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Columbus McKinnon MAGNETEK LaserGuard 2 Technical Manual

Laser collision avoidance system
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LaserGuard™ 2
Laser Collision Avoidance System
Technical Manual
Part Number: 144-20004 R3
February 2025
© Copyright 2025 Magnetek

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Summary of Contents for Columbus McKinnon MAGNETEK LaserGuard 2

  • Page 1 LaserGuard™ 2 Laser Collision Avoidance System Technical Manual Part Number: 144-20004 R3 February 2025 © Copyright 2025 Magnetek...

  • Page 2: Service Information

    This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of the Columbus McKinnon Corporation.

  • Page 3: Product Safety Information

    PRODUCT SAFETY INFORMATION Magnetek offers a broad range of radio remote control products, control products and adjustable ® frequency drives, industrial braking systems, and power delivery products for material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek Products).

  • Page 4: Danger, Warning, Caution, And Note Statements

    DANGER, WARNING, CAUTION, and NOTE Statements Read and understand this manual before installing, operating, or servicing this product. Install the product according to this manual and local codes. The following conventions indicate safety messages in this manual. Failure to heed these messages could cause fatal injury or damage products and related equipment and systems.
  • Page 5 Collision Avoidance Unit Warnings WARNING Range detector relays should never be electrically or mechanically disabled to be ON or OFF for any crane motion. If the unit is for any reason disengaged or turned off the crane operating personnel must be notified immediately, and proper alternate precautions should be taken.

  • Page 6: Table Of Contents

    Table of Contents Product Warranty Information ........................3 DANGER, WARNING, CAUTION, and NOTE Statements ............... 4 LaserGuard2 System Information ..................... 7 1.1. Model Numbers ........................... 7 1.2. Class 1 Laser Device ........................7 1.3. System Description ........................7 1.4. Optical Path Fault Detector ......................8 1.5.

  • Page 7: Laserguard2 System Information

    1. LaserGuard2 System Information Optional 1.1. Model Numbers LG2 – H – 4 – XX 25 = 25m cable 40 = 40m cable 75 = 75m cable 4 = NEMA 4 Enclosure 4X = NEMA 4X Enclosure S5 = Built-In Series 5 VFD Intelligence H = High Voltage (85-264 VAC or 120-370 VDC) L = Low Voltage (9-36 VDC) 1.2.

  • Page 8: Optical Path Fault Detector

    A rugged, fully adjustable mount is also supplied with the system, along with a reflective target. The target is mounted on the wall or other crane that is going to be protected by the collision avoidance system. The LSU contains three fully adjustable range detectors and a fault detector. The range detectors are adjustable to trip the relays from approximately 8 in.

  • Page 9: System Specifications

    1.6. System Specifications Laser Support Unit (LSU) Specification Laser LG2-H-4 LG2-L-4 LG2-H-4X LG2-L-4X Operating -30° to 50°C -30° to 70°C Temperature Operating Range 8 in.-150 ft. 85 - 264 VAC or 85 - 264 VAC or Input Voltage 9-36 VDC 9-36 VDC 120 - 370 VDC 120 - 370 VDC...

  • Page 10: Installation Information

    2. Installation Information NOTE: In the event that parts of an original LaserGuard system are used with the LaserGuard2, please refer to the LaserGuard2 Replacement Guide Application Bulletin on http://www.magnetekmh.com. CAUTION THE LASER CONTROL UNIT AND RELAYS ARE NOT RATED AS EXPLOSION PROOF. THE UNIT MUST NOT BE INSTALLED IN EXPLOSIVE ENVIRONMENTS UNLESS APPROPRIATE SECONDARY ENCLOSURE MEASURES ARE TAKEN.

  • Page 11: Laser Dimensions

    2.4. Laser Dimensions Figure 2: Laser Sensor (P/N: LG2-HEAD) Dimensions (mm) LaserGuard2 Technical Manual February 2025 Page 11 of 36...

  • Page 12: Mechanical Installation

    2.5. Mechanical Installation The Collision Avoidance System measures the distance between the laser unit's lens and the target surface. There must be no projections on the wall or the overhead crane that may extend in front of either (or both) the laser unit or the companion target.
  • Page 13 Figure 4: Laser Mounting Bracket Dimensions (mm) LaserGuard2 Technical Manual February 2025 Page 13 of 36...
  • Page 14 Figure 5: LG2-x-4 Mounting Instructions LaserGuard2 Technical Manual February 2025 Page 14 of 36...
  • Page 15 Figure 6: LG2-x-4X Laser Bracket (P/N: 147-20043) Figure 7: LG2-x-4X Enclosure Bracket (P/N: 147-20073) LaserGuard2 Technical Manual February 2025 Page 15 of 36...
  • Page 16 Figure 8: LG2-x-4X Mounting Instructions Install the laser and the target in the positions found in Figure 9 and Figure 10. Mount the laser securely to a solid surface to minimize vibration so that the crane’s load or movement will not affect the laser’s alignment.
  • Page 17 Figure 9: Laser and Target Installation LaserGuard2 Technical Manual February 2025 Page 17 of 36...
  • Page 18 For best reflectivity/laser signal, mount the reflector in the same orientation as the laser so the laser beam is perpendicular to the reflector. The arrow on the back of the reflector should be the same direction as the laser (refer to Figure 10). Figure 10: Laser and Target Orientation LaserGuard2 Technical Manual February 2025...
  • Page 19 Figure 11: Target Dimensions (P/N: REFLX-R) LaserGuard2 Technical Manual February 2025 Page 19 of 36...
  • Page 20 Figure 12: Enclosure (P/N: 23226T) Dimensions for LG2-x-4 A – 12.00 in (305 mm) G – 10.50 in (267 mm) B – 12.00 in (305 mm) H – 10.50 in (267 mm) C – 6.00 in (152 mm) M – 8.74 in (222 mm) D –...

  • Page 21: Electrical Installation

    2.6. Electrical Installation The laser unit interface cable and all other wiring should be run in separate 1/2" or 3/4" conduit. Do not run any other cables in the same conduit with the laser head cable. A suitable disconnect should be provided by the installer. Run conduit between the laser support unit and the crane's control panel.
  • Page 22 Figure 15: Laser Support Unit (P/N: LG2-H-LSU) Wiring for LG2-H-4 LaserGuard2 Technical Manual February 2025 Page 22 of 36...
  • Page 23 Figure 16: Laser Support Unit (P/N: LG2-L-LSU) Wiring for LG2-L-4 LaserGuard2 Technical Manual February 2025 Page 23 of 36...
  • Page 24 Figure 17: Laser Connector Wiring Diagram Wire the outputs of the laser support unit (TB3) to the crane control panel (refer to Figure 15 or Figure 18). The recommended wire size is 16 AWG, but can be between 24 to 12 AWG. Please observe National Electrical Code (NEC) guidelines when wiring electrical devices.

  • Page 25: Mechanical Alignment

    When using the LG2-L-S5 model variant (LaserGuard Series 5 Kit), the laser sensor head will be wired directly to the IMPULSE® Series 5 VFD analog input terminals. Blue Wire  0V (SN) Brown Wire  24V Input (SP) White Wire  Analog Input 1-3 (A1/A2/A3) Optionally: The laser can be routed to the external power supply and relay assembly (LG2-S5-PSU).

  • Page 26: Fault Check

    1. Move the crane to the point at which the warning is needed and press the white WARNING button. 2. Move the crane to the slowdown point and press the gray SLOWDOWN button. This distance must be less than that in the previous step. 3.

  • Page 27: Color Function

    Table 1: Laser Diagnostic LED Functions NOTE: See Figure 18 for LED locations. COLOR FUNCTION Laser Head Green Monitors voltage to the Laser Head Operating Display Normally ON. Laser Head Yellow Monitors target acquisition. Signal Normally ON when target is acquired. It turns off when the laser is off the target, out of range, or has a dirty lens.

  • Page 28: Installation Diagrams

    3. Installation Diagrams Figure 18: Component Locations LaserGuard2 Technical Manual February 2025 Page 28 of 36...
  • Page 29 Figure 19: LaserGuard2 Stepped Series 4 VFD Control, Protection in One Direction (Recommended) LaserGuard2 Technical Manual February 2025 Page 29 of 36...
  • Page 30 Figure 20: LaserGuard2 Crane Control, Protection in One Direction LaserGuard2 Technical Manual February 2025 Page 30 of 36...
  • Page 31 Figure 21: LaserGuard2 Crane Control with Timed Bypass, Protection in One Direction LaserGuard2 Technical Manual February 2025 Page 31 of 36...
  • Page 32 Figure 22: LaserGuard Magnetic Crane Control, Protection in Both Directions LaserGuard2 Technical Manual February 2025 Page 32 of 36...
  • Page 33 Figure 23: LaserGuard2 Stepped VFD Control, Protection in One Direction LaserGuard2 Technical Manual February 2025 Page 33 of 36...
  • Page 34 Figure 24: Typical LaserGuard2 Interface with Stepless VFD Control LaserGuard2 Technical Manual February 2025 Page 34 of 36...
  • Page 35 Figure 25: Typical LaserGuard2 Interface with P&H Stepless Control LaserGuard2 Technical Manual February 2025 Page 35 of 36...
  • Page 36 LaserGuard2 Laser Collision Avoidance System Technical Manual February 2025...

This manual is also suitable for:

Lg2-h-4Lg2-l-4Lg2-h-4xLg2-l-4x

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