guarded machine. In addition to everything for which the Designated Person is empowered, the Qualified Person is empowered to: •...

  • Page 18: Mechanical Installation Considerations

    Separation distance is calculated so that the EZ-SCREEN Grid System will send a stop signal to the machine when an object or a person is detected (by blocking a sensing beam), allowing the machine to come to a stop by the time the person can reach any machine hazard point.
  • Page 19 = 36" or 48", the added distance due to depth penetration factor (for U.S. applications, prescribed in ANSI/RIA R15.06 and ANSI B11). Because the beam spacing of the EZ-SCREEN Grid is larger than 2.5" but less than 24", D pf is either 36" or 48": Beam 2 •...
  • Page 20 Adequate Separation D s = 58" Distance In this example, the EZ-SCREEN Grid emitter and receiver must be mounted so that no part of the light grid will be closer than 58" from the closest The emitter and receiver must be reachable hazard point of the guarded machine.

  • Page 21: Supplemental Safeguarding

    EZ-SCREEN Reset switch (i.e. behind the robot and the conveyor). Additional supplemental safeguarding may be required by relevant standards, such as preventing clearance or trapping hazards as described by ANSI/RIA R15.06 (e.g.

  • Page 22: Emitter/Receiver Orientation

    Emitter Failure to do so will impair the Emitter Receiver Receiver performance of the EZ-SCREEN System and result in incomplete Beam 1 guarding; serious bodily injury or Beam 1 Beam 1 Beam 1 death could result.

  • Page 23: Adjacent Reflective Surfaces

    EZ-SCREEN Grid Installation and Alignment Instruction Manual 3.3.4 Adjacent Reflective Surfaces WARNING . . . Avoid Installation Near A reflective surface located adjacent to the light grid may deflect one or more Reflective Surfaces beams around an object in the light grid. In the worst case, such a situation may allow an object to pass undetected through the light grid.

  • Page 24: Use Of Corner Mirrors

    3.3.5 Use of Corner Mirrors WARNING . . . Avoid Retroreflective EZ-SCREEN Grid Systems may be used with one or more vertical corner mirrors Installation in perimeter-guarding applications (see Section 2.2 for availability). The use of corner mirrors reduces the maximum specified emitter/receiver separation by Do not install emitters and approximately 8 percent per mirror (see Section 3.4).

  • Page 25: Avoiding Electrical And Optical Noise

    “see” an emitter set to another code. See Section 4.1 for more information. Figure 3-8. Mounting multiple EZ-SCREEN emitters and receivers to mechanically prevent optical crosstalk Banner Engineering Corp. Minneapolis, MN U.S.A.

  • Page 26: Mechanical Mounting Procedure

    Short-range emitters and receivers may be mounted up to 20 m (65') apart. Long-range emitters and receivers may be mounted between 15 m (49') and 70 m (230') apart. If Banner SSM corner mirrors are used, the total range decreases by approximately 8 percent per mirror, as follows:...
  • Page 27 Installation Without Mirrors 1. If using Banner MSA series stands and bases to mount the EZ-SCREEN emitter and receiver, position the bases at the desired locations and loosely mount using the bolt locations in the four corners as described in the MSA literature. Do not tighten the mounting nuts, because the stand and sensor must still be leveled.

  • Page 28: Electrical Connections

    • Make no connections to the into the EZ-SCREEN System. It is good wiring practice (and may be System other than those required by code) to isolate EZ-SCREEN System wires from high-voltage described in Section 3.5 of this...
  • Page 29 Terminals 7, 8 and 9 are provided to allow convenient power connection (24V dc, 2 amp max.) to another EZ-SCREEN emitter. These terminals are a direct connection to terminals 3, 2 and 1 respectively. A 24V dc, 2-amp external fuse is recommended to limit the current on terminal 7.

  • Page 30: Light Grid Initial Checkout And Optical Alignment Procedure

    Remaining problem reflections will become apparent during step 5. 2) Verify that power is removed from the EZ-SCREEN Grid System and from the guarded machine. Remove all obstructions from the light grid. Leaving power to the guarded machine OFF, power up the EZ-SCREEN Grid System.
  • Page 31 Do not slide the LAT-1 along the length of either sensor; emitter housing twist may deflect the laser beam, resulting in misalignment. Any twist in the housing (a normal occurrence) is compensated for within the EZ-SCREEN optic components. Receiver Retroreflective Tape...
  • Page 32 Installation and Alignment Instruction Manual 1) Attach the battery-powered LAT-1 to the housing of the emitter over the location of beam 1 (closest to the display), using the EZ-SCREEN bracket clip included Emitter Receiver with the tool. A dot on the sensor housing next to the lens window indicates the beam’s location.

  • Page 33: Electrical Interface To The Guarded Machine (Permanent Hookup)

    Depending on the application, the use of FSDs can facilitate controlling voltage Machine Control circuitry must be and current that differs from the OSSD outputs of the EZ-SCREEN. FSDs can also designed so that the maximum load be used to control an additional number of hazards by creating multiple safety resistance value is not exceeded stop circuits.
  • Page 34 EZ-SCREEN. The normally open safety outputs from an interface module provide a series connection of redundant contacts that form safety stop circuits for use in either 1-channel or 2-channel control.

  • Page 35: Machine Primary Control Elements And Edm Inputs

    DIP switch EDM settings on the receiver (see Section 4.1). One- and 2-channel EDM is used when the EZ-SCREEN Grid OSSD outputs directly control the energizing and de- energizing of the guarded machine’s MPCEs.

  • Page 36: Remote Test Input

    A pair of terminals is provided on the emitter terminal block (labeled TEST1 and TEST2) for the connection of an external remote test switch (typically a normally open contact held closed). This remote test input may be useful for EZ-SCREEN Grid System setup and checkout procedures. Opening this switch “turns OFF” the emitter, simulating an interruption of the light beams;...
  • Page 37 FSD1 and FSD2 is recommended. NOTE: Do not exceed machine could result in serious OSSD maximum load capacitance specification. bodily injury or death. Figure 3-16. EZ-SCREEN receiver generic hookup – FSD (2-channel EDM, key reset) Banner Engineering Corp. Minneapolis, MN U.S.A. •...
  • Page 38 WARNING . . . OSSD Interfacing To ensure proper operation, the EZ-SCREEN OSSD output parameters and machine input parameters must be considered when interfacing the EZ-SCREEN solid-state OSSD outputs to machine inputs. Machine Control circuitry must be designed so that the maximum load resistance value is not exceeded and that the maximum specified OSSD OFF-state voltage does not result in an ON condition.
  • Page 39 WARNING . . . OSSD Interfacing To ensure proper operation, the EZ-SCREEN OSSD output parameters and machine input parameters must be considered when interfacing the EZ-SCREEN solid-state OSSD outputs to machine inputs. Machine Control circuitry must be designed so that the maximum load resistance value is not exceeded and that the maximum specified OSSD OFF-state voltage does not result in an ON condition.

  • Page 40: System Operation

    1 position. For 2-channel monitoring or no monitoring, set both EDM DIP switches to the 2 position. See Section 3.7.3 for more information. Emitter Receiver EZ-SCREEN Grid EZ-SCREEN Grid Figure 4-1. EZ-SCREEN Grid configuration switches Banner Engineering Corp. Minneapolis, MN U.S.A. • www.bannerengineering.com • Tel: 763.544.3164 page...

  • Page 41: Reset Procedures

    4.2 Reset Procedures 4.2.1 Receiver Resets The EZ-SCREEN Grid receiver has a RESET input, terminal 5, that allows the System to be manually reset. To reset the receiver, close the Reset switch for 1/4 to 2 seconds, then open the Reset switch. (If Reset switch model MGA-KS0-1, listed in Section 2, is used, close the switch by turning the key 1/4 turn clockwise;...
  • Page 42 EZ-SCREEN Grid System Operation Instruction Manual Receiver: A bi-color red/green Beam Status indicator for each beam shows whether that beam is aligned and clear with a strong signal, clear but with a weak signal, or is blocked and/or misaligned. A yellow Reset indicator shows when the system is in Run mode or is waiting for a reset.

  • Page 43: Normal Operation

    EZ-SCREEN Grid System Operation Instruction Manual 4.4 Normal Operation System Power-Up The System will power up in one of two ways, depending on the Trip/Latch output configuration. If the System is set for Trip output, it will power up and reset automatically;...

  • Page 44: Periodic Checkout Requirements

    (see Section 6.5). A copy of these test results should be posted on or near the machine. Whenever changes are made to the System (either a new configuration of the EZ-SCREEN System or changes to the machine), the Commissioning Checkout should be performed (see Section 6.3). Banner Engineering Corp.

  • Page 45: Troubleshooting And Maintenance

    Evaluate status indicators per Section 4.3. 5.1 Troubleshooting Lockout Conditions A lockout condition causes all of the EZ-SCREEN OSSD outputs to turn or remain OFF, sending a “stop” signal to the guarded machine. Each sensor provides diagnostic error codes to assist in the identification of the cause(s) of Lockouts (see Figure 5-1).

  • Page 46: Receiver Error Codes

    EZ-SCREEN Grid Troubleshooting and Maintenance Instruction Manual 5.1.1 Receiver Error Codes Refer to Figure 5-1 for a full description of receiver error codes and what to do when they occur. Diagnostic Error Display Description Appropriate Action Output Error • Disconnect the OSSD loads and reset the receiver.
  • Page 47 EZ-SCREEN Grid Troubleshooting and Maintenance Instruction Manual Diagnostic Error Display Description Appropriate Action DIP Switch Error • Verify that the DIP switch settings are valid (per Section 4.1). Make any This error can be caused by incorrect corrections necessary and perform a receiver reset.

  • Page 48: Emitter Error Codes

    EZ-SCREEN Grid Troubleshooting and Maintenance Instruction Manual 5.1.2 Emitter Error Codes NOTE: The emitter flashes the number 2 followed by the other error code digit, pauses, then flashes the sequence again. Diagnostic Error Display Description Cause of Error Test Input Error •...

  • Page 49: Electrical And Optical Noise

    Turn off the emitter, completely block the emitter beams, or open the Test input, Person (see Safety Glossary). then use a Banner BT-1 Beam Tracker to check for light at the receiver. Press the “RCV” button on the BT-1 and move it across the full length of the receiver’s sensing window.

  • Page 50: Test Mode

    NEMA 1 (IP20). It may be dusted, but avoid contact with any liquids. Warranty Service The EZ-SCREEN System is designed for reliability. Do not open the emitter or receiver housings, other than to access the configuration port or to make terminal connections.

  • Page 51: Checkout Procedures

    The procedure must be performed by a Qualified Person. Commissioning Checkout: Should be performed at installation or whenever changes are made to the system (either a new configuration of the EZ-SCREEN System or changes to the machine). The procedure must be performed by a Qualified Person.
  • Page 52 Green. Do not continue operation until the entire checkout procedure is complete and all problems are corrected. Mirror #1 Figure 6-2. EZ-SCREEN Grid trip test with corner mirrors Banner Engineering Corp. Minneapolis, MN U.S.A. • www.bannerengineering.com • Tel: 763.544.3164 page...

  • Page 53: Commissioning Checkout

    1) Examine the guarded machine to verify that it is of a type and design compatible with the EZ-SCREEN Grid System. See page 2 for a list of misapplications. 2) Verify that the minimum separation distance from the closest danger point of the guarded machine to the Safety Light Grid is not less than the calculated distance, per Section 3.3.1 of this manual.
  • Page 54 Failure to do so could result in serious bodily injury or death. 13) Remove electrical power to the EZ-SCREEN Grid System. All OSSD outputs should immediately turn OFF, and should not be capable of turning ON until power is re-applied and, if in Latch Output mode, a manual reset is performed (Trip Output mode requires no manual reset).

  • Page 55: Daily Checkout

    5) Test the effectiveness of the EZ-SCREEN Grid System with power ON, using the trip test (Section 6.2). 6) Initiate machine motion of the guarded machine and, while it is moving, use the supplied test piece to block one of the grid beams.

  • Page 56: Semi-Annual Checkout

    3) Inspect the guarded machine to verify that no other mechanical or structural problems could prevent the machine from stopping or assuming an otherwise safe condition when signalled to do so by the EZ-SCREEN Grid System. 4) Examine and inspect the machine controls and connections to the EZ- SCREEN Grid System to verify that no modifications have been made which adversely affect the System.

  • Page 57: Appendix - Qd Models

    EZ-SCREEN Grid Appendix Instruction Manual EZ-SCREEN Grid Quick-Disconnect Models Short-Range Models Long-Range Models Number Beam Protected (0.8 m - 20 m) (15 m - 70 m) Connector of Beams Spacing Height 3-pin Mini-style QD, SGE2-584Q3 Emitter SGXLE2-584Q3 Emitter (Test input jumpered)

  • Page 58: Qd Model Accessories

    – Converts hard-wire end cap to QD model Models Description EZA-QDE-3 3-pin for emitter (Test input jumpered) EZA-QDE-5 5-pin for emitter (Test input available) EZA-QDE-8 8-pin for receiver Banner Engineering Corp. Minneapolis, MN U.S.A. • www.bannerengineering.com • Tel: 763.544.3164 page...

  • Page 59: Accessory Bracket Dimensions

    30.0 mm (0.83") (1.18") 4.0 mm (0.16") 10.0 mm 4.2 mm (0.39") (0.17") 14.0 mm 31.0 mm (0.55") (1.22") 2x 7.0 mm (0.28") 52.0 mm 60.0 mm (2.05") (2.36") Banner Engineering Corp. Minneapolis, MN U.S.A. • www.bannerengineering.com • Tel: 763.544.3164 page...

  • Page 60: Glossary Of Safety Terms

    Machine response time: The time between the interruption analyzed to determine their results or effects on the system. by the EZ-SCREEN OSSDs and the instant when the danger- Component failure modes that produce either no effect or a ous parts of the machine reach a safe state by being lockout condition are permitted;...
  • Page 61 (e.g., Test piece: An opaque object of sufficient size used to block shearing, forming, punching, assembling, welding) is a light grid beam to test the operation of the EZ-SCREEN performed upon it. Grid System.

  • Page 62: Safety Standards

    EZ-SCREEN Grid Safety Standards Instruction Manual U.S. Application Standards SOURCES ANSI B11 Documents American National Standards ANSI B11.1 ANSI B11.13 Institute Machine Tools – Mechanical Power Machine Tools – 11 West 42nd Street Presses – Safety Requirements for Single – and Multiple-Spindle...
  • Page 63 EZ-SCREEN Grid Safety Standards Instruction Manual SOURCE U.S. Design Standards Underwriters Laboratories Inc. 333 Pfingsten Road UL 991 UL 1998 Northbrook, IL 60062-2096 Tests for Safety-Related Controls Standard for Safety-Related Software Employing Solid-state Devices Telephone: (847) 272-8800 SOURCE OSHA Regulations...
  • Page 64 This warranty does not cover damage or liability for the improper application of Banner products. This warranty is in lieu of any other warranty either expressed or implied.

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