SGSMP3-400Q128 Datasheet by Banner Engineering Corporation

BANNER mesemsmmmsmmms moss
SGS Safety Grid System (Emitter/Receiver
with Integral Muting)
Instruction Manual
Original Instructions
203065 Rev. B
5 September 2019
© Banner Engineering Corp. All rights reserved
203065
Contents
1 About This Document .....................................................................................................................................................4
1.1 Important . . . Read This Before Proceeding! .................................................................................................................................. 4
1.2 Use of Warnings and Cautions ........................................................................................................................................................ 4
1.3 EU Declaration of Conformity (DoC) ................................................................................................................................................ 4
2 Standards and Regulations ............................................................................................................................................. 6
2.1 Applicable U.S. Standards ...............................................................................................................................................................6
2.2 Applicable OSHA Regulations ......................................................................................................................................................... 6
2.3 International/European Standards ................................................................................................................................................... 7
3 Product Overview ............................................................................................................................................................ 8
3.1 Models ............................................................................................................................................................................................. 8
3.2 Appropriate Applications and Limitations ........................................................................................................................................9
3.2.1 Appropriate Applications .......................................................................................................................................................10
3.2.2 Examples: Inappropriate Applications .................................................................................................................................. 10
3.2.3 Control Reliability: Redundancy and Self-Checking ............................................................................................................. 10
3.3 Operating Features ........................................................................................................................................................................ 10
3.3.1 Selectable Auto or Manual Start/Restart ................................................................................................................................10
3.3.2 External Device Monitoring (EDM) ..........................................................................................................................................11
3.3.3 Scan Code Configuration ......................................................................................................................................................11
3.3.4 Status Indicators ................................................................................................................................................................... 11
3.3.5 Muting Functions ...................................................................................................................................................................12
4 Mechanical Installation .................................................................................................................................................. 21
4.1 Mechanical Installation Considerations ........................................................................................................................................ 21
4.1.1 Safety (Minimum) Distance .....................................................................................................................................................21
4.1.2 Calculating Safety Distance Formula and Examples ............................................................................................................. 22
4.1.3 Reducing or Eliminating Pass-Through Hazards .................................................................................................................. 23
4.1.4 Supplemental Safeguarding ..................................................................................................................................................24
4.1.5 Reset Switch Location ........................................................................................................................................................... 24
4.1.6 Adjacent Reflective Surfaces ................................................................................................................................................ 25
4.1.7 Use of Corner Mirrors ............................................................................................................................................................26
4.1.8 Emitter and Receiver Orientation .......................................................................................................................................... 27
4.1.9 Installing Adjacent Systems .................................................................................................................................................. 27
4.2 Mounting System Components ..................................................................................................................................................... 28
4.2.1 Mounting Hardware ...............................................................................................................................................................28
4.2.2 Mounting the End-Mount Brackets ....................................................................................................................................... 29
4.2.3 Sensor Mounting and Mechanical Alignment ....................................................................................................................... 29
4.2.4 Mounting Dimensions .............................................................................................................................................................29
4.2.5 Mount the Muting Arms .........................................................................................................................................................30
4.2.6 Mounting the Muting Connection Box .................................................................................................................................. 31
5 Electrical Installation and Testing .................................................................................................................................. 32
5.1 Routing Cordsets ...........................................................................................................................................................................32
5.2 Initial Electrical Connections .........................................................................................................................................................33
5.3 Initial Checkout Procedure ............................................................................................................................................................ 33
5.3.1 Configuring the System for Initial Checkout ..........................................................................................................................33
5.3.2 Apply (Initial) Power to the System ........................................................................................................................................34
5.3.3 Optically Align the Components ............................................................................................................................................34
5.3.4 Optically Align the Components with Corner Mirrors ............................................................................................................36
5.3.5 Conduct a Trip Test ...............................................................................................................................................................37
5.4 Electrical Connections to the Guarded Machine .......................................................................................................................... 38
5.4.1 OSSD Output Connections .................................................................................................................................................... 38
5.4.2 FSD Interfacing Connections ................................................................................................................................................ 39
5.4.3 Machine Primary Control Elements and EDM Input ...............................................................................................................40
5.4.4 External Device Monitoring ................................................................................................................................................... 40
5.4.5 Select the Scan Code ............................................................................................................................................................ 41
5.4.6 Preparing for System Operation ............................................................................................................................................41
5.5 Wiring Diagrams .............................................................................................................................................................................41
5.5.1 Reference Wiring Diagrams ...................................................................................................................................................41
5.5.2 Generic Wiring Diagram for the Emitter ................................................................................................................................ 41
5.5.3 Generic Wiring for a Receiver and Safety Module/Controller or Safety PLC/PES ................................................................42
5.5.4 Generic Wiring for a Receiver and Redundant FSD ..............................................................................................................43
5.5.5 Generic Wiring for a Receiver and IM-T-9A Interface Module ............................................................................................... 44
5.5.6 Generic Mute Sensor Connections ....................................................................................................................................... 44
6 System Operation .........................................................................................................................................................46
6.1 Security Protocol .......................................................................................................................................................................... 46
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
6.2 System Configuration Settings ..................................................................................................................................................... 46
6.3 Reset Procedures ......................................................................................................................................................................... 47
6.3.1 Reset the Receiver or Active Transceiver After a Lockout ....................................................................................................47
6.3.2 Reset in Manual Start/Restart Mode .....................................................................................................................................48
6.4 Normal Operation ......................................................................................................................................................................... 48
6.4.1 System Power-Up ................................................................................................................................................................. 48
6.4.2 Run Mode ...............................................................................................................................................................................48
6.5 Periodic Checkout Requirements ................................................................................................................................................. 48
7 Product Support and Maintenance .............................................................................................................................. 49
7.1 Cleaning ........................................................................................................................................................................................49
7.2 Disposal ......................................................................................................................................................................................... 49
7.3 Warranty Service ...........................................................................................................................................................................49
7.4 Banner Engineering Corp Limited Warranty ................................................................................................................................. 49
7.5 Contact Us .....................................................................................................................................................................................49
8 Troubleshooting ............................................................................................................................................................50
8.1 Error Codes ...................................................................................................................................................................................50
8.2 Lockout Conditions ........................................................................................................................................................................52
8.3 Recovery Procedure ..................................................................................................................................................................... 52
8.4 Electrical and Optical Noise ..........................................................................................................................................................53
8.4.1 Check for Sources of Electrical Noise ...................................................................................................................................53
8.4.2 Check for Optical Noise Sources .......................................................................................................................................... 53
9 Checkout Procedures ....................................................................................................................................................54
9.1 Schedule of Checkouts .................................................................................................................................................................54
9.2 Perform a Commissioning Checkout ............................................................................................................................................54
9.3 Perform a Muting Checkout ..........................................................................................................................................................55
9.4 Perform a One-Way (Directional) Muting Checkout Procedure .....................................................................................................56
9.5 Perform an Exit-Only Application Checkout Procedure ............................................................................................................... 56
9.6 Perform a Mute-Dependent Override Checkout Procedure ......................................................................................................... 56
10 Typical Muting Applications ....................................................................................................................................... 57
10.1 Entry/Exit Applications ................................................................................................................................................................57
10.2 Robot Load/Unload Station Applications ................................................................................................................................... 59
11 Specifications ............................................................................................................................................................. 61
11.1 General Specifications .................................................................................................................................................................61
11.2 Dimensions .................................................................................................................................................................................. 62
11.3 Muting Arms Dimensions ............................................................................................................................................................63
12 Accessories ................................................................................................................................................................. 64
12.1 Bracket and Test Piece ................................................................................................................................................................64
12.2 Cordsets ..................................................................................................................................................................................... 64
12.2.1 Single-Ended (Machine Interface) Cables ........................................................................................................................... 64
12.2.2 Machine Interface Cordsets ................................................................................................................................................. 65
12.3 Muting Accessories .................................................................................................................................................................... 65
12.4 Universal (Input) Safety Modules ................................................................................................................................................ 66
12.5 Safety Controllers ........................................................................................................................................................................ 66
12.6 Interface Modules ........................................................................................................................................................................ 66
12.7 Contactors ................................................................................................................................................................................... 67
12.8 Alignment Aids ............................................................................................................................................................................67
12.9 SSM Series Corner Mirrors .........................................................................................................................................................67
12.10 MSA Series Stands ................................................................................................................................................................... 68
13 Glossary ......................................................................................................................................................................69
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
DD
1 About This Document
1.1 Important . . . Read This Before Proceeding!
It is the responsibility of the machine designer, controls engineer, machine builder, machine operator, and/or maintenance
personnel or electrician to apply and maintain this device in full compliance with all applicable regulations and standards.
The device can provide the required safeguarding function only if it is properly installed, properly operated, and properly
maintained. This manual attempts to provide complete installation, operation, and maintenance instruction.
Reading the
manual in its entirety is highly recommended.
Please direct any questions regarding the application or use of the device to
Banner Engineering.
For more information regarding U.S. and international institutions that provide safeguarding application and safeguarding
device performance standards, see
Standards and Regulations
(p. 6).
WARNING:
• The user is responsible for following these instructions.
•Failure to follow any of these responsibilities may potentially create a dangerous condition that
could result in serious injury or death.
• Carefully read, understand, and comply with all instructions for this device.
• Perform a risk assessment that includes the specific machine guarding application. Guidance on
a compliant methodology can be found in ISO 12100 or ANSI B11.0.
• Determine what safeguarding devices and methods are appropriate per the results of the risk
assessment and implement per all applicable local, state, and national codes and regulations.
See ISO 13849-1, ANSI B11.19, and/or other appropriate standards.
• Verify that the entire safeguarding system (including input devices, control systems, and output
devices) is properly configured and installed, operational, and working as intended for the
application.
• Periodically re-verify, as needed, that the entire safeguarding system is working as intended for
the application.
1.2 Use of Warnings and Cautions
The precautions and statements used throughout this document are indicated by alert symbols and must be followed for
the safe use of the SGS Safety Grid System with Integral Muting. Failure to follow all precautions and alerts may result in
unsafe use or operation. The following signal words and alert symbols are defined as follows:
Signal Word Definition Symbol
WARNING
Warnings refer to potentially hazardous situations which, if not
avoided, could result in serious injury or death.
CAUTION
Cautions refer to potentially hazardous situations which, if not
avoided, could result in minor or moderate injury.
These statements are intended to inform the machine designer and manufacturer, the end user, and maintenance
personnel, how to avoid misapplication and effectively apply the SGS Safety Grid System with Integral Muting to meet the
various safeguarding application requirements. These individuals are responsible to read and abide by these statements.
1.3 EU Declaration of Conformity (DoC)
Banner Engineering Corp. herewith declares that these products are in conformity with the provisions of the listed directives
and all essential health and safety requirements have been met.
Product Directive
SGS Safety Grid System with Integral Muting 2006/42/EC
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
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Representative in EU: Peter Mertens, Managing Director Banner Engineering Europe. Address: Park Lane, Culliganlaan 2F,
bus 3,1831 Diegem, Belgium.
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
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2 Standards and Regulations
The list of standards below is included as a convenience for users of this Banner device. Inclusion of the standards below
does not imply that the device complies specifically with any standard, other than those specified in the Specifications
section of this manual.
2.1 Applicable U.S. Standards
ANSI B11.0 Safety of Machinery, General Requirements,
and Risk Assessment
ANSI B11.1 Mechanical Power Presses
ANSI B11.2 Hydraulic Power Presses
ANSI B11.3 Power Press Brakes
ANSI B11.4 Shears
ANSI B11.5 Iron Workers
ANSI B11.6 Lathes
ANSI B11.7 Cold Headers and Cold Formers
ANSI B11.8 Drilling, Milling, and Boring
ANSI B11.9 Grinding Machines
ANSI B11.10 Metal Sawing Machines
ANSI B11.11 Gear Cutting Machines
ANSI B11.12 Roll Forming and Roll Bending Machines
ANSI B11.13 Single- and Multiple-Spindle Automatic Bar
and Chucking Machines
ANSI B11.14 Coil Slitting Machines
ANSI B11.15 Pipe, Tube, and Shape Bending Machines
ANSI B11.16 Metal Powder Compacting Presses
ANSI B11.17 Horizontal Extrusion Presses
ANSI B11.18 Machinery and Machine Systems for the
Processing of Coiled Strip, Sheet, and Plate
ANSI B11.19 Performance Criteria for Safeguarding
ANSI B11.20 Manufacturing Systems
ANSI B11.21 Machine Tools Using Lasers
ANSI B11.22 Numerically Controlled Turning Machines
ANSI B11.23 Machining Centers
ANSI B11.24 Transfer Machines
ANSI/RIA R15.06 Safety Requirements for Industrial Robots
and Robot Systems
ANSI NFPA 79 Electrical Standard for Industrial Machinery
ANSI/PMMI B155.1 Package Machinery and Packaging-
Related Converting Machinery — Safety Requirements
2.2 Applicable OSHA Regulations
OSHA Documents listed are part of: Code of Federal Regulations Title 29, Parts 1900 to 1910
OSHA 29 CFR 1910.212 General Requirements for (Guarding of) All Machines
OSHA 29 CFR 1910.147 The Control of Hazardous Energy (lockout/tagout)
OSHA 29 CFR 1910.217 (Guarding of) Mechanical Power Presses
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
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2.3 International/European Standards
EN ISO 12100 Safety of Machinery – General Principles for
Design — Risk Assessment and Risk Reduction
ISO 13857 Safety Distances . . . Upper and Lower Limbs
ISO 13850 (EN 418) Emergency Stop Devices, Functional
Aspects – Principles for Design
ISO 13851 Two-Hand Control Devices – Principles for
Design and Selection
IEC 62061 Functional Safety of Safety-Related Electrical,
Electronic and Programmable Control Systems
EN ISO 13849-1 Safety-Related Parts of Control Systems
EN 13855 (EN 999) The Positioning of Protective Equipment
in Respect to Approach Speeds of Parts of the Human Body
ISO 14119 (EN 1088) Interlocking Devices Associated with
Guards – Principles for Design and Selection
EN 60204-1 Electrical Equipment of Machines Part 1:
General Requirements
IEC 61496 Electro-sensitive Protection Equipment
IEC 60529 Degrees of Protection Provided by Enclosures
IEC 60947-1 Low Voltage Switchgear – General Rules
IEC 60947-5-1 Low Voltage Switchgear – Electromechanical
Control Circuit Devices
IEC 60947-5-5 Low Voltage Switchgear – Electrical
Emergency Stop Device with Mechanical Latching Function
IEC 61508 Functional Safety of Electrical/Electronic/
Programmable Electronic Safety-Related Systems
IEC 62046 Safety of Machinery – Applications of Protective
Equipment to Detect the Presence of Persons
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
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3 Product Overview
Banner SGS Safety Grid System with Integral Muting is a two-piece (emitter and
receiver), redundant, microprocessor-controlled, opposed-mode optoelectronic "light
grid". Standard models are available in 2 beam (500 mm beam spacing), 3 beam (400
mm beam spacing), or 4 beam (300 mm and 400 mm beam spacing) systems.
Emitters have a row of synchronized modulated infrared (invisible) light-emitting diodes
(LEDs) in a robust metal housing. Receivers have a corresponding row of synchronized
photodetectors. The sensing range spans from 0.5 m to 30 m (20 in to 98 ft). The
sensing range decreases if corner mirrors are used.
The SGS can be configured for Trip Output (Automatic start/restart) or Latch Output
(Manual start/restart). In typical operation, if any part of an operator's body (or any
opaque object) of more than a pre-determined cross section is detected, the solid-state
output signal switching device (OSSD) safety outputs turn Off. These safety outputs are
connected to the guarded machine's final switching devices (FSDs) that control the
machine primary control elements (MPCEs), which immediately stop the motion of the
guarded machine.
The SGS Safety Grid System with Integral Muting monitors the redundant mute device
inputs and automatically suspends (mutes) the safeguarding function of a device during
the non-hazardous portion of the machine cycle.
In this manual, the term 'muting' refers to the automatic suspension of the safeguarding
function of the primary safety device during a non-hazardous portion of the machine
cycle where personnel are not exposed to harm.
SGS sensors are extensively FMEA (Failure Mode and Effects Analysis) tested to
establish an extremely high degree of confidence that when properly installed, no
system component (even if it should ever fail) can cause a failure to danger.
SGS systems (receivers with 12-pin M12 QD) do not require an external controller when
using the external device monitoring (EDM) function. This function ensures the fault
detection capability required by U.S. Control Reliability and ISO 13849-1 Categories 3
or 4 and PL d or e for controlling final switching devices (FSDs) or Machine Primary
Control Elements (MPCEs).
When the SGS is connected to a self-checking safety module, safety controller, or
safety PLC/PES, that conforms to the level of performance required by the risk
assessment, the EDM function of the SGS is not used. Examples include the UM-
FA-9A/-11A safety module, SC10-2roe or XS/SC26-2 safety controller for applications
requiring Control Reliability and/or ISO 13849-1 Categories 3 or 4 and PL d or e.
The electrical connections to the muting sensors are made via 5-pin M12 QDs on the emitter and receiver. These
connections supply power to the sensors and receive the output status back from the sensors.
Electrical connections (power, ground, inputs and outputs) are made via M12 quick-disconnect cordsets.
Both the emitter and receiver feature 7-segment Diagnostic Displays and individual LEDs to provide continuous indication
of operating status, configuration and error conditions.
3.1 Models
An SGS Safety Grid System with Integral Muting refers to a compatible emitter and receiver of equal length and resolution
(available in pairs only), including their cordsets. Mounting hardware must be ordered separately. Interfacing solutions
include IM-T-.. modules, redundant positively guided contactors, safety modules/controllers, and muting modules.
WARNING: The emitters and receivers are tested and sold only as a unique pair (with matching serial
numbers) and must not be used with a mismatched emitter/receiver. The range and the Effective
Aperture Angle (EAA) can not be guaranteed if mismatched emitters and receivers are used. Failure to
follow these instructions could result in serious injury or death.
SGS Safety Grid System with Integral Muting pair model numbers include the following items:
Qty Description
1 SGS Safety Grid System with Integral Muting Receiver
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
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Qty Description
1 SGS Safety Grid System with Integral Muting Emitter
1 Literature packet with MiniDVD
The following items, ordered separately from the sensors, are required for a complete system.
Qty Description
1 End cap bracket kit (SGSA-MBK-10-4), includes four brackets per kit
2 Appropriate cables
See
Accessories
(p. 64) for a list of brackets and cordsets.
Table 1: SGS Safety Grid System Emitter/Receiver with Integral Muting Models
Model Beams Beam Spacing
(mm)
Protected Height
(mm)
Response Time (ms)
(with no scan code)
Response Time (ms)
(with scan code)
Operating
Range (m)
SGSMP2-500Q128 2 500 500 12 19
0.5 to 30
SGSMP3-400Q128 3 400 800 13 22
SGSMP4-300Q128 4 300 900 14 25
SGSMP4-400Q128 4 400 1200 14 25
For dimensions, see
Dimensions
(p. 62).
3.2 Appropriate Applications and Limitations
WARNING: Read this Section Carefully Before Installing the System
If all mounting, installation, interfacing, and checkout procedures are not followed properly, the Banner
device cannot provide the protection for which it was designed. The user is responsible for ensuring that
all local, state, and national laws, rules, codes, or regulations relating to the installation and use of this
control system in any particular application are satisfied. Ensure that all legal requirements have been
met and that all technical installation and maintenance instructions contained in this manual are followed.
The user has the sole responsibility to ensure that this Banner device is installed and interfaced to the
guarded machine by Qualified Persons1, in accordance with this manual and applicable safety
regulations. Failure to follow these instructions could result in serious injury or death.
The Banner SGS is intended for safeguarding applications as determined by a risk assessment. It is the user’s responsibility
to verify whether the safeguarding is appropriate for the application and is installed, as instructed by this manual, by a
Qualified Person.
The SGS ability to perform its safeguarding function depends upon the appropriateness of the application and upon its
proper mechanical and electrical installation and interfacing to the guarded machine. If all mounting, installation, interfacing,
and checkout procedures are not followed properly, the SGS cannot provide the protection for which it was designed.
WARNING:
•Access and Perimeter Safeguard Installation
•Failure to follow these instructions could result in serious injury or death.
• If an SGS Safety Grid System with Integral Muting is installed for use as an access or perimeter
guard (where a pass-through hazard may exist, see
Reducing or Eliminating Pass-Through
Hazards
(p. 23)), configure the SGS for Manual Start/Restart (Latch Output). The dangerous
machine motion can be initiated by normal means only after the safeguarded area is clear of
individuals and the SGS Safety Grid System with Integral Muting has been manually reset.
1A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and
experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work.
SGS Safety Grid System (Emitter/Receiver with Integral Muting)
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3.2.1 Appropriate Applications
This SGS Safety Grid System with Integral Muting is typically used in access guarding and perimeter guarding applications.
Some potential applications are:
• Automated production equipment
• Robotic work cells
• Palletizers
• Assembly and packaging machines
• Lean manufacturing systems
• Automated warehouses
3.2.2 Examples: Inappropriate Applications
Do not use the SGS in the following applications:
• With any machine that cannot be stopped immediately after a stop signal is issued, such as single-stroke (or full-
revolution) clutched machinery
• With any machine with inadequate or inconsistent machine response time and stopping performance
• With any machine that ejects materials or component parts through the defined area
• In any environment that is likely to adversely affect photoelectric sensing efficiency. For example, corrosive
chemicals or fluids or unusually severe levels of smoke or dust, if not controlled, may degrade sensing efficiency
• As a tripping device to initiate or reinitiate machine motion (PSDI applications), unless the machine and its control
system fully comply with the relevant standard or regulation (see OSHA 29CFR1910.217, ANSI/NFPA 79, ANSI
B11.19, ISO 12100, IEC 60204-1, IEC 61496-1, or other appropriate standard)
3.2.3 Control Reliability: Redundancy and Self-Checking
Redundancy requires that the SGS circuit components be backed up to the extent that, if the failure of a single component
will prevent effective machine stopping action when needed, that component must have a redundant counterpart which will
perform the same function. The SGS is designed with redundant microprocessors.
Redundancy must be maintained whenever the SGS is in operation. Because a redundant system is no longer redundant
after a component has failed, the SGS is designed to monitor itself continuously. A component failure detected by or within
the self-checking system causes a stop signal to be sent to the guarded machine and puts the SGS into a Lockout
condition.
A recovery from this type of Lockout condition requires:
• Replacement of the failed component (to restore redundancy)
• The appropriate reset procedure
The Diagnostic Display is used to diagnose causes of a Lockout condition. See
Error Codes
(p. 50).
3.3 Operating Features
The Banner SGS Safety Grid System with Integral Muting models described in this manual feature several functions.
3.3.1 Selectable Auto or Manual Start/Restart
The setting for Automatic Start/Restart (Trip Output) or Manual Start/Restart (Latch Output) determines if the SGS enters
Run mode automatically or if a manual reset is required first. If the SGS is set for Automatic Start/Restart (Trip Output),
other measures must be taken to prevent a pass-through hazard. For more information, see
Reducing or Eliminating Pass-
Through Hazards
(p. 23).
If Automatic Start/Restart (Trip Output) is selected, the OSSD outputs turn on after power is applied, and the receiver
passes its internal self-test/ synchronization and recognizes that all beams are clear. The OSSD outputs also turn on after all
beams are cleared following a blocked beam.
If Manual Start/Restart (Latch Output) is selected, the SGS requires a manual reset for the OSSD outputs to turn on when
power is applied and all beams are clear or after a blocked beam has been cleared.
Factory Default Setting: Manual Start/Restart
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WARNING: Use of Auto (Trip) or Manual (Latch) Start/Restart
Application of power to the Banner device, the clearing of the sensing field, or the reset of a manual
start/restart (latch) condition MUST NOT initiate dangerous machine motion. Machine control circuitry
must be designed so that one or more initiation devices must be engaged (in a conscious act) to start the
machine – in addition to the Banner device going into Run mode. Failure to follow these instructions
could result in serious injury or death.
3.3.2 External Device Monitoring (EDM)
The external device monitoring (EDM) feature allows the SGS to monitor the status of external devices, such as final switch
devices (FSD) and machine primary control elements (MPCE). The choices are 1-channel monitoring or no monitoring. EDM
is used when the SGS OSSD outputs directly control the FSDs, MPCEs, or other external devices.
Factory default setting: 1-channel monitoring
3.3.3 Scan Code Configuration
The coding function allows the SGS to remain in normal operation when another SGS pair creates interference, for example
when the emitter of one SGS pair radiates in the direction of the receiver of a second SGS pair. If this happens, configure
the two SGS pairs to use different scan codes.
To set the scan code, use the emitter and receiver DIP switches. The available options are: No Coding, Code, 1, or Code 2.
Select No Coding for the fastest response time. Use Code 1 or Code 2 to reduce cross talk between collocated curtain
pairs. See
Models
(p. 8) for the response times for systems with and without scan codes.
Factory default: No Coding.
3.3.4 Status Indicators
Status indicators on both the emitter and receiver are visible on each sensor's front panel.
Emitter
1-Digit Diagnostic Display
—indicates configuration or specific error
conditions.
Green Power—Indicates when power is applied.
Amber Status—Indicates when the emitter is emitting light.
Status
Power ON
Figure 1. Status Indicators—Emitter
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Receiver
1-Digit Diagnostic Display
—indicates configuration or specific error
conditions.
Green Status—Indicates when all the OSSD outputs are on.
Red Status—Indicates when the OSSD outputs are off.
Amber Last and Sync Beam—Indicates when the beam is not made when
the system is in alignment mode. The Sync Beam light is on when all beams
are clear and the system is waiting for a reset when it is configured for
Manual Start/Restart.
EDM Status—Indicates when EDM is being used (decimal point).
Last Beam
Sync Beam
EDM Status
OSSD
Outputs
ON
OSSD
Outputs
OFF
Figure 2. Status Indicators—Receiver
3.3.5 Muting Functions
To mute the primary safeguard appropriately, the design of a muting system must:
1. Identify the non-hazardous portion of the machine cycle.
2. Select the proper muting devices.
3. Include proper mounting and installation of those devices
The SGS Safety Grid System with Integral Muting can monitor and respond to redundant signals that initiate the mute. The
mute suspends the safeguarding function to allow an object to pass through the defined area of the safety light screen,
without generating a stop command.
The mute may be triggered by a variety of external devices. This feature provides a variety of options to tailor the system to
the requirements of a specific application. The mute sensors can not turn on simultaneously, their must be at least a 0.01
second difference between mute device initiations. A pair of muting devices must be triggered within 4 seconds of each
other, but the order does not matter. This reduces the chance of common mode failures or defeat.
WARNING:
•Muting is allowed only during the non-hazardous portion of the machine cycle
• Failure to follow these instructions could result in serious injury or death.
• Design the muting application so that no single component failure can prevent the stop
command or allow subsequent machine cycles until the failure is corrected (per ISO 13849-1 and
ANSI B11.19).
WARNING:
•Muting inputs must be redundant
• A single device, with multiple outputs, can fail so that the system is muted at an inappropriate
time, causing a hazardous situation.
• Do not use a single switch, device, or relay with two normally open contacts for the mute inputs.
Mute Devices
The beginning and end of a mute cycle must be triggered by outputs from the muting devices, depending on the
application. The mute devices must either have normally open contacts or have PNP outputs, both of which fulfill the
muting device requirements. These contacts must close (conduct) when the switch is actuated to initiate the mute and must
open (non-conducting) when the switch is not actuated and in the power OFF condition.
The SGS Safety Grid System with Integral Muting monitors the mute devices to verify that their outputs turn ON within 4
seconds of each other, but not simultaneously (order does not matter). If the inputs do not meet this simultaneity
requirement, a mute condition will not occur.
The mute devices should be powered from the receiver's (and emitter's, if through-beam sensors are used) 5-pin M12 QD.
Several types and combinations of mute devices can be used, including but not limited to: limit switches, photoelectric
sensors, positive-driven switches, inductive proximity sensors and 'whisker' switches.
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General Muting Device Requirements
The muting devices (typically sensors or switches) must, at a minimum, comply with the following requirements:
1. There must be a minimum of two independent hard-wired muting devices.
2. The muting devices must either both have normally open contacts or PNP outputs both of which must fulfill the
input requirements listed in the Specifications. These contacts must close when the switch is actuated, and must
open (or not conduct) when the switch is not actuated or in a power OFF condition.
3. The activation of the inputs to the muting function must be from separate sources. These sources must be mounted
separately in order to prevent an unsafe muting condition resulting from misadjustment, misalignment, or a single
common mode failure. (For example, physical damage to the mounting surface could cause both muting devices to
be knocked out of alignment, resulting in false muting input signals.) Only one of these sources may pass through,
or be affected by, a programmable logic controller or similar device.
4. The muting devices must be installed so that they can not be easily defeated or bypassed.
5. The muting devices must be mounted so that their physical position and alignment can not be easily changed.
6. It must not be possible for environmental conditions to initiate a mute condition (for example, extreme airborne
contamination).
7. The muting devices must not be set to use any delay or other timing functions (unless such functions are
accomplished so that no single component failure prevents the removal of the hazard, subsequent machine cycles
are prevented until the failure is corrected, and no hazard is created by extending the muted period).
Examples of Muting Sensors and Switches
Photoelectric Sensors (Opposed Mode)—Configure opposed mode sensors, which initiate the muted condition when the
beam path is blocked, for dark operate (DO) and to have open (non-conducting) output contacts in a power OFF condition.
Both the emitter and receiver from each pair should be powered from the SGS emitter and/or receiver.
Photoelectric Sensors (Polarized Retroreflective Mode)—The user must ensure that false 'proxing' (activation due to shiny
or reflective surfaces) is not possible. Banner LP sensors with linear polarization can greatly reduce or eliminate this effect.
Use a sensor configured for Light Operate (LO or N.O.) if initiating a mute when the retroreflective target or tape is detected
(e.g. home position). Use a sensor configured for Dark Operate (DO or N.C.) when a blocked beam path initiates the muted
condition (e.g. entry/exit). Both situation must have open (non-conducting) output contacts in a power OFF condition.
Positive Opening Safety Switches—Two (or four) independent switches, each with a minimum of one closed safety contact
to initiate the mute cycle, are typically used.
Inductive Proximity Sensors—Typically, inductive proximity sensors are used to initiate a muted cycle when a metal surface
is detected. Because of an excessive leakage current causing false ON conditions, do not use two-wire sensors. Only use
three or four wire sensors that have discrete PNP or hard contact outputs separate from the input power.
Note: Typical Entry/Exit is Dark Operate (DO) with through-beam or polarized retroreflective sensors.
Typical Home Position and Power Press applications are Light Operate (LO) or "closed switch to mute".
WARNING: Avoid Hazardous Installations
Two or four independent position switches must be properly adjusted or positioned so that they close
only after the hazard no longer exists, and open again when the cycle is complete or the hazard is again
present. If the switches are improperly adjusted or positioned, injury or death may result.
The user is responsible to satisfy all local, state, and national laws, rules, codes, and regulations relating
to the use of safety equipment in any particular application. Make sure that all appropriate agency
requirements have been met and that all installation and maintenance instructions contained in the
appropriate manuals are followed.
Mute Enable (ME)
The Mute Enable function allows the user control of the start of a mute condition.
• To enable a mute condition on the receiver, tie the Mute Enable input (pink wire) to 0 V or open (floating line level is
same as 0 V). Shorting this input to +24 V dc while the system is muted has no effect.
• To disable a mute condition, connect the Mute Enable input (pink wire) to +24 V. No mute cycle starts when the
mute enable line is tied high.
• If M1 is blocked and the mute enable is closed then reopened, the 4 second simultaneity clock is reset to zero (the
system has 4 seconds to block M2).
The +24 V and 0 V should come from the same power supply as the SGS's power.
Typical uses for Mute Enable include:
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1. To allow the machine control logic to create a 'window' for muting to begin.
2. To inhibit muting from occurring
3. To reduce the chance of unauthorized or unintended bypassing of defeat of the safety system.
Muting Lamp/Lamp Outputs
The Mute Lamp integrated on top of the receiver provides a visible indication that the safety device's safeguarding function
is muted. The mute lamp flashes when the system is muted.
The Lamp Output also conducts when the system is muted. The Lamp Output (red wire) goes to +24 V dc via a load (or
PLC). This +24 V dc should come from the same power supply as the SGS's power.
When the system is muted, the Lamp Output pulses at the same rate as the Mute Lamp flashes.
When the system is in Override, the Mute Lamp flashes and the Lamp Output pulses.
CAUTION:
•Mute status must be readily observed
• Failure of the mute indicator should be detectable from the location of the muted device and
prevent the next mute.
• Verify the indicator's operation at suitable intervals. Provide easily observed indication that the
safety device is muted.
Mute Time Limit (Backdoor Timer)
The Mute Time Limit (Backdoor Timer) allows the user to select a maximum period of time that muting is allowed to occur.
The Mute Time Limit is either 10 minutes or infinite, depending on the DIP switch settings outlined in the System
Configuration Settings section.
The timer begins when the second muting device makes the simultaneity requirement (within 4 seconds of the first device)
and allows a mute to continue for the predetermined time. After the timer expires, the mute ends no matter what the signals
from the mute devices indicate. A bypass or override can be performed to clear the obstruction.
Factory default setting: 10 minutes
WARNING:
•Selecting the Muting Time Limit (Backdoor Timer)
• It is the user’s responsibility to ensure the Mute Time Limit (Backdoor Timer) setting does not
create a hazardous situation.
• Select an infinite time for the backdoor timer (disabling) only if the possibility of an inappropriate
or unintended mute cycle is minimized, as determined and allowed by the machine’s risk
assessment.
Muting Low-Pass Filter
The muting low-pass filter is a filter (debounce setting) on the muting inputs. Low to high and high to low transitions of the
muting signals are considered valid only if maintained for 0.1 seconds. To enable the low-pass filter, use the DIP switches
as outlined in the System Configuration Settings section.
Factory default setting: Disabled
Note: This setting will delay the start and/or ending of the mute cycle by the 0.1 second that the signal
must be maintained.
Mute-Dependent Override
Overriding a safeguarding device is the manual interruption or suspension of the normal function of a safeguard under
supervisor control. Typically, an Override is needed to clear an object that is stuck within the light curtain's defined area,
such as on an entry/exit application.
Overriding a safeguarding device should not be confused with muting, which is the temporary, automatic suspension of the
safeguarding function of a safeguarding device during a non-hazardous portion of the machine cycle. Muting allows for
material to be manually or automatically fed into a machine or process without issuing a stop command.
When Override (or Bypass) is used, the following precautions must be taken:
• Prevent exposure to any hazards during an Override; supplemental safeguarding must be provided per ANSI
B11.19, ANSI/NFPA 79, IEC/EN60204-1, and ISO 13849-1.
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• The means of overriding and visual indication must be provided and be readily observable from the location of the
safeguard.
• The reset, actuation, clearing, or enabling of the safeguarding device must not initiate hazardous motion or create a
hazardous situation.
• Standards require the use of spring return, hold-to-run device or secure momentary action push buttons, located so
that it will not be possible to enter the hazardous zone while maintaining the state of the devices.
The Override switches must be supervised and must prevent automatic operation. This function requires one normally open
switch connecting +24 V dc to Override 1 (yellow wire) and one normally open switch connecting 0 V dc to Override 2 (gray
wire). These inputs must be engaged within 400 ms of each other to commence the override process. Also, one or more of
the following must be true:
• Motion should be initiated by a hold-to-run or similar device
• If a portable control station (e.g. an enabling device) with an emergency stop device is used, motion may be initiated
only from that station/device. All emergency stops must remain active.
• Automatic machine operation must be prevented by limiting range of motion, speed, or power (e.g. only used in
inch, jog, or slow speed modes).
Mute-Dependent Override function allows the user to manually force the OSSD outputs ON for up to 120 seconds. To
initiate an override, the light curtain defined area must be blocked with the OSSD outputs OFF and at least one mute device
must be blocked. The override function will automatically terminate when one of the following happens:
• All the mute sensor inputs are de-actuated 2
• The 120 second time limit has expired
• One or both the override switches are opened.
The light curtain outputs stay on at the end of the override sequence (assuming the light curtain is clear and in Automatic
Restart mode). The mute lamp flashes and lamp out line pulses while the override process is active.
2This is true for light curtains configured as T or X muting. For light curtains configured as L muting, the override ends when both mute sensors are
de-actuated AND the light curtain's beams are clear.
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(loom:
Figure 3. Muting Timing Diagram — L Configuration
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Figure 4. Muting Timing Diagram — T Configuration
WARNING: Limit Use of Bypass and Override Function
The Bypass and Override functions are not intended for production purposes; they are to be used only
for temporary or intermittent actions, such as to clear the sensing field of a safety light screen if material
becomes "stuck". When used, it is the user's responsibility to install and use it according to relevant
standards (such as ANSI NFPA79 or IEC/EN60204-1).
Muting Function T (X) or L Selection
The SGS Safety Grid System with Integral Muting has multiple muting configurations. The SGS can monitor and respond to
muting sensors in the T (and X) configuration or in the L configuration. Select the T or L configuration style using the DIP
switches.
Factory default setting: T configuration
Use the X configuration when the SGS is set to the T muting configuration. The X configuration uses two pairs of opposed-
mode photoelectric sensors as shown below. The crossing point of the two sensing paths must be on the hazardous side of
the safety light screen.
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Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
Safe Area
Safety Mat
sensor
reflector
A1
reflector
sensor
B1
Figure 5. X Configuration—Uses two pairs of opposed-mode photoelectric muting devices
Use the T configuration when the SGS is set to the T muting configuration. The T configuration uses four pairs of opposed-
mode or retro-reflective photoelectric sensors or diffuse photoelectric sensors with background elimination, spaced with
two on the inside and two on the outside of the SGS.
Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
Safe Area
DD
AB
sensor
reflector reflector
sensor
A1 B1
reflector reflector
sensor sensor
B2 A2
Figure 6. T Configuration—Uses four pairs of opposed-mode photoelectric sensors for mute devices
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Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
A1 B2
Safety Mat B1 A2
Diffuse Mode
Muting Sensor
D
Figure 7. T Configuration—Uses two pairs of diffuse sensors
Use the L configuration when the SGS System is set to the L muting configuration. This configuration is suitable for
applications requiring unidirectional movement of objects. This configuration uses two pairs of opposed-mode photoelectric
sensors stationed on one side of the light curtain. The muting is initiated when the two sensors are made (A1, then B1)
within four seconds of each other. The mute cycle ends up to eight seconds after the first mute sensor (A1) clears. The
Muting Off Delay is equal to two times (2x) the travel time between sensors A1 and B1, with a maximum of 8 seconds.
Tab is the interval of time between the activation of A1 and B1. TMoff is the interval of time between the deactivation of A1
and the light curtain exiting the muted state (returning to normal operation).
TMoff = 2 × Tab
Tab has a maximum time of 4 seconds. TMoff has a maximum time of 8 seconds.
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Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
Safe Area
DA
sensor
reflector reflector
sensor
A1 B1
Figure 8. L Configuration—Uses two pairs of opposed-mode photoelectric sensors stationed on one side of the light curtain
Muting Arms
The SGS Safety Grid System with Integral Muting are capable of performing the muting operation but are not supplied with
muting sensors or arms. Muting arms can be ordered separately (see
Muting Accessories
(p. 65)) and connected to the
sides of the SGS housing. One muting arm contains retro-reflective photoelectric sensors and one arm contains reflectors.
Muting arms may be used for the following muting configurations.
•SGSA-ML-L-LPQ20 for the L configuration made with retro-reflective photoelectric sensors to mount on the left side
of the receiver (when looking at the front of the receiver)
•SGSA-ML-R-LPQ20 for the L configuration made with retro-reflective photoelectric sensors to mount on the right
side of the receiver (when looking at the front of the receiver)
•SGSA-MT-LPQ20 for the T configuration made with retro-reflective photoelectric sensors
•SGSA-MX-LPQ20 for the X configuration made with retro-reflective photoelectric sensors
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4 Mechanical Installation
The SGS system performance as a safety guarding device depends on:
• The suitability of the application
• The proper mechanical and electrical installation and interfacing to the guarded machine
WARNING: Read this Section Carefully Before Installing the System
If all mounting, installation, interfacing, and checkout procedures are not followed properly, the Banner
device cannot provide the protection for which it was designed. The user is responsible for ensuring that
all local, state, and national laws, rules, codes, or regulations relating to the installation and use of this
control system in any particular application are satisfied. Ensure that all legal requirements have been
met and that all technical installation and maintenance instructions contained in this manual are followed.
The user has the sole responsibility to ensure that this Banner device is installed and interfaced to the
guarded machine by Qualified Persons3, in accordance with this manual and applicable safety
regulations. Failure to follow these instructions could result in serious injury or death.
4.1 Mechanical Installation Considerations
The two primary factors that influence the layout of the SGS system mechanical installation are the Safety Distance
(Minimum Distance) (see
Safety (Minimum) Distance
(p. 21)) and the supplemental safeguarding/eliminating pass-through
hazards (see
Reducing or Eliminating Pass-Through Hazards
(p. 23)). Other considerations include:
• Emitter and Receiver Orientation (see
Emitter and Receiver Orientation
(p. 27))
• Adjacent Reflective Surfaces (see
Adjacent Reflective Surfaces
(p. 25))
• Use of Corner Mirrors (see
Use of Corner Mirrors
(p. 26))
• Installation of Multiple Systems (see
Installing Adjacent Systems
(p. 27))
WARNING: The Hazard Must Be Accessible Only through the Sensing Field
The installation of the SGS must prevent any individual from reaching around, under, over or through the
sensing field and into the hazard without being detected. Mechanical barriers (for example, hard (fixed)
guarding) or supplemental safeguarding may be required to comply with this requirement, and is
described by ANSI B11.19 safety requirements or other appropriate standards. Failure to follow these
instructions could result in serious injury or death.
4.1.1 Safety (Minimum) Distance
Safety Distance (Ds), also called Minimum Distance (S), is the minimum distance required between the SGS sensing field
and the closest reachable hazard point. The distance is calculated so that when an object or a person is detected (by
blocking a sensing beam), the SGS sends a stop signal to the machine, causing it to stop by the time the object or person
can reach any machine hazard point.
The distance is calculated differently for U.S. and European installations. Both methods take into account several factors,
including a calculated human speed, the total system stopping time (which itself has several components), and the depth
penetration factor. After the distance has been determined, record the calculated distance on the Daily Checkout Card.
WARNING:
•Safety Distance (Minimum Distance)
•Failure to establish and maintain the minimum distance could result in serious injury or death.
• Mount the Banner emitters and receivers at a distance from the nearest hazard such that an
individual cannot reach the hazard before cessation of hazardous motion or situation. Calculate
this distance using the formulas as described by ANSI B11.19 and ISO 13855.
3A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and
experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work.
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4.1.2 Calculating Safety Distance Formula and Examples
U.S. Applications European Applications
The Safety (Separation) Distance formula for U.S. applications:
Ds = K × (Ts + Tr) + Dpf
The Minimum Distance formula for European applications:
S = (K × T) + C
Ds
the Safety Distance
K
1600 mm per second (or 63 in per second), the OSHA
29CFR1910.217, and ANSI B11.19 recommended approach speed
constant (see Note 1 below)
Ts
the overall stop time of the machine (in seconds) from the initial
stop signal to the final ceasing of all motion, including stop times
of all relevant control elements (for example, IM-T-.. Interface
Modules) and measured at maximum machine velocity (see Note 3
below)
Tr
Maximum response time, in seconds, of the SGS emitter/receiver
pair (depending on model)
Dpf
Added distance due to the depth penetration factor as prescribed
in OSHA 29CFR1910.217, and ANSI B11.19 for U.S. applications
Dpf is 900 mm (36 in) for reach-through applications if the top of
the sensing field cannot be reached over and the bottom beam is
no more than 300 mm (12 in) above the floor
Dpf is 1200 mm (48 in) for reach-over applications where the top
of the sensing field is between 900 mm (36 in) and 1200 mm (48 in)
above the floor and the bottom beam is no more than 300 mm (12
in) above the floor
S
the Minimum Distance, in mm, from danger zone to SGS sensing
field center line
K
1600 mm per second recommended approach speed constant
(see Note 2 below)
T
the overall machine stopping response time (in seconds), from the
physical initiation of the safety device and the machine coming to
a stop (or the hazard removed). This can be broken down into two
parts: Ts and Tr where T = Ts + Tr
C
the additional distance, in mm, based on intrusion of a hand or
object towards the danger zone prior to actuation of a safety
device. Calculate using the formula (in mm):
C = 850
since the resolution is greater than 40 mm.
Notes:
1. The OSHA-recommended approach speed constant K has been determined by various studies and, although these
studies indicate speeds of 1600 mm/sec. (63 in/sec.) to more than 2500 mm/sec. (100 in/sec.), they are not
conclusive determinations. Consider all factors, including the physical ability of the operator, when determining the
value of K to be used.
2. The recommended approach speed constant K, derived from data on approach speeds of the body or parts of the
body as stated in ISO 13855.
3. Ts is usually measured by a stop-time measuring device. If the machine manufacturer's specified stop time is used,
at least 20% should be added to allow for possible clutch/ brake system deterioration. This measurement must take
into account the slower of the two MPCE channels, and the response time of all devices or controls that react to
stop the machine.
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Example Calculation
US Application example: Model SGSxP4-400xxx
K = 1600 mm/s (63 in/s)
Ts = 0.32 (0.250 seconds is specified by the machine manufacturer; plus
20% safety factor; plus 20 ms interface module IM-T-9A response)
Tr = 0.014 second (the specified SGSxP4-400xxx response time)
Dpf = 900 mm (36 in)
Ds = 1600 × (0.32 + 0.014) + 900 = 1434 mm (57 in)
Mount the SGS emitter and receiver so that no part of the sensing field
is closer than 1434 mm (57 in) to the closest reachable hazard point on
the guarded machine.
European Application example: Model SGSxP4-400xxx
K = 1600 mm per second
T = 0.334 (0.250 seconds is specified by the machine manufacturer;
plus 20% safety factor; plus 20 ms interface module IM-T-9A response),
plus 0.014 seconds (the specified SGSxP4-400xxx response time)
C = 850 mm
S = (1600 × 0.334) + 850 = 1384 mm
Mount the SGS emitter and receiver so that no part of the sensing field
will be closer than 1384 mm to the closest reachable hazard point on
the guarded machine.
WARNING: Determine Correct Stop Time
Stop time (Ts) must include the response time of all devices or controls that react to stop the machine. If
all devices are not included, the calculated safety distance (Ds or S) will be too short. Failure to follow
these instructions could result in serious injury or death. Be sure to include the stop time of all relevant
devices and controls in your calculations.
If required, each of the two Machine Primary Control Elements (MPCE1 and MPCE2) must be capable of
immediately stopping the dangerous machine motion, regardless of the state of the other. These two
channels of machine control need not be identical, but the stop time performance of the machine (Ts,
used to calculate the safety distance) must take into account the slower of the two channels.
4.1.3 Reducing or Eliminating Pass-Through Hazards
A
pass-through
hazard is associated with applications where personnel may pass through a safeguard, such as the SGS
Safety Grid System with Integral Muting (which issues a stop command to remove the hazard), and then continues into the
guarded area. This is common in access and perimeter guarding applications. Subsequently, their presence is no longer
detected, and the related danger becomes the unexpected start or restart of the machine while personnel are within the
guarded area.
A pass-through hazard typically results from large safety distances calculated from long stopping times, large minimum
object sensitivities, reach-over, reach-through, or other installation considerations. A pass-through hazard can be generated
with as little as 75 mm (3 in) between the sensing field and the machine frame or hard (fixed) guarding.
Eliminate or reduce pass-through hazards whenever possible. While it is recommended to eliminate the pass-through
hazard altogether, this may not be possible due to machine layout, machine capabilities, or other application
considerations.
One solution is to ensure that personnel are continually sensed while within the hazardous area. This can be accomplished
by using supplemental safeguarding, such as described by the safety requirements in ANSI B11.19 or other appropriate
standards.
An alternative method is to ensure that once the safeguarding device is tripped it will latch and will require a deliberate
manual action to reset. This method of safeguarding relies upon the location of the reset switch as well as safe work
practices and procedures to prevent an unexpected start or restart of the guarded machine. The SGS Safety Grid System
with Integral Muting provides a configurable Manual Start/Restart (Latch Output) function for these applications.
WARNING:
•Use of the Banner device for Access or Perimeter Guarding
• Failure to observe this warning could result in serious injury or death.
• If a Banner device is installed in an application that results in a pass-through hazard (for example,
perimeter guarding), either the Banner device or the Machine Primary Control Elements (MPCEs)
of the guarded machine must cause a Latched response following an interruption of the defined
area.
• The reset of this Latched condition may only be achieved by actuating a reset switch that is
separate from the normal means of machine cycle initiation.
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WARNING:
•Perimeter guarding applications
• Failure to observe this warning could result in serious injury or death.
• Use lockout/tagout procedures per ANSI Z244.1, or use additional safeguarding as described by
ANSI B11.19 safety requirements or other applicable standards if a passthrough hazard cannot
be eliminated or reduced to an acceptable level of risk.
4.1.4 Supplemental Safeguarding
As described, the SGS must be properly positioned such that an individual cannot reach through the sensing field and
access the hazard point before the machine has stopped.
Additionally, the hazard cannot be accessible by reaching around, under, or over the sensing field. To accomplish this,
supplemental guarding (mechanical barriers, such as screens or bars), as described by ANSI B11.19 safety requirements or
other appropriate standards, must be installed. Access will then be possible only through the sensing field of the SGS
System or through other safeguarding that prevents access to the hazard.
The mechanical barriers used for this purpose are typically
called "hard (fixed) guarding"; there must be no gaps
between the hard (fixed) guarding and the sensing field. Any
openings in the hard (fixed) guarding must comply with the
safe opening requirements of ANSI B11.19 or other
appropriate standard.
This example shows an example of supplemental
safeguarding inside a robotic work cell. The SGS, in
conjunction with the hard (fixed) guarding, is the primary
safeguard. Supplemental safeguarding (such as a
horizontal-mounted safety light screen as an area guard) is
required in areas that cannot be viewed from the reset
switch (for example, behind the robot and the conveyor).
Additional supplemental safeguarding may be required to
prevent clearance or trapping hazards (for example, a safety
mat as an area guard between the robot, the turntable, and
the conveyor).
Light Screen
Reset Switch
Hard Guarding
(Fixed)
Hard Guarding
(Fixed)
Opening
Conveyor
Light Screen
DS
Robot
Area
Guarding
Area
Guarding
Turn-
table
Figure 9. An example of supplemental safeguarding
WARNING:
•The hazard must be accessible only through the sensing field
• Incorrect system installation could result in serious injury or death.
• The installation of the SGS must prevent any individual from reaching around, under, over or
through the defined area and into the hazard without being detected.
• See OSHA CFR 1910.217, ANSI B11.19, and/or ISO 14119, ISO 14120 and ISO 13857 for
information on determining safety distances and safe opening sizes for your guarding device.
Mechanical barriers (for example, hard (fixed) guarding) or supplemental safeguarding might be
required to comply with these requirements.
4.1.5 Reset Switch Location
Mount the reset switch at a location that complies with the warning and guidelines below. If any hazardous areas are not in
view from the switch location, additional means of safeguarding must be provided. The switch should be protected from
accidental or unintended actuation (for example, through the use of rings or guards).
A key-actuated reset switch provides some operator or supervisory control, as the key can be removed from the switch and
taken into the guarded area. However, this does not prevent unauthorized or inadvertent resets due to spare keys in the
possession of others, or additional personnel entering the guarded area unnoticed. When considering where to locate the
reset switch, follow the guidelines below.
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WARNING: Reset Switch Location
When considering where to locate the reset switch, you must follow the guidelines outlined in this
section.
If any areas within the guarded area are not visible from the reset switch, additional safeguarding must
be provided, as described by the ANSI B11.19 series or other appropriate standards.
Failure to follow these instructions could result in serious injury or death.
All reset switches must be:
• Outside the guarded area
• Located to allow the switch operator a full, unobstructed, view of the entire guarded area while the reset is
performed
• Out of reach from within the guarded area
• Protected against unauthorized or inadvertent operation (such as through the use of rings or guards).
Important: Resetting a safeguard must not initiate hazardous motion. Safe work procedures require a
start-up procedure to be followed and the individual performing the reset to verify that the entire
hazardous area is clear of all personnel before each reset of the safeguard is performed. If any area
cannot be observed from the reset switch location, additional supplemental safeguarding must be used:
at a minimum, visual and audible warnings of machine start-up.
4.1.6 Adjacent Reflective Surfaces
WARNING:
•Do not install the system near reflective surfaces
•Reflective surfaces could reflect the sensing beam(s) around an object or person within the
defined area, preventing detection by the system. Failure to prevent reflection problems results in
incomplete guarding and an optical short circuit that could result in serious injury or death.
• Do not locate the defined area near a reflective surface. Perform the trip test, as described in the
product documentation, to detect such reflection(s).
A reflective surface located adjacent to the sensing field may deflect one or more beams around an object in the sensing
field. In the worst case, an optical short circuit may occur, allowing an object to pass undetected through the sensing field.
This reflective surface may result from shiny surfaces or glossy paint on the machine, the workpiece, the work surface, the
floor, or the walls. Beams deflected by reflective surfaces are discovered by performing the trip test and the periodic
checkout procedures. To eliminate problem reflections:
• If possible, relocate the sensors to move the beams away from the reflective surface(s), being careful to maintain
adequate separation distance
• Otherwise, if possible, paint, mask, or roughen the shiny surface to reduce its reflectivity
• Where these are not possible (as with a shiny workpiece or machine frame), determine the worst-case resolution
resulting from the optical short circuit and use the corresponding depth penetration factor (Dpf or C) in the Safety
Distance (Minimum Distance) formula; or mount the sensors in such a way that the receiver's field of view and/or the
emitter's spread of light are restricted from the reflective surface
• Repeat the trip test (see
Conduct a Trip Test
(p. 37)) to verify these changes have eliminated the problem
reflection(s). If the workpiece is especially reflective and comes close to the sensing field, perform the trip test with
the workpiece in place
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Tab/e 2. $5M Serves mass-Surface Murals
Do not position reflective surfaces within the shaded area
Operating Range
(R)
d
d
side view
d
Figure 10. Adjacent Reflective Surfaces
For 0.1 to 3 m (4 in to 10 ft) Operating range: d = 0.13 m (5 in)
For Operating range > 3 m (> 10 ft): d = 0.0437 x R (m or ft)
4.1.7 Use of Corner Mirrors
SGS may be used with one or more corner mirrors. Mirrors are not allowed for applications that would allow undetected
personnel access into the safeguarded area. The use of glass-surface corner mirrors reduces the maximum specified
emitter/receiver separation by approximately 8 percent per mirror, as follows:
Table 2: SSM Series Glass-Surface Mirrors 4 —Maximum Emitter and Receiver Separation
Number of Corner Mirrors Maximum Emitter/Receiver Separation
Standard (m)
1 27.6
2 25.4
3 23.4
If mirrors are used, the difference between the angle of incidence from the emitter to the mirror and from the mirror to the
receiver must be between 45° and 120° (see
Figure 11
(p. 27)). If placed at a sharper angle, an object in the light screen
may deflect beam(s) to the receiver, preventing the object from being detected, also know as false proxing. Angles greater
than 120° result in difficult alignment and possible optical short circuits.
WARNING:
•Retroreflective Mode Installation
• Failure to follow these instructions may create unreliable sensing and may result in serious injury
or death.
• Do not install emitters and receivers in retroreflective mode with less than a 45° angle of
incidence. Install emitters and receivers at an appropriate angle.
4See the specific mirror data sheet or www.bannerengineering.com for further information.
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A
Emitter
Receiver
Mirror
45˚ < A < 120˚
Emitter
Receiver
Mirror
Figure 11. Using SGS sensors in a retroreflective mode
4.1.8 Emitter and Receiver Orientation
Mount the emitter and receiver parallel to each other and aligned in a common plane, with both machine interface cable
ends pointing in the same direction. Never mount the emitter with its machine interface cable end oriented in the opposite
direction of the cable end of the receiver. If this occurs, voids in the SGS sensing field may allow objects or personnel to
pass through the defined area undetected. Verify the SGS Safety Grid System with Integral Muting completely covers all
access to the hazard point that is not already protected by hard (fixed) guarding or other supplemental guarding.
WARNING: Proper Orientation of System Emitters and Receivers
SGS emitters and receivers must be installed with their corresponding cabled ends pointing in the same
direction (for example, both cabled ends facing down). Failure to orient the SGS emitters and receivers
properly will impair the performance of the SGS System and will result in incomplete guarding, which
could result in serious injury or death.
Receiver
Emitter
Receiver
Emitter
Figure 12. Examples of Incorrect Emitter/Receiver Orientation
4.1.9 Installing Adjacent Systems
When two or more SGS emitter and receiver pairs are adjacent to one another, optical crosstalk may take place between
the systems. To minimize optical crosstalk, alternate the positions of the emitters and receivers (see
Figure 13
(p. 28)).
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When three or more systems are installed in the same plane (as shown in
Figure 13
(p. 28)), optical crosstalk may occur
between sensor pairs whose emitter and receiver lenses are oriented in the same direction. In this situation, eliminate
optical crosstalk by mounting these sensor pairs exactly in line with each other within one plane, or by adding a mechanical
barrier between the pairs.
To further aid in avoiding crosstalk, the sensors feature two selectable scan codes. A receiver set to one scan code will not
respond to an emitter set to another code. See
Scan Code Configuration
(p. 11).
Receiver
Emitter
Scan Code 1
Receiver
Emitter
Scan Code 2
a. Two systems in a horizontal plane b. Multiple systems
Receiver 3
Emitter 3
Scan Code 2
Receiver 2
Emitter 2
Opaque Shield
Scan Code 2
Receiver 1
Emitter 1
Scan Code 1
Figure 13. Installing Multiple Systems
WARNING: Scan Code
In situations where multiple systems are mounted closely together, or where a secondary emitter is in
view (within ±5°) and within range of an adjacent receiver, the adjacent systems must be configured for
different Scan Codes (one system set for Scan Code 1 and the other for Scan Code 2). If not, a receiver
may synchronize to the signal from the wrong emitter, reducing the safety function of the light screen.
This situation is discovered by performing the trip test. Failure to follow these instructions could result in
serious injury or death.
4.2 Mounting System Components
4.2.1 Mounting Hardware
After the mechanical layout consideration of
Mechanical Installation Considerations
(p. 21) are addressed, mount the
sensors and route the cables. Emitter/receiver pairs can be spaced from 0.5 m to 30 m apart.
The end mount bracket kit is ordered separately. The end mount brackets allow 360 degree rotation.
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4.2.2 Mounting the End-Mount Brackets
Figure 14. End-Mount Brackets
• See
Sensor Mounting and Mechanical Alignment
(p. 29) for additional
mounting recommendations.
• The machine interface connector ends of both sensors must point in the
same direction.
• Four brackets are supplied with each SGSA-MBK-10-4 kit ordered.
1. Mount the bottom brackets to the desired surfaces using user-supplied
hardware.
2. Place the sensors into the bottom bracket and temporarily tighten enough
to secure the sensors but allow for adjustment.
3. Verify that the sensor windows directly face each other by rotating the
sensor(s), then tighten the nut on the bottom bracket.
4. Measure from a reference plane, for example, a level building floor, to the
same point(s) on the sensors to verify their mechanical alignment. Use a
carpenter's level, a plumb bob, or the optional LAT-1-SGS Laser
Alignment Tool (see
Alignment Aids
(p. 67)) or check the diagonal
distances between the sensors, to achieve mechanical alignment. See
Sensor Mounting and Mechanical Alignment
(p. 29).
5. Place the top brackets on the top of the sensors, attach to the mounting
surface using user-supplied hardware, and temporary tighten the nut on
the bracket to secure the sensors in place but allow for adjustment. Final
alignment procedures are explained in
Initial Checkout Procedure
(p.
33).
4.2.3 Sensor Mounting and Mechanical Alignment
Verify that:
• The emitter and receiver are directly opposite each
other
• Nothing is interrupting the defined area
• The defined area is the same distance from a
common reference plane for each sensor
• The emitter and receiver are in the same plane and
are level/plumb and square to each other (vertical or
inclined at the same angle, not tilted front-to-back or
side-to-side)
Figure 15. Incorrect Sensor Alignment
Vertical Installations – verify that:
• Distance X at the emitter and receiver are equal
• Both sensors are level/plumb (check both the side
and face)
•Defined area is square. Check diagonal
measurements if possible (Diagonal A = Diagonal B).
Level Surface
A B
level level
XX
4.2.4 Mounting Dimensions
All measurements are listed in millimeters [inches], unless noted otherwise. See
Specifications
(p. 61) for the SGS
dimensions with and without brackets installed.
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End-Mount Bracket Dimensions
SGSA-MBK-10-4
• 8-gauge, zinc-plated cold rolled
steel
ø43
89
56
41
2 x ø5.6
2 x ø6.8
4.2.5 Mount the Muting Arms
1. Wire the muting arms to the SGS Safety Grid System with Integral Muting using the 5-pin M12/Euro-style connector
on the base of the receiver/active transceiver unit.
2. Mount the arms to the SGS using the t-slot on the SGS housing.
3. After the arms are mounted at the appropriate height for the application, adjust the sensors and reflectors position
by loosening the center screw.
4. Align each sensor and each reflector using the two Philips screws that hold them in place.
Figure 16. L Configuration Muting Arms (Left
Side)
Figure 17. L Configuration Muting Arms (Right
Side) Figure 18. T Configuration Muting Arms
Figure 19. X Configuration Muting Arms
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4.2.6 Mounting the Muting Connection Box
Mount the muting connection box directly to the side of the SGS housing.
Use the connection box to properly wire the muting sensors to the SGS
muting connector.
The mounting hardware for the muting connection box is ordered
separately (see
Muting Accessories
(p. 65)).
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5 Electrical Installation and Testing
WARNING:
Read this Section Carefully Before Installing the System— If all mounting, installation, interfacing, and
checkout procedures are not followed properly, the Banner device cannot provide the protection for
which it was designed. The user is responsible for ensuring that all local, state, and national laws, rules,
codes, or regulations relating to the installation and use of this control system in any particular
application are satisfied. Ensure that all legal requirements have been met and that all technical
installation and maintenance instructions contained in this manual are followed.
The user has the sole responsibility to ensure that this Banner device is installed and interfaced to the
guarded machine by Qualified Persons5, in accordance with this manual and applicable safety
regulations. Failure to follow these instructions could result in serious injury or death.
WARNING:
•Properly connect multiple pairs of sensors
• Connecting multiple output signal switching devices (OSSD) safety outputs to one interface
module or otherwise parallel OSSD outputs can result in serious bodily injury or death, and is
prohibited.
• Do not connect multiple pairs of sensors to a single device.
The following are the main steps to electrically install the SGS components and interface with the guarded machine:
1. Connect the routing cordsets and make the initial electrical connections (see
Routing Cordsets
(p. 32) and
Initial
Electrical Connections
(p. 33)).
2. Apply power to each emitter/receiver pair (see
Apply (Initial) Power to the System
(p. 34)).
3. Perform an Initial Checkout Procedure (see
Initial Checkout Procedure
(p. 33)).
4. Make all electrical interface connections to the guarded machine (see
Electrical Connections to the Guarded
Machine
(p. 38)).
5. Perform a commissioning checkout procedure (see
Perform a Commissioning Checkout
(p. 54)).
5.1 Routing Cordsets
Attach the required cordsets to the sensors and route the sensor cables to the junction box, electrical panel, or other
enclosure in which the interface module, the redundant mechanically linked interposing relays, FSDs, or other safety-related
parts of the control system are located. This must be done per local wiring code for low-voltage dc control cables and may
require installation of electrical conduit. See
Accessories
(p. 64) for selection of Banner supplied cables.
SGS is designed and manufactured to be highly resistant to electrical noise and to operate reliably in industrial settings.
However, extreme electrical noise may cause a random Trip condition; in extreme cases, a Lockout is possible.
Emitter and receiver wiring is low voltage; routing the sensor wires alongside power wires, motor/servo wires, or other high
voltage wiring may inject noise into the SGS System. It is good wiring practice, and sometimes may be required by code, to
isolate emitter and receiver cables from high-voltage wires, avoid routing cables close to “noisy” wiring, and provide a good
connection to earth ground.
Sensor cabling and any interconnect wiring should have an insulation temperature rating of at least 90 °C (194 °F). The
maximum machine interface cable length is 70 m.
5A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and
experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work.
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5.2 Initial Electrical Connections
WARNING:
•Risk of electric shock
• Use extreme caution to avoid electrical shock. Serious injury or death could result.
• Always disconnect power from the safety system (for example, device, module, interfacing, etc.),
guarded machine, and/or the machine being controlled before making any connections or
replacing any component. Lockout/tagout procedures might be required. Refer to OSHA
29CFR1910.147, ANSI Z244-1, or the applicable standard for controlling hazardous energy.
• Make no more connections to the device or system than are described in this manual. Electrical
installation and wiring must be made by a Qualified Person6 and must comply with the applicable
electrical standards and wiring codes, such as the NEC (National Electrical Code), ANSI NFPA79,
or IEC 60204-1, and all applicable local standards and codes.
Lockout/tagout procedures may be required (refer to OSHA1910.147, ANSI Z244-1, ISO 14118, or the appropriate standard
for controlling hazardous energy). Follow relevant electrical standards and wiring codes, such as the NEC, NFPA79 or
IEC60204-1. A functional earth is available on the green wire of the M12 connector. This ground can be connected or left
open (floating) to achieve the best electromagnetic compliance for a specified application.
Make the electrical connections in the order described in this section. Do not remove end-caps; no internal connections are
to be made. All connections are made through the QD connections.
Emitter Cordset
SGS emitters have an 8-pin cordset, but not all conductors are used. The other wires are in place to allow a parallel
connection (color-for-color) to a standard (non-muting) receiver cable, providing sensor interchangeability (or
“swapability”); either sensor may be installed at either cordset connection. In addition to providing similar cabling,
this wiring scheme is advantageous during installation, wiring, and troubleshooting.
Receiver Cordset—12-pin
Connect the OSSD outputs to the IM module or other control relays but make sure that power is not available to
the guarded machine. For the initial power-up and checkout, External Device Monitoring (EDM) must be configured/
wired (see
External Device Monitoring
(p. 40)), the Scan Code must be selected (see
Select the Scan Code
(p.
41)), and the reset line must be connected to +24 V dc via a NC switch. Take precautions to prevent unused wires
from shorting to ground or to other sources of energy (for example, terminate with a wire-nut). Complete the final
output wiring later.
5.3 Initial Checkout Procedure
The initial checkout procedure must be performed by a Qualified Person. It must be performed only after configuring the
System and after connecting the components.
Perform this procedure to:
• Ensure proper installation when the System is first installed
• Ensure proper System function whenever any maintenance or modification is performed on the System or on the
machinery that is guarded by the System.
5.3.1 Configuring the System for Initial Checkout
For the initial checkout, the SGS System must be checked without power available to the guarded machine. Final interface
connections to the guarded machine cannot take place until the light screen system has been checked out. This may
require lockout/tagout procedures (refer to OSHA1910.147, ANSI Z244-1, ISO 14118, or the appropriate standard for
controlling hazardous energy). The OSSD connections will be made after the initial checkout procedure has been
successfully completed.
Verify that:
• The reset line (violet wire) is connected via a NC switch to +24 V dc (or directly connected)
• Power has been removed from (or is not available to) the guarded machine and its controls or actuators
• EDM is configured and wired per application requirements (1-channel or no monitoring, see
External Device
Monitoring
(p. 40))
6A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and
experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work.
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• If no EDM is configured, do not connect the OSSD lines to the machine control circuit. If 1-channel EDM is
configured, wire the OSSD to relays but power must not be available to the guarded machine (permanent
connections will be made later).
5.3.2 Apply (Initial) Power to the System
1. Inspect the area near the light screen for reflective surfaces, including work pieces and the guarded machine.
Reflective surfaces may cause light beams to reflect around a person in the light screen, preventing the person from
being detected and not stopping the machine motion (see
Adjacent Reflective Surfaces
(p. 25)).
2. Eliminate the reflective surfaces as much as possible by relocating, painting, masking, or roughening them.
Remaining problem reflections will become apparent during the trip test.
3. Verify that power is removed from the SGS Safety Grid System with Integral Muting System and from the guarded
machine.
4. Remove all obstructions from the light screen.
5. With the power to the guarded machine off, make external device monitoring (EDM), power, and earth ground
connections on both the emitter and receiver cables (see
Reference Wiring Diagrams
(p. 41)).
The +24 V dc (brown wire) and 0 V dc (blue wire) should be connected to a SELV-rated supply and ground (green
wire) to earth ground. See
General Specifications
(p. 61) for power supply requirements. If the installation does not
allow direct connection to earth ground via the cordset, the earth ground must be provided via the mounting
brackets. Connect the reset line (violet wire) via a NC switch to +24 V dc. If 1-channel EDM is configured, wire the
OSSDs to the controlling relays.
6. Power up the SGS Safety Grid System with Integral Muting only.
7. Verify the input power is present to both the emitter and the receiver.
At least one indicator on both the emitter and the receiver should be On and the start-up sequence should cycle.
8. Watch both the emitter and the receiver Status indicators and the receiver Alignment indicators to determine the
light screen alignment status. See
Error Codes
(p. 50).
9. Optically align the SGS Safety Grid System with Integral Muting components.
5.3.3 Optically Align the Components
CAUTION: Ensure that no individuals are exposed to any hazard if the OSSD outputs turn ON when the
emitter and receiver become aligned.
Verify the optimal alignment, adjusting the sensor rotation with the power on. (It is easiest to align in trip mode.) At power-
up, all indicators are tested (cycle), then the Scan Code is displayed.
1. Before applying power, verify the emitter and the receiver are pointed squarely at each other. Use a straight edge
(for example, a level) to determine the direction the sensor is facing. The sensor face must be perpendicular to the
optical axis.
2. Enter Alignment mode by holding the NC Reset Switch open during the power-on sequence for at least 0.5 s past
the power being applied.
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If the Sync beam is not aligned, the Sync and Last Beam lights are on, the green status light is off, the red status
light is on, and the 7-segment display shows an A.
3. On the receiver: If the green Status light is on, the red status light is off, and a 4 shows on the display, go to the next
step. If not, rotate each sensor (one at a time) left and right until the green Status indicator is on and the highest
number shows on the display.
The better the alignment, the faster the amber light in the end cap flashes. (As the sensor rotates out of alignment,
the red Status indicator turns on).
4. To optimize alignment and maximize excess gain, slightly loosen the sensor mounting screws and rotate one sensor
left and right, noting the positions in each arc where the Status indicators turn red (blocked condition); repeat with
the other sensor. Center each sensor between those two positions and tighten the mounting screws, making sure to
maintain the positioning as the screws are tightened.
Straight Edge
Straight Edge
For situations where alignment is difficult, use an LAT-1-SGS Laser Alignment Tool to assist or confirm alignment by
providing a visible red dot along the sensor’s optical axis.
5. After alignment is complete, cycle power to return to normal operation.
Alignment Procedure Display Codes
Display Alignment state Alignment quality OSSD state out of alignment-
function
no sync; check 1st beam bad OFF
last beam isn't aligned bad OFF
one or more intermediate beam is not aligned bad OFF
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Alignment Procedure Display Codes
Display Alignment state Alignment quality OSSD state out of alignment-
function
marginal ON
every beam over the lower threshold and up to 25% of beams
over the upper threshold good ON
every beam over the lower threshold and up to 50 % of beam
over the upper threshold better ON
every beam over the lower threshold and up to 75% of beam
over the upper threshold very good ON
every beam over the lower threshold and up to 100% of beam
over the upper threshold excellent ON
The alignment level is monitored also during device normal operating mode, and is displayed using a bar graph shown on
the user interface. After the curtain has been aligned and correctly fastened, use the display signal to check the alignment
and view any change in the environmental conditions (presence of dust, light disturbance and so on). The behavior is
demonstrated in the next table.
Visualization Alignment state Alignment quality
every beam over the lower threshold and up to 25% of beams over the upper
threshold Minimum
every beam over the lower threshold and up to 50 % of beam over the upper
threshold Medium
every beam over the lower threshold and up to 75% of beam over the upper
threshold Good
every beam over the lower threshold and up to 100% of beam over the upper
threshold Excellent
5.3.4 Optically Align the Components with Corner Mirrors
SGS sensors may be used with one or more corner mirrors for guarding more than one side of an area. The SSM-... rear-
surface glass mirrors are rated at 85% efficiency. Thus, excess gain and sensing range are reduced when using mirrors; see
Use of Corner Mirrors
(p. 26).
During any adjustments, allow only one individual to adjust any one item at any one time.
In addition to the standard optical alignment procedure, verify:
1. The emitter, receiver, and all mirrors are level and plumb.
2. The middle of the defined area and the center point of the mirrors are approximately the same distance from a
common reference point, such as the same height above a level floor.
3. There are equal amounts of mirror surface above and below the defined area such that the optical beams are not
passing below or above the mirror.
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Note: A LAT-1-SGS Laser Alignment Tool is very helpful by providing a visible red dot along the optical
axis. See
Figure 20
(p. 37) and Banner Safety Applications Note SA104 (p/n
57477
) for more
information.
Figure 20. Optical alignment using the LAT-1-SGS
Component 2 (Mirror)
Component 3 (Mirror)
Component 4 (Receiver)
Component 1 (Emitter)
Figure 21. Corner Mirror Alignment
5.3.5 Conduct a Trip Test
After optimizing the optical alignment, perform the trip test to verify the detection capability of the SGS system.
To conduct the trip test, use a 60 mm or larger diameter test piece (not supplied).
This test also verifies correct sensor orientation and identifies optical short circuits. After the installation has passed the trip
test, connect the safety outputs and perform the commissioning checkout (for initial installations only).
1. Verify the system is in Run mode and the green Status indicator is on.
2. Pass the test piece through each beam in three paths: near the emitter, near the receiver, and midway between the
emitter and receiver.
Test Piece
Figure 22. Trip Test
During each pass, while the test piece is interrupting each beam, the red Status indicator turns on and the green
indicator turns off. If this does not happen, the installation has failed the trip test.
3. If the installation fails the trip test, check for correct sensor orientation and reflective surfaces.
When the test piece is removed from the sensing field, if configured for Automatic Start/Restart operation, the green
Status indicator must turn on and the red indicator turn off.
WARNING: If the Trip Test Indicates a Problem
If the SGS System does not respond properly to the trip test, do not attempt to use the System. If
this occurs, the System cannot be relied on to stop dangerous machine motion when a person or
object enters the sensing field. Failure to follow these instructions could result in serious injury or
death.
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4. If mirrors are used in the application, test the sensing field on each leg of the sensing path (for example, emitter to
mirror, between mirror and receiver.
Receiver
Emitter Test Piece
Mirror
Figure 23. Trip Test with Corner Mirror
5. If the SGS System passes all checks during the trip test, make the electrical connections to the guarded machine.
5.4 Electrical Connections to the Guarded Machine
Verify that power has been removed from the SGS and the guarded machine. Make the permanent electrical connections as
described in
OSSD Output Connections
(p. 38) and
FSD Interfacing Connections
(p. 39) as required by each individual
application.
Lockout/tagout procedures may be required (refer to OSHA 1910.147, ANSI Z244-1, ISO 14118, or the appropriate
standard for controlling hazardous energy). Follow relevant electrical standards and wiring codes, such as the NEC,
NFPA79 or IEC 60204-1.
Supply power and external device monitoring (EDM) should already be connected. The SGS must also have been aligned
and passed the Initial Checkout, as described in
Initial Checkout Procedure
(p. 33).
The final connections to be made or verified are:
• OSSD outputs
• FSD interfacing
• MPCE/EDM
CAUTION: Shock Hazard
Always disconnect power from the Banner device and the guarded machine before making any
connections or replacing any component. Use extreme caution to avoid electrical shock at all times.
5.4.1 OSSD Output Connections
Refer to the output specifications in the electrical specifications (see
Specifications
(p. 61)) and the warning below before
making OSSD output connections and interfacing the SGS to the machine.
WARNING: Interfacing of Both OSSDs
Both OSSD (Output Signal Switching Device) outputs must be connected to the machine control so that
the machine’s safety-related control system interrupts the circuit to the machine primary control
element(s), resulting in a non-hazardous condition.
Never wire an intermediate device(s) (for example, PLC, PES, or PC) that can fail in such a manner that
there is the loss of the safety stop command, OR in such a manner that the safety function can be
suspended, overridden, or defeated, unless accomplished with the same or greater degree of safety.
Failure to follow these instructions could result in serious injury or death.
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WARNING: OSSD Interfacing
To ensure proper operation, the Banner device output parameters and machine input parameters must
be considered when interfacing the Banner device 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.
Failure to properly interface the OSSD Outputs to the guarded machine could result in serious injury or
death.
5.4.2 FSD Interfacing Connections
FSDs (Final Switching Devices) take many forms. The most common are forced-guided devices, mechanically linked relays,
or interface modules. The mechanical linkage between the contacts allows the device to be monitored by the External
Device Monitoring circuit for certain failures.
Depending on the application, the use of FSDs can facilitate controlling voltage and current that differs from the OSSD
outputs of the SGS. FSDs can also be used to control an additional number of hazards by creating multiple safety stop
circuits.
Protective Stop (Safety Stop) Circuits
A protective stop (safety stop) allows for an orderly cessation of motion for safeguarding purposes, which results in a stop
of motion and removal of power from the MPCEs (assuming this does not create additional hazards). A protective stop
circuit typically comprises a minimum of two normally open contacts from forced-guided, mechanically linked relays, which
are monitored through External Device Monitoring to detect certain failures in order to prevent the loss of the safety
function. Such a circuit can be described as a "safe switching point". Typically, protective stop circuits are either single-
channel, which is a series connection of at least two normally open contacts; or dual-channel, which is a separate
connection of two normally open contacts. In either method, the safety function relies on the use of redundant contacts to
control a single hazard. If one contact fails On, the second contact arrests the hazards and prevents the next cycle from
occurring. See
Generic Wiring for a Receiver and Redundant FSD
(p. 43).
The interfacing of the protective stop circuits must be accomplished so that the safety function cannot be suspended,
overridden, or defeated, unless accomplished in a manner of the same or greater degree of safety as the machine’s safety
related control system that includes the SGS.
The normally open safety outputs from an interface module provide a series connection of redundant contacts that form
protective stop circuits for use in either single-channel or dual-channel control. See
Generic Wiring for a Receiver and
Redundant FSD
(p. 43).
Dual-Channel Control
Dual-channel control provides the ability to electrically extend the safe switching point beyond the FSD contacts. With
proper monitoring, this method of interfacing is capable of detecting certain failures in the control wiring between the safety
stop circuit and the MPCEs. These failures include a short-circuit of one channel to a secondary source of energy or
voltage, or a loss of the switching ability of one of the FSD outputs. Such failures may lead to a loss of redundancy, or to a
complete loss of safety, if not detected and corrected.
The possibility of a failure to the wiring increases as the physical distance between the FSD safety stop circuits and the
MPCEs increases, as the length or the routing of the interconnecting wires increases, or if the FSD safety stop circuits and
the MPCEs are located in different enclosures. For this reason, dual-channel control with EDM monitoring should be used in
any installation where the FSDs are located remotely from the MPCEs.
Single-Channel Control
Single-channel control uses a series connection of FSD contacts to form a safe switching point. After this point in the
machine’s safety-related control system, failures can occur that would result in a loss of the safety function (such as a
short-circuit to a secondary source of energy or voltage). For this reason, single-channel control interfacing should be used
only in installations where FSD safety stop circuits and the MPCEs are mounted within the same control panel, adjacent to
each other, and are directly connected to each other; or where the possibility of such a failure can be excluded. If this
cannot be achieved, then dual-channel control should be used.
Methods to exclude the possibility of these failures include, but are not limited to:
• Physically separating interconnecting control wires from each other and from secondary sources of power
• Routing interconnecting control wires in separate conduit, runs, or channels
• Locating all elements (modules, switches, and devices under control) within one control panel, adjacent to each
other, and directly connected with short wires
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• Properly installing multi-conductor cabling and multiple wires through strain relief fittings. Over-tightening of a
strain-relief can cause short-circuits at that point.
• Using positive-opening or direct-drive components, installed and mounted in a positive mode
5.4.3 Machine Primary Control Elements and EDM Input
A machine primary control element (MPCE) is an electrically powered element that directly controls the normal operation of
a machine in such a way that it is the last element (in time) to function when machine operation is to be initiated or arrested
(per IEC 61496-1). Examples include motor contactors, clutch/brakes, valves, and solenoids.
Depending on the level of risk of harm, it may be required to provide redundant MPCEs or other control devices that are
capable of immediately stopping the dangerous machine motion, irrespective of the state of the other. These two machine
control channels need not be identical (diverse redundant), but the stop time performance of the machine (Ts, used to
calculate the safety distance, see
Safety (Minimum) Distance
(p. 21)) must take into account the slower of the two channels.
Consult the machine manufacturer for additional information.
To ensure that an accumulation of failures does not compromise the redundant control scheme (cause a failure to danger),
a method to verify the normal functioning of MPCEs or other control devices is required. The SGS system provides a
convenient method for this verification: external device monitoring (EDM).
For the SGS external device monitoring to function properly, each device must include a normally closed, forced-guided
(mechanically linked) contact that can accurately reflect the status of the device. This ensures that the normally open
contacts, used for controlling hazardous motion, have a positive relationship with the normally closed monitoring contacts
and can detect a failure to danger (for example, contacts that are welded closed or stuck On).
It is strongly recommended that a normally closed, forced-guided monitoring contact of each FSD and MPCE be connected
in series with the EDM input (see
Generic Wiring for a Receiver and IM-T-9A Interface Module
(p. 44)). If this is done,
proper operation will be verified. Monitoring FSD and MPCE contacts is one method of maintaining control reliability (OSHA/
ANSI) and Category 3 and 4 (ISO 13849-1).
If monitoring contacts are not available or do not meet the design requirement of being forced-guided (mechanically linked),
it is recommended you:
• Replace the devices so that they are capable of being monitored; or
• Incorporate the EDM function into the circuit as close to the MPCE as possible (for example, monitor the FSDs); and
• Employ the use of well-tried, tested, and robust components, and generally accepted safety principles, including
fault exclusion, into the design and installation to either eliminate, or reduce to an acceptable (minimal) level of risk,
the possibility of undetected faults or failures that can result in the loss of the safety function.
The principle of fault exclusion allows the designer to design out the possibility of various failures and justify it through the
risk assessment process to meet the required level of safety performance, such as the requirements of Category 2, 3, or 4.
See ISO 13849-1/-2 for further information.
WARNING: EDM Monitoring. If the System is configured for “No Monitoring,” it is the user’s responsibility
to ensure that this does not create a hazardous situation. Failure to follow these instructions could result
in serious injury or death.
5.4.4 External Device Monitoring
SGS provides two possible EDM configurations: 1-channel monitoring and no monitoring. Their functions are described
below. The most common form of EDM is 1-channel monitoring; its primary advantages is the simplicity of wiring. The
installation must prevent short circuits across the N.C. monitoring contacts and to secondary sources of power.
OSSDs Status
EDM
Tc
Normal Operation
24V dc
0V dc
Safe
To
Figure 24. One-channel EDM status, with respect to safety output
External Device Monitoring Wiring
If not connected previously, it is again strongly recommended that one normally closed, forced-guided monitoring contact
of each FSD and MPCE be wired as shown in the monitoring circuit (see
Generic Wiring for a Receiver and IM-T-9A
Interface Module
(p. 44)). The orange wire of the receiver connector provides connection for the external device
monitoring input.
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External device monitoring (EDM) must be wired in one of two configurations described below.
One-Channel Monitoring: This is a series connection of normally closed monitor contacts that are force-guided
(mechanically linked) from each device controlled by the SGS. The monitor contacts must be closed before the SGS OSSDs
can turn on. After the safety outputs (OSSDs) turn on, the monitor contacts must open in 350 ms. However, the monitor
contacts must be closed within 100 ms of the OSSD outputs going from on to off.
Refer to
Generic Wiring for a Receiver and IM-T-9A Interface Module
(p. 44) for wiring. Connect the monitor contacts
between +24 V dc and EDM (orange wire).
No Monitoring: Use this configuration to perform the initial checkout; see
Initial Checkout Procedure
(p. 33).
If the
application does not require the EDM function, it is the user's responsibility to ensure that this configuration does not create
a hazardous situation.
To configure the SGS Safety Grid System with Integral Muting for no monitoring, see
System Configuration Settings
(p.
46).
WARNING:
•Retrofit of 2-channel EDM Installations. If there are any questions concerning retrofit installations,
contact Banner Engineering.
• If the required wiring changes are not made, the device connected to the EDM 2 wire will not be
monitored and could result in undetected faults and create an unsafe condition, which could
result in serious bodily injury or death.
• In existing installations using 2-channel external device monitoring (default setting of EZ-
SCREEN), the parallel wiring of the N.C. monitoring contacts must be rewired for the series
connection used for 1-channel EDM.
5.4.5 Select the Scan Code
Configure the emitter and receiver to use uncoded or one of two Scan Codes (1 or 2). Both the emitter and its
corresponding receiver must have the same setting; a receiver recognizes light only from an emitter with the same scan
code. The scan code is configured using switches and is recognized at power-up and remains set until the input is changed
and power is cycled.
To set the scan code, use the emitter and receiver DIP switches. The available options are: No Coding, Code, 1, or Code 2.
Selecting No Coding provides the fastest response time, but immunity to adjacent systems and other sources of noise may
decrease. For the most reliable operation, use Code 1 or Code 2 to reduce cross talk between collocated curtain pairs.
See
System Configuration Settings
(p. 46) for the DIP switch settings.
5.4.6 Preparing for System Operation
After the initial trip test has been accomplished, and the OSSD safety outputs and EDM connections have been made to the
machine to be controlled, the SGS is ready for testing in combination with the guarded machine.
The operation of the SGS with the guarded machine must be verified before the combined System and machine may be put
into service. To do this, a Qualified Person must perform the Commissioning Checkout Procedure (see
Perform a
Commissioning Checkout
(p. 54)).
5.5 Wiring Diagrams
5.5.1 Reference Wiring Diagrams
Other interfacing modules and solutions are available, see
Accessories
(p. 64) and
www.bannerengineering.com
.
5.5.2 Generic Wiring Diagram for the Emitter
All pins shown as no connection (nc) are not connected internally so do not need to be connected externally.
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Emitter (Standard)
8-pin male M12
+24 V dc 0 V dc
1 - brown
7 - green
6 - blue
5 - black
4 - white
8 - violet
3 - orange
2 - orange/black
nc
nc
nc
nc
nc
5.5.3 Generic Wiring for a Receiver and Safety Module/Controller or
Safety PLC/PES
XS/SC26-2xx
XS2so or XS4so
+24Vdc
+24V dc 0V dc
0Vdc
SO1a
(SO1 not split)
SO1b
EDM
FSD1
FSD2
Single-Channel
Safety Stop Circuit
Dual-Channel
Safety Stop Circuit
2 - Brown
3 - Green
7 - Dark blue
11 - Black
1 - White
12 - Violet
9 - Orange
6 - Pink
4 - Yellow
5 - Gray
8 - Red
** Open or 0V dc for Mute Enabled. Short to +24V dc for Mute Disabled.
* EDM Mode on the SGS Receiver must be set for No Monitoring
+24 V dc
Reset
Ground
0V dc
OSSD1
OSSD2
EDM - no connection*
no connection**
Override 1
Override 2
Lamp Out
12-pin male
M12
IN1
IN2
2
3
4
567
8
9
1
10
11 12
10 - Light blue no connection
Note: Refer to the XS/SC26-2 Instruction Manual (p/n 174868) for complete installation instructions.
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5.5.4 Generic Wiring for a Receiver and Redundant FSD
2
3
4
567
8
9
1
10
11 12
+24V dc 0V dc
12-pin male
M12
+24V dc
Ground
0V dc
OSSD1
OSSD2
Reset
EDM
N/C Mute Enable *
FSD2
FSD1
Single-Channel
Safety Stop
Circuit
Dual-Channel
Safety Stop
Circuit
NOTE: Do not exceed OSSD maximum load
capacitance specification.
4 - Yellow
5 - Gray
8 - Red
Override 1
Override 2
Lamp Out
2 - Brown
3 - Green
7 - Dark blue
11 - Black
1 - White
12 - Violet
9 - Orange
6 - Pink
* Open or 0V dc for Mute Enabled. Tied to +24V dc for Mute Disabled
10 - Light blue
no connection
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5.5.5 Generic Wiring for a Receiver and IM-T-9A Interface Module
2
3
4
567
8
9
1
10
11 12
+24V dc 0V dc
S1
S2
Y4
Y2
14
24
34
S3
S4
Y3
Y1
13
23
33
K2 K1
Machine
Control
Feedback (optional)
MPCE
2
MPCE
1
IM-T-9A
*
*
Reset
EDM
Mute Enable *
OSSD2
OSSD1
Override 1
2 - Brown
4 - Yellow
3 - Green
7 - Dark blue
11 - Black
1 - White
12 - Violet
9 - Orange
6 - Pink
12-pin male
M12
Override 2
5 - Gray
Lamp Out
8 - Red
* Open or 0V dc for Mute Enabled. Tied to +24V dc for Mute Disabled
10 - Light blue
no connection
Note: See the IM-T-..A module datasheet (p/n
62822
) for complete installation instructions.
WARNING: Use of Transient Suppressors
If transient suppressors are used, they MUST be installed across the coils of the machine control
elements. NEVER install suppressors directly across the contacts of the IM-T-..A Module. It is possible
for suppressors to fail as a short circuit. If installed directly across the contacts of the IM-T-..A Module, a
short-circuit suppressor creates an unsafe condition. Failure to follow these instructions could result in
serious injury or death.
5.5.6 Generic Mute Sensor Connections
The muting sensors are powered directly from the SGS Safety Grid System with Integral Muting. Connect the outputs of the
muting receivers or self-contained muting sensors to the receiver. Power the emitters for E/R pairs of muting sensors from
the emitter.
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5-pin M12/Euro-style Male Pin Description
1
4
5
3
2
1 Brown: 24 V dc
2 White: Output Mute 2
3 Blue: 0 V dc
4 Black: Output Mute 1
5 Gray: Not Connected
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6 System Operation
6.1 Security Protocol
Certain procedures for installing, maintaining, and operating the SGS must be performed by either Designated Persons or
Qualified Persons.
A Designated Person is identified and designated in writing, by the employer, as being appropriately trained and qualified to
perform system resets and the specified checkout procedures on the SGS. The Designated Person is empowered to:
• Perform manual resets and hold possession of the reset key (see
Reset Procedures
(p. 47))
• Perform the Daily Checkout Procedure
A Qualified Person, by possession of a recognized degree or certificate of professional training, or by extensive knowledge,
training, and experience, has successfully demonstrated the ability to solve problems relating to the installation of the SGS
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:
• Install the SGS System
• Perform all checkout procedures
• Make changes to the internal configuration settings
• Reset the System following a Lockout condition
6.2 System Configuration Settings
There is a configuration panel on the top of each sensor. Do not lose the gasket under the white cover. Installing the cover
without the gasket lowers the environmental rating.
To change the configuration settings:
1. Remove power from the device.
2. Unscrew the white plastic cover from the top of the unit.
3. Make the desired changes on the configuration panel. Note that each sensor has its own panel and DIP switch
settings must match for each sensor in the pair.
4. Reinstall the white plastic cover and gasket to maintain NEMA/IP ratings.
1 2 3 4 5 6 7 8
ON
Figure 25. Emitter DIP Switches
1 2 3 4 5 6 7 8
ECEON
1 2 3 4 5 6 7 8
ECEON
Figure 26. Receiver DIP Switches
Emitter Settings
DIP Switches
1 2
Scan Code: Uncoded ON ON
Scan Code 1 OFF ON
Scan Code 2 ON OFF
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Receiver Settings
DIP Switches
1 2 3 4 5 6 7 8
Muting Timeout: 10 Minutes ON
Muting Timeout: infinite OFF
Mute Selection: T (X) Configuration ON
Mute Selection: L Configuration OFF
Muting Filter: Disabled ON
Muting FIlter: Enabled OFF
Manual Start/Restart Mode (Latch) ON
Auto Start/Restart Mode (Trip) OFF
EDM Mode: Monitoring via pin 9 (orange) ON
EDM Mode: No Monitoring OFF
Scan Code: Uncoded ON ON
Scan Code: Code 1 OFF ON
Scan Code: Code 2 ON OFF
The DIP switches are in the ON position (default position) when the switch is away from the numbers and in the OFF
position when the switch is toward the numbers.
If Automatic Start/Restart (Trip Output) is selected, the OSSD outputs turn on after power is applied, and the receiver
passes its internal self-test/ synchronization and recognizes that all beams are clear. The OSSD outputs also turn on after all
beams are cleared following a blocked beam.
If Manual Start/Restart (Latch Output) is selected, the SGS requires a manual reset for the OSSD outputs to turn on when
power is applied and all beams are clear or after a blocked beam has been cleared.
6.3 Reset Procedures
Perform system resets using an external reset switch.
Mount the reset switch outside the guarded area and not within reach from within the guarded area. Its location should
provide a clear view of the entire safeguarded area. If any hazardous areas are not in view from the switch location,
additional means of safeguarding must be provided. Protect the switch from accidental or unintended actuation (for
example, through the use of rings or guards).
If supervisory control of the reset switch is required, a key switch may be used, with the key kept in the possession of a
Designated or Qualified Person. Using a key switch provides some level of personal control, since the key may be removed
from the switch. This hinders a reset while the key is under the control of an individual, but must not be relied upon solely to
guard against accidental or unauthorized reset. Spare keys in the possession of others or additional personnel entering the
safeguarded area unnoticed may create a hazardous situation.
Receiver manual resets are required in the following situations:
• Automatic Start/Restart—Only after specific types of lockouts
• Manual Start/Restart—At power-up, after each block condition is cleared, or after specific types of lockouts
6.3.1 Reset the Receiver or Active Transceiver After a Lockout
Follow these reset instructions to return the SGS receiver or active transceiver to its active state.
Use this reset procedure to reset the receiver or active transceiver from the following lockout conditions:
• Output Fault
• Optic Fault
• EDM Fault
• Lamp Fault
1. Correct the condition that caused the lockout
2. Hold the reset line open for a minimum of 5 seconds.
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3. If the fault is not cleared, turn off the power for 10 seconds, then turn the power back on.
6.3.2 Reset in Manual Start/Restart Mode
Follow these steps to reset your SGS Safety Grid System with Integral Muting in Manual Start/Restart mode at startup or
after all channels are cleared.
1. Clear all beams of the SGS.
If you are starting your SGS, ignore this step.
2. Hold the reset line open for a minimum of 0.5 seconds.
3. Close the reset line.
The reset cycle is complete.
6.4 Normal Operation
6.4.1 System Power-Up
When power is applied, each sensor conducts self-tests to detect critical internal faults, determine configuration settings,
and prepare the SGS for operation.
If either sensor detects a critical fault, scanning ceases, the receiver outputs remain Off and diagnostic information displays
on the sensor’s Diagnostic Display.
If no faults are detected, the SGS receiver looks for an optical sync pattern from the emitter. If the receiver is aligned and
receives the proper sync pattern, the SGS enters Run mode and begins scanning to determine the status (blocked or clear)
of each beam.
6.4.2 Run Mode
If any beams become blocked while the SGS is running, the receiver outputs turn Off within the stated SGS response time
(see
Specifications
(p. 61)). If all the beams then become clear, the receiver outputs come back On. No resets are needed
if the SGS is in Auto Start/Restart mode. If the system is in Manual Start/Restart mode, manually reset the system. All
required machine control resets are provided by the machine control circuit.
Internal Faults (Lockouts): If either sensor detects a critical fault, scanning ceases, the receiver outputs turn Off and
diagnostic information displays on the sensor’s Diagnostic Display. See
Lockout Conditions
(p. 52) for resolution of error/
fault conditions.
6.5 Periodic Checkout Requirements
To ensure continued reliable operation, the System must be checked out periodically. Banner Engineering highly
recommends performing the System checkouts as described below. However, a Qualified Person should evaluate these
recommendations, based on the specific application and the results of a machine risk assessment, to determine the
appropriate content and frequency of checkouts.
At every shift change, power-up, and machine setup change, the Daily Checkout should be performed; this checkout may
be performed by a Designated or Qualified Person.
Semi-annually, the System and its interface to the guarded machine should be thoroughly checked out; this checkout must
be performed by a Qualified Person (see
Schedule of Checkouts
(p. 54)). 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 SGS System or changes to the machine),
perform the Commissioning Checkout (see
Perform a Commissioning Checkout
(p. 54)).
Note: Verify Proper Operation
The SGS can operate as it is designed only if it and the guarded machine are operating properly, both
separately and together. It is the user’s responsibility to verify this, on a regular basis, as instructed in
Schedule of Checkouts
(p. 54). Failure to correct such problems can result in an increased risk of harm.
Before the System is put back into service, verify that the SGS System and the guarded machine perform
exactly as outlined in the checkout procedures and any problem(s) are found and corrected.
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7 Product Support and Maintenance
7.1 Cleaning
SGS components are constructed of aluminum with a yellow painted finish and are rated IEC IP65. Lens covers are acrylic.
Components are best cleaned using mild detergent or window cleaner and a soft cloth. Avoid cleaners containing alcohol,
as they may damage the acrylic lens covers.
7.2 Disposal
Devices that are no longer in use should be disposed of according to the applicable national and local regulations.
7.3 Warranty Service
Contact Banner Engineering for troubleshooting of this device. Do not attempt any repairs to this Banner device; it contains
no field-replaceable parts or components. If the device, device part, or device component is determined to be defective by
a Banner Applications Engineer, they will advise you of Banner's RMA (Return Merchandise Authorization) procedure.
Important: If instructed to return the device, pack it with care. Damage that occurs in return shipping is
not covered by warranty.
7.4 Banner Engineering Corp Limited Warranty
Banner Engineering Corp. warrants its products to be free from defects in material and workmanship for one year following
the date of shipment. Banner Engineering Corp. will repair or replace, free of charge, any product of its manufacture which,
at the time it is returned to the factory, is found to have been defective during the warranty period. This warranty does not
cover damage or liability for misuse, abuse, or the improper application or installation of the Banner product.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED
(INCLUDING, WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE), AND WHETHER ARISING UNDER COURSE OF PERFORMANCE, COURSE OF DEALING OR TRADE USAGE.
This Warranty is exclusive and limited to repair or, at the discretion of Banner Engineering Corp., replacement. IN NO
EVENT SHALL BANNER ENGINEERING CORP. BE LIABLE TO BUYER OR ANY OTHER PERSON OR ENTITY FOR ANY
EXTRA COSTS, EXPENSES, LOSSES, LOSS OF PROFITS, OR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL
DAMAGES RESULTING FROM ANY PRODUCT DEFECT OR FROM THE USE OR INABILITY TO USE THE PRODUCT,
WHETHER ARISING IN CONTRACT OR WARRANTY, STATUTE, TORT, STRICT LIABILITY, NEGLIGENCE, OR
OTHERWISE.
Banner Engineering Corp. reserves the right to change, modify or improve the design of the product without assuming any
obligations or liabilities relating to any product previously manufactured by Banner Engineering Corp. Any misuse, abuse, or
improper application or installation of this product or use of the product for personal protection applications when the
product is identified as not intended for such purposes will void the product warranty. Any modifications to this product
without prior express approval by Banner Engineering Corp will void the product warranties. All specifications published in
this document are subject to change; Banner reserves the right to modify product specifications or update documentation
at any time. Specifications and product information in English supersede that which is provided in any other language. For
the most recent version of any documentation, refer to:
www.bannerengineering.com
.
For patent information, see
www.bannerengineering.com/patents
.
7.5 Contact Us
Banner Engineering Corp. headquarters is located at:
9714 Tenth Avenue North
Minneapolis, MN 55441, USA
Phone: + 1 888 373 6767
For worldwide locations and local representatives, visit
www.bannerengineering.com
.
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8 Troubleshooting
8.1 Error Codes
Emitter Error Codes
Display Status Description User Action
emitting emitting, uncoded If set for scan code 1, a 1 displays. if set for scan code 2, a 2
displays.
failure lockout (not
recoverable)
microcontroller failure Turn off/on SGS.
If the problem persists, contact the factory for technical
support.
failure lockout (not
recoverable)
optical failure Turn off/on SGS.
If the problem persists, contact the factory for technical
support.
off power supply failure Check power supply connection.
If the problem persists, contact the factory for technical
support.
FAILURE LOCKOUT
(recoverable)
DIP switch failure Check the DIP-switch configuration and activate the reset.
If the problem persists, contact the factory for technical
support.
Receiver Error Codes
Display Status Description User Action
latched beams clear Activate the reset line to turn the outputs on
outputs off beams blocked, OSSDs are
off in manual reset mode
Clear the beam path before resetting the device
normal operation OSSDs on
outputs off beams blocked, OSSDs are
off in auto reset mode
If set for scan code 1, a 1 displays. if set for scan code 2, a 2
displays.
EDM function active
EDM function not active
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Receiver Error Codes
Display Status Description User Action
beams blocked and at least
one mute sensor is blocked
override function is ready to
be activated
The user can activate the Override function,
F
failure lockout (recoverable) failure on one or both OSSDs,
OSSDs off
Activate reset line.
If the SGS does not reset, contact the factory for technical
support.
failure lockout (not
recoverable)
microcontroller failure,
OSSDs off
Turn off/on SGS.
If the problem persists, contact the factory for technical
support.
failure lockout (recoverable) optical failure, OSSDs off Activate reset line.
If the SGS does not reset, contact the factory for technical
support.
failure lockout (recoverable) EDM failure, OSSDs off Check EDM enable line or DIP switches, EDM line, external
switching device, and activate reset line.
If the SGS does not reset, contact the factory for technical
support.
FAILURE LOCKOUT (not
recoverable)
Override connection failure,
OSSDs OFF
User must check Override lines connection and turn OFF/ON
the SGS system.
If the problem persists, contact the factory for technical
assistance.
Outputs off Override sequence failure User must check Override lines activation sequence timings
and repeat Override sequence.
If the problem persists, contact the factory for technical
assistance.
SGS off power supply failure, OSSDs
off
Check the power supply connection.
If the problem persists, contact the factory for technical
support.
FAILURE LOCKOUT (not
recoverable)
DIP switch failure, OSSDs
OFF
Check the DIP-switch configuration and turn OFF/ON the
SGS.
If the problem persists, contact the factory for technical
support.
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Receiver Error Codes
Display Status Description User Action
FAILURE LOCKOUT
(recoverable)
Internal and external lamp
failure, OSSDs OFF
User must check LAMP INPUT line and activate RESET line.
If SGS system does not reset, contact the factory for technical
assistance
8.2 Lockout Conditions
A Lockout condition causes all of the SGS 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
Error
Codes
(p. 50)).
Receiver Lockout Conditions
Green Status indicator Off
Red Status indicator On
Beam indicators Off
Diagnostic display Error code
Emitter Lockout Conditions
Status indicator Off
Diagnostic Display Error code
If both the emitter and its corresponding receiver do not have the same scan code setting, the receiver indicates the units
are not aligned. This is not considered a lockout and can occur if the Scan Code input is not set the same for both sensors.
8.3 Recovery Procedure
To recover from a lockout condition, follow these steps.
WARNING: Shut Down Machinery Before Servicing
The machinery to which the Banner device is connected must not be operating at any time during major
service or maintenance. This may require lockout/tagout procedures (refer to OSHA1910.147, ANSI
Z244-1, ISO 14118 or the appropriate standard for controlling hazardous energy). Servicing the Banner
device while the hazardous machinery is operational could result in serious injury or death.
WARNING: Lockouts and Power Failures
Power failures and Lockout conditions are indication of a problem and must be investigated immediately
by a Qualified Person7. Attempts to continue to operate machinery by bypassing the Banner device or
other safeguards is dangerous and could result in serious injury or death.
1. Correct all errors.
2. If the lockout is non-recoverable:
a) Remove power from the sensor and wait a few seconds.
b) Apply power to the sensor.
3. If the lockout is recoverable: Hold the reset line open for 5 seconds, then release it.
After a few seconds, the SGS performs a self check. If all faults are cleared, the SGS resumes functioning.
7A person who, by possession of a recognized degree or certificate of professional training, or who, by extensive knowledge, training and
experience, has successfully demonstrated the ability to solve problems relating to the subject matter and work.
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8.4 Electrical and Optical Noise
The SGS is designed and manufactured to be highly resistant to electrical and optical noise and to operate reliably in
industrial settings. However, serious electrical and/or optical noise may cause a random Trip. In very extreme electrical
noise cases, a Lockout is possible. To minimize the effects of transitory noise, the SGS dual scan technology responds to
noise only if the noise is detected on multiple consecutive scans.
If random nuisance Trips occur, check the following:
• Poor connection between the sensor and earth ground
• Optical interference from adjacent light screens or other photoelectrics
• Sensor input or output wires routed too close to noisy wiring
8.4.1 Check for Sources of Electrical Noise
It is important that the light screen sensors have a good earth ground. Without this, the System can act like an antenna and
random Trips and Lockouts can occur.
All SGS wiring is low voltage; running these wires alongside power wires, motor/servo wires, or other high-voltage wiring
can inject noise into the SGS System. It is good wiring practice (and may be required by code) to isolate SGS wires from
high-voltage wires.
1. Use the Banner model BT-1 Beam Tracker Alignment Aid (see
Alignment Aids
(p. 67)) to detect electrical transient
spikes and surges.
2. Cover the lens of the BT-1 with electrical tape to block optical light from entering the receiver lens.
3. Press the RCV button on the BT-1 and position the Beam Tracker on the wires going to the SGS or any other nearby
wires.
4. Install proper transient suppression across the load to reduce the noise.
8.4.2 Check for Optical Noise Sources
To check for optical noise sources, follow these steps.
1. Turn off the emitter or completely block the emitter.
2. Use a Banner BT-1 Beam Tracker (see
Alignment Aids
(p. 67)) to check for light at the receiver.
3. Press the RCV button on the BT-1 and move it across the full length of the receiver’s sensing window.
4. If the BT-1’s indicator lights up, check for emitted light from other sources (other safety light screens, grids or
points, or standard photoelectric sensors).
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9 Checkout Procedures
This section lists the schedule of checkout procedures and describes where each procedure is documented. Checkouts
must be performed as described. Results should be recorded and kept in the appropriate place (for example, near the
machine, and/or in a technical file).
Banner Engineering highly recommends performing the System checkouts as described. However, a qualified person (or
team) should evaluate these generic recommendations considering their specific application and determine the appropriate
frequency of checkouts. This will generally be determined by a risk assessment, such as the one contained in ANSI B11.0.
The result of the risk assessment will drive the frequency and content of the periodic checkout procedures and must be
followed.
9.1 Schedule of Checkouts
Checkout cards and this manual can be downloaded at
http://www.bannerengineering.com
.
Checkout Procedure When to Perform Where to Find the Procedure Who Must Perform
the Procedure
Trip Test
At Installation
Any time the System, the guarded machine, or
any part of the application is altered.
Conduct a Trip Test
(p. 37) Qualified Person
Commissioning
Checkout
At Installation
Whenever changes are made to the System (for
example, either a new configuration of the SGS or
changes to the guarded machine).
Perform a Commissioning Checkout
(p. 54) Qualified Person
Shift/Daily Checkout
At each shift change
Machine setup change
Whenever the System is powered up
During continuous machine run periods, this
checkout should be performed at intervals not to
exceed 24 hours.
Daily Checkout Card (Banner p/n
203650
)
A copy of the checkout results should be recorded
and kept in the appropriate place (for example, near
or on the machine, in the machine's technical file).
Designated Person or
Qualified Person
Semi-Annual
Checkout
Every six months following System installation, or
whenever changes are made to the System (either
a new configuration of the SGS or changes to the
machine).
Semi-Annual Checkout Card (Banner p/n
203651
)
A copy of the checkout results should be recorded
and kept in the appropriate place (for example, near
or on the machine, in the machine's technical file).
Qualified Person
9.2 Perform a Commissioning Checkout
Perform a commissioning checkout as part of the System installation after the System has been interfaced to the guarded
machine, or after changes are made to the System (either a new configuration of the SGS or changes to the machine). A
Qualified Person must perform the procedure. Checkout results should be recorded and kept on or near the guarded
machine as required by applicable standards.
WARNING: Do Not Use Machine Until System Is Working Properly
If all of these checks cannot be verified, do not attempt to use the safety system that includes the Banner
device and the guarded machine until the defect or problem has been corrected. Attempts to use the
guarded machine under such conditions could result in serious injury or death.
1. Examine the guarded machine to verify that it is of a type and design compatible with the SGS System. See
Examples: Inappropriate Applications
(p. 10) for a list of misapplications.
2. Verify the SGS is configured for the intended application.
3. Verify the safety distance (minimum distance) from the closest danger point of the guarded machine to the sensing
field is not less than the calculated distance, per
Mechanical Installation
(p. 21).
4. Verify:
a) Access to any dangerous parts of the guarded machine is not possible from any direction not protected by the
SGS System, hard (fixed) guarding, or supplemental safeguarding, and
b) It is not possible for a person to stand between the sensing field and the dangerous parts of the machine, or
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>1
c) Supplemental safeguarding and hard (fixed) guarding, as described by the appropriate safety standards, are in
place and functioning properly in any space (between the sensing field and any hazard) which is large enough to
allow a person to stand undetected by the SGS.
5. Verify all reset switches are mounted outside and in full view of the guarded area, out of reach of anyone inside the
guarded area, and that means of preventing inadvertent use is in place.
6. Examine the electrical wiring connections between the SGS OSSD outputs and the guarded machine’s control
elements to verify that the wiring meets the requirements stated in
Electrical Connections to the Guarded Machine
(p. 38).
7. Inspect the area near the sensing field (including work pieces and the guarded machine) for reflective surfaces (see
Adjacent Reflective Surfaces
(p. 25)). Remove the reflective surfaces if possible by relocating them, painting,
masking or roughening them. Remaining problem reflections will become apparent during the Trip Test.
8. Verify power to the guarded machine is Off. Remove all obstructions from the sensing field. Apply power to the SGS
System.
9. Observe the Status indicators and Diagnostic Display:
•Lockout: Error code on display
•Blocked: Red Status indicator is on
•Clear: Green Status is on
10. A Blocked condition indicates that one or more of the beams is misaligned or interrupted. See
Optically Align the
Components
in the
Initial Checkout Procedure
(p. 33) section to correct this situation.
11. After the green Status indicator is on, conduct a trip test on each sensing field to verify proper System operation and
to detect possible optical short circuits or reflection problems. Do not continue until the SGS passes the trip test.
Important: Do not expose any individual to any hazard during the following checks.
WARNING: Before Applying Power to the Machine
Verify that the guarded area is clear of personnel and unwanted materials (such as tools) before
applying power to the guarded machine. Failure to follow these instructions could result in
serious injury or death.
12. Apply power to the guarded machine and verify the machine does not start up.
13. Interrupt (block) the sensing field with a 60 mm, opaque, cylindrical test piece (not supplied) and verify it is not
possible for the guarded machine to be put into motion while the beam(s) is blocked.
14. Initiate machine motion of the guarded machine and, while it is moving, use the test piece to block a beam. Do not
attempt to insert the test piece into the dangerous parts of the machine.
Upon blocking any beam, the dangerous parts of the machine must come to a stop with no apparent delay.
15. Remove the test piece from the beam. Verify the machine does not automatically restart and the initiation devices
must be engaged to restart the machine.
16. Remove electrical power to the SGS.
Both OSSD outputs should immediately turn Off, and the machine must not be capable of starting until power is re-
applied to the SGS.
17. Test the machine stopping response time, using an instrument designed for that purpose, to verify it is the same or
less than the overall system response time specified by the machine manufacturer.
Do not continue operation until the entire checkout procedure is complete and all problems are corrected.
9.3 Perform a Muting Checkout
While performing this procedure, ensure that personnel are not exposed to any hazard.
1. Verify that the system has been reset and the green Status indicator is on. If the L is on the display (indicating the
system is waiting for a reset of a latched condition), perform a valid manual reset.
2. Mute the system by blocking (or activating) both mute devices (typically A1-B1) simultaneously (within 4 seconds).
3. Verify that the Mute Lamps (amber flashing on top of receiver and Lamp Out line (red wire) pulses) come on. If not:
a) Check the indicator and its wiring.
b) Verify that the Mute Enable input (pink wire) is open or tied to 0 V dc.
c) Check the Diagnostic Display for error codes.
4. Interrupt (block) a SGS system beam and verify the green Status indicator stays on.
5. Clear the beams of the SGS system before the Mute Timer expires if used (see
Mute Time Limit (Backdoor Timer)
(p.
14)), and verify that the green Status indicator stays on.
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6. Clear (deactivate) the mute devices before the Mute Timer expires and verify the mute lamp on the receiver turns off
and the Lamp Out line stops conducting.
The green Status indicator should remain on.
7. Verify that an individual:
• Cannot initiate a mute condition by triggering the mute devices (for example, by blocking both photoelectric
beams or actuating both switches); and
• Cannot access the hazard without being detected and a stop command is not issued to the machine.
Do not expose any individuals to the hazard while attempting to mute the system.
8. Verify that it is not possible for personnel to pass in front of, behind, or next to the muted object without being
detected and a stop command is not issued to the machine.
9. When the muting function is used, verify all optional functions. Do not expose any individuals to a hazard while
attempting to mute or override the system.
9.4 Perform a One-Way (Directional) Muting Checkout
Procedure
Follow these instructions to perform a one-way (directional) muting using the Mute Enable input.
Do not expose any individuals to a hazard while attempting to mute the system.
1. Use a switch to tie the Mute Enable input (pin 6, pink wire) to +24 V dc.
2. Verify that the system cannot be muted by blocking (or activating) the mute devices within 4 seconds of each other.
9.5 Perform an Exit-Only Application Checkout Procedure
Follow these steps to perform an exit-only application (L muting configuration) checkout procedure.
1. Verify the minimum carrier length requirement for this mute configuration.
See
Entry/Exit Applications
(p. 57).
2. From the non-hazardous side (safe area) of the SGS system, verify that the system cannot be muted and the SGS
system OSSDs turn OFF and remain OFF when the defined area is blocked.
9.6 Perform a Mute-Dependent Override Checkout
Procedure
1. Clear all mute sensors and the light screen and verify the OSSDs are on.
2. Block (interrupt) a beam of the SGS system.
3. Verify the OSSDs turn off.
4. Block (activate) one or both of the mute sensors.
The bottom half of the 7-segment display of the receiver is lighted and displays 'o'.
5. With the SGS system and at least one mute sensor blocked, start the override process by closing both override
switches (override 1 and 2) within 400 ms of each other.
6. Verify the OSSDs turn on.
7. Verity the OSSDs turn off after 120 seconds when the Override timer expires.
8. Clear the SGS system and all the mute sensors.
9. If the system is in automatic restart mode, verify the OSSDs turn on. If the system is in manual restart mode, a
proper reset is required.
10. Open both override inputs.
11. Verify the OSSDs remain on.
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10 Typical Muting Applications
10.1 Entry/Exit Applications
Place the muting devices to ensure the points that trigger the mute's start and end are very close to the SGS system's
sensing field. This prevents personnel from following, or being pushed by, the object into the hazardous area without
interrupting the SGS before the mute window opens or at the time the mute window closes.
When two pairs of retroreflective photoelectric sensors are used as muting devices, the crossing point of the two sensing
paths must be on the hazardous side of the safety light screen. The safety light screen will be interrupted before any
personnel would be able to block both beams and mute the system. The devices should detect the material and not the
pallet or the transport to prevent an individual from riding into the hazardous area.
Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
Safe Area
Safety Mat
sensor
reflector
A1
reflector
sensor
B1
Figure 27. “X”-Pattern Entry/Exit system using two pairs of opposed-mode photoelectric muting devices
Where A1 is mute 1 and B1 is mute 2.
M1
(Emitter)
Light Screen
Defined Area
M1 *
M2
(Receiver)
M2 *
* Sensor not shown
Figure 28. Horizontal photoelectric muting devices placed at different
heights
M1
(Emitter)
Light Screen
Defined Area M1 *
M2
(Receiver)
M2 *
* Sensor not shown
Figure 29. Photoelectric muting devices placed diagonally
Where M1 is mute 1 and M2 is mute 2.
To configure the system for X muting, set the Muting T/L switches of the receiver to T (ON/away from the numbers).
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WARNING:
• It must not be possible for an individual or 500 mm diameter object to block both photoelectric
beams (e.g. dashed diagonal lines) and initiate a mute condition.
• Failure to follow these instructions could result in serious injury or death.
• Check the installation to verify that unintentional muting is not possible.
• Locate the "crossing point" of the photoelectric beams in the hazardous area and not accessible
to personnel (by reaching over, under, through, or around).
Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
Safe Area
DD
AB
sensor
reflector reflector
sensor
A1 B1
reflector reflector
sensor sensor
B2 A2
Figure 30. Entry/Exit Application using four pairs of opposed-mode photoelectric sensors for mute devices
To configure the system for T muting, set the Muting T/L switches of the receiver to T (ON/away from the numbers).
A ≥ Line Speed × 0.1 s
B ≥ Line Speed × 0.1 s
Length of carrier basket > A + B + (D x 2) (must be greater than 500 mm)
(A2 must be blocked before A1 clears)
D < Line speed × 4.0 s, but beams A1 and B1 must be far enough apart to prevent an individual from triggering both
sensors simultaneously.
CAUTION:
•Four Mute Device Applications
• Failure to follow these instructions could result in serious injury or death.
• When four mute devices are used, configure the maximum mute time limit to ON by setting the
Muting Timeout switches to 10 minutes (ON/away from the numbers).
• Use the Mute Enable function to enforce one-way muting when four muting devices are used.
WARNING: In all applications, it must not be possible for personnel to walk in front of, behind, or next to
the muted object (e.g., the carrier basket) without being detected and stopping the hazardous motion.
Supplemental safeguarding must be used to prevent personnel from entering the hazardous area during
a mute condition.
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Hazardous Area
Carrier Basket
Light
Screen
R
E
Fixed Guarding
Safe Area
DA
sensor
reflector reflector
sensor
A1 B1
Figure 31. Exit Application with 1-Way Muting using two opposed-mode sensors
To configure the system for L muting, set the Muting T/L switches of the receiver to L (OFF/toward the numbers).
A ≥ Line speed × 0.1 s
D < line speed × 2 × 2 tab (tab is the initiation time between A1 and B1 and has a four-second maximum)
Length of carrier basket > D
Note: Light screen must be blocked before A1 clears.
10.2 Robot Load/Unload Station Applications
This station muting application uses two independent safety light screen circuits, each with its own muting circuit and
muting devices (for example, polarized-retroreflective photoelectrics).
The application (shown) also includes a two-hand control run bar, auxiliary controls, and an emergency stop button. The
two-hand control is provided at each station to safeguard the operator during the momentary clamping action of the fixture
while the safety light screen is muted.
In this example, the area inside the light curtain is fairly large, allowing the use of area guarding. Because of the larger
separation distance of the SGS system, protection against pass-through hazards must be considered. In muting
applications involving an operator, the operator must be continually detectable inside the protected area. This ensures that
if a hazard arises that causes the mute to end while the operator is present, the system immediately stops the hazard (via
the light curtain or other safety devices).
While the robot is at station A, the light screen at station B is muted (A2 and B2 are active), allowing the loading or
unloading of station B without issuing a stop command to the robot. As the robot moves out of the A work envelope (as
defined by Station B mute devices, see detail B) the mute discontinues at station B. If anything is still blocking the SGS
system, a stop command is immediately issued. As the robot moves to the work envelope of station B, the mute devices A1
and B1 activate and mute the safety light screen at station A.
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Station B
Hard Guarding
Station A
Retroreflective Targets
Station A Run-Bar
Station A
Work Envelope
Clamping and Welding Fixtures
A2 and B2 Station B
Mute Circuit
A1 and B1
Station A Mute
Circuit
Station B Run-Bar with
Two-Hand Control,
E-Stop, and Clamping
Manual Release
Figure 32. A robot load/unload application with two-station home-position muting, using polarized retroreflective photoelectrics as muting devices
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11 Specifications
11.1 General Specifications
Electrical
Supply Voltage
24 V dc ± 20% (At a minimum, use a SELV-rated power supply
according to EN IEC 60950. Depending on the installation, a Class 2
low-voltage power supply and circuit as described by NFPA 70 may be
required.)
Power Consumption
Emitter: 2.5 W maximum
Receiver: 4 W maximum (without load)
Pollution Degree
2
Safety Category
Type 4 (per EN 61496-1)
SIL 3 (per EN 61508)
SIL CL 3 (per EN 62061)
PLe and Cat. 4 (per EN ISO 13849-1)
PFHd 1.10 × 10-8
Proof Test Interval: 20 years
Electrical Protection
Class III (per IEC 61140)
Outputs Signal Switching Devices (OSSDs)
2 PNP
Short-circuit protection (1.4 A at 55 °C)
Maximum output current: 0.5 A maximum per output
On-state voltage: Power supply value less 1 V dc
Off-state voltage: 0.2 V dc maximum (no load)
Maximum load capacitance: 2.2 µF at 24 V dc
Response Time
11 to 24 ms (varies by model)
Protected Height
500 mm to 1200 mm (varies by model)
Auxiliary Functions
Reset, Restart selection, Alignment, EDM, Muting, Override
Connections
8-pin M12 quick disconnect for emitter
12-pin M12 quick disconnect for receiver
5-pin M12 quick disconnect for connecting mute sensors
Power supply cable length: 70 m maximum
Optical
Light Source
Infrared LED (950 nm wavelength)
Operating Distance
0.5 m to 30 m (for standard range models)
Ambient Light Rejection
IEC 61496-2
Optic Beams
Varies by model: 2, 3, or 4
Beam Spacing
Varies by model: 300 mm, 400 mm, or 500 mm
Effective Aperture Angle (EAA)
Meets Type 4 requirements per IEC 61496-2, Section 5.2.9
Mechanical and Environmental
Connections
M12
Construction
Housing: Painted aluminium (yellow RAL 1003)
Caps: PBT Valox 508 (pantone 072-CVC)
Front glass: PMMA
Environmental Rating
IEC IP65 (EN 60529)
Vibration and Shock
0.35 mm width, 10…55 Hz frequency, 20 sweep for each axis, 1
octave/min (EN 60068-2-6)
16 ms (10g) 1.000 shock for each axis (EN 60068-2-29)
Environmental Conditions
Operating: 0 °C to +55 °C (+32 °F to +131 °F)
Storage: –25 °C to +70 °C (–13 °F to +158 °F)
Temperature Class: T6
15% to 95% (non-condensing) relative humidity
Certifications
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11.2 Dimensions
10.85
13.85
10 52
Ø42
M4 TCEI inox
40
L1
L2
30
15
20
30
36
17 21
56.9
Mirror Assembly
Models
Mirror Assembly
Models
5-Pin M12 QD
(muting models only)
12-Pin M12 QD
500
500 mm spacing
Two-beam
400 mm spacing
Three-beam
300 mm spacing
Four-beam
400 mm spacing
Four-beam
40
10
40
10
40
10
40
10
55
10
55
10
55
10
55
10
400 400
300 300 300
400 400 400
Model L1 (mm) L2 (mm)
SGSMP2-500Q88 606.35 520.5
SGSMP3-400Q88 906.35 820.5
SGSMP4-300Q88 1006.35 920.5
SGSMP4-400Q88 1306.35 1220.5
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0: D mm dSODQDOCKKCDODOQOSODODOQO O \ M F x en Q EOEOQOEOEOEOSOEOEOEOEO O
11.3 Muting Arms Dimensions
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12 Accessories
12.1 Bracket and Test Piece
Model Description
STP-15 60 mm test piece (60 mm resolution systems)
SGSA-MBK-10-4 End-cap bracket kit (includes 4 end brackets and hardware); 360° sensor rotation possible; zinc-plated, 8-gauge, cold-rolled
steel
12.2 Cordsets
Machine interface cordsets provide power to the emitter/receiver pair. Cordsets typically have yellow PVC cables and black
overmolds.
Single-ended (to connect to the machine interface)— QDEG-8..D QD-to-flying lead is used with sensors with a 8-pin M12
QD (model ends in Q8). QDEG-12..E QD-to-flying lead is used with sensors with a 12-pin M12 QD (model ends in Q12).
12.2.1 Single-Ended (Machine Interface) Cables
Typically you use one cordset for each emitter and receiver.
QDEG-8..D 8-pin M12/Euro-style QD to flying lead cordsets—This cordset has a M12 QD connector on one end and is unterminated (cut to length) on
the other end to interface with guarded machine. PVC jacketed overmold and cables.
Model Length Banner Cordset Pinout/Color Code M12 Connector (female face view)
QDEG-815D 4.5 m (15 ft) Pin Color Emitter Function
1 Brown +24 V dc
2 Or/Bk no connection
3 Orange no connection
4 White no connection
5 Black no connection
6 Blue 0 V dc
7 Gn Ground/Chassis
8 Violet no connection
5
4
3
2
8
1
7
6
QDEG-825D 7.6 m (25 ft)
QDEG-850D 15.2 m (50 ft)
QDEG-875D 22.8 m (75 ft)
QDEG-8100D 30.4 m (100 ft)
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1’ kg“ Figlmg; ” fl [Em] 1
12.2.2 Machine Interface Cordsets
Model Length Banner Cordset Pinout/Color Code M12/Euro Connector (female face view)
QDEG-1215E 4.5 m (15 ft) QD pin Color Function
1 White OSSD 2
2 Brown +24 V dc
3 Green Gnd/Chassis
4 Yellow Override 1
5 Gray Override 2
6 Pink Mute Enable
7 Dark Blue 0 V dc
8 Red Lamp Out
9 Orange EDM Input
10 Light Blue N.C.
11 Black OSSD 1
12 Violet Reset/Restart
QDEG-1225E 7.6 m (25 ft)
QDEG-1250E 15.2 m (50 ft)
QDEG-1275E 22.8 m (75 ft)
QDEG-12100E
30.4 m (100 ft)
DEE2R-5..D 5-pin M12/Euro-style QD to M12/Euro-style QD (female-male) cordsets—Use the DEE2R-5... cordsets to
extend the length of cordsets and directly connect to other devices with a 5-pin M12/Euro-style quick disconnect. Other
lengths are available.
5-Pin Threaded M12/Euro-Style Cordsets—Double Ended
Model Length Style Dimensions Pinout
DEE2R-51D 0.31 m (1 ft)
Female Straight/
Male Straight
40 Typ.
ø 14.5
M12 x 1
44 Typ.
ø 14.5
M12 x 1
Male
1
4
5
3
2
Female
2
3
4
1
5
1 = Brown
2 = White
3 = Blue
4 = Black
5 = Green/Yellow
DEE2R-53D 0.91 m (3 ft)
DEE2R-58D 2.44 m (8 ft)
DEE2R-515D 4.57 m (15 ft)
DEE2R-525D 7.62 m (25 ft)
DEE2R-550D 15.2 m (50 ft)
DEE2R-575D 22.9 m (75 ft)
DEE2R-5100D 30.5 m (100 ft)
12.3 Muting Accessories
Model Description
SGSA-MCB Muting Connection Box
SGSA-MCS-2 Muting Connection cable for X and L mute arm kits
SGSA-MCS-4 Muting Connection cable for T mute arm kits
SGSA-MCB-HW Optional hardware kit for mounting Connection Box to the t-slot of SGS Receiver or Active unit
SGSA-ML-L-LPQ20 L-configuration Mute Arm Kit, left side, (as viewed from the front of the receiver); one SGSA-Q20PLPQ5 mute
sensor, and one retroreflector
SGSA-ML-R-LPQ20 L-configuration Mute Arm Kit, right side, (as viewed from the front of the receiver); one SGSA-Q20PLPQ5 mute
sensor, and one retroreflector
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Model Description
SGSA-MT-LPQ20 T-configuration Mute Arm Kit; includes four mute arms, four SGSA-Q20PLPQ5 mute sensors, and four
retroreflectors
SGSA-MX-LPQ20 X-configuration Mute Arm Kit; includes four mute arms, two SGSA-Q20PLPQ5 mute sensors, and two
retroreflectors
SGSA-Q20PLPQ5 Q20 Retroreflective mute sensor with 600 mm cordset and M12/Euro-style quick disconnect
BRT-2X2 Retroreflective target for use with mute sensor
SGSA-M-HW Mute Arm replacement hardware, two M5 screws and one M5 double t-nut
SGSA-M-TN-1 Mute Arm replacement double t-nut
SGSA-M-TN-10 Ten (10) Mute Arm replacement double t-nuts
12.4 Universal (Input) Safety Modules
UM-FA-xA Safety Modules provide forced-guided, mechanically-linked relay (safety) outputs for the SGS system when an
external manual reset (latch) is desired or external device monitoring is required in the application. See datasheet p/n
141249
for more information.
Model Description
UM-FA-9A 3 normally open (N.O.) redundant-output 6 amp contacts
UM-FA-11A 2 normally open (N.O.) redundant-output 6 amp contacts, plus 1 normally closed (N.C.) auxiliary contact
12.5 Safety Controllers
Safety Controllers provide a fully configurable, software-based safety logic solution for monitoring safety and non-safety
devices. For additional models and XS26 expansion modules, see instruction manual p/n
174868
(XS/SC26-2).
Non-Expandable Models Expandable Models Description
SC26-2 XS26-2 26 convertible I/O and 2 Redundant Solid State Safety Outputs
SC26-2d XS26-2d 26 convertible I/O and 2 Redundant Solid State Safety Outputs with Display
SC26-2e XS26-2e 26 convertible I/O and 2 Redundant Solid State Safety Outputs with Ethernet
SC26-2de XS26-2de 26 convertible I/O and 2 Redundant Solid State Safety Outputs with Display and Ethernet
SC10-2roe 10 Inputs, 2 redundant relay safety outputs (3 contacts each)
12.6 Interface Modules
IM-T-..A interface modules provide forced-guided, mechanically-linked relay (safety) outputs for the SGS system with the
EDM function selected. The IM-T-..A interface module is required to be monitored by the EDM function. See Banner
datasheet p/n
62822
for more information.
Model Description
IM-T-9A Interface module, 3 normally open (N.O.) redundant-output 6 amp contacts
IM-T-11A Interface module, 2 normally open (N.O.) redundant-output 6 amp contacts, plus 1 normally closed (N.C.) auxiliary
contact
SR-IM-9A Interface module, 3 normally open (N.O.) redundant-output contacts (see datasheet)
SR-IM-11A Interface module, 2 normally open (N.O.) redundant-output contacts (see datasheet), plus 1 normally closed (N.C.)
auxiliary contact
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12.7 Contactors
If used, two contactors per SGS system that are monitored by the EDM circuit are required. See Banner datasheet p/n
111881
for more information.
Model Description
11-BG00-31-D-024 10 amp positive-guided contactor, 3 N.O., 1 N.C.
BF1801L024 18 amp positive-guided contactor, 3 N.O., 1 N.C. (N.C. contact rated at 10 amps)
12.8 Alignment Aids
Model Description
LAT-1-SGS Self-contained visible-beam laser tool for aligning the SGS system
components. Includes retroreflective target material and mounting clip.
SGSA-LAT-2 Replacement adaptor (clip) hardware for SGS models
SGSA-LAT-1 LAT reflective tape clip-on target for SGS models
BRT-THG-2-100 2.5 m (100 in) of retroreflective tape, 2 inches wide
BT-1 Beam Tracker
12.9 SSM Series Corner Mirrors
• Robust for heavy-duty applications
• Extra wide for use with long-range optical safety systems
• Rear-surface glass mirrors are rated at 85% efficiency. The total sensing
range decreases by approximately 8% per mirror. See mirror datasheet
p/n 61934 or
www.bannerengineering.com
for further information.
• Stainless steel reflective surface models are also available. See datasheet
p/n
67200
.
• Robust construction, two mounting brackets and hardware included.
• EZA-MBK-2 adapter bracket is required for use with MSA Series stand,
refer to the mounting bracket accessories list.
• Brackets may be inverted from the positions shown, decreasing
dimension L1 by 58 mm (2.3 in).
L1
L3
L2
Y
101.2 mm
(3.98")
100 mm
(3.94")
115 mm
(4.53")
M6 x 19 mm
screw
(4 supplied)
M5 x 10 mm
screw
(4 supplied)
Mirror Model Fits Model Reflective Area Y Mounting L1 Mounting L2
SSM-550 SGS...2-500Q88 550 mm (21.7 in) 661 mm (26 in) 628 mm (24.7 in)
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Mirror Model Fits Model Reflective Area Y Mounting L1 Mounting L2
SSM-875 SGS...3-400Q88 875 mm (34.4 in) 986 mm (38.8 in) 953 mm (37.5 in)
SSM-975 SGS...4-300Q88 975 mm (38.4 in) 1086 mm (42.8 in) 1053 mm (41.5 in)
SSM-1275 SGS...4-400Q88 1275 mm (47.2 in) 1386 mm (54.6 in) 1353 mm (53.3 in)
12.10 MSA Series Stands
• Provides mounting T-slots with 20 mm dimension between slots
• Base included. Available without a base by adding the suffix NB to the model
number (for example, MSA-S42-1NB).
Stand Model Pole Height Useable Stand Height Overall Stand Height
MSA-S24-1 610 mm (24 in) 483 mm (19 in) 616 mm (24.25 in)
MSA-S42-1 1067 mm (42 in) 940 mm (37 in) 1073 mm (42.25 in)
MSA-S66-1 1676 mm (66 in) 1550 mm (61 in) 1682 mm (66.25 in)
MSA-S84-1 2134 mm (84 in) 2007 mm (79 in) 2140 mm (84.25 in)
MSA-S105-1 2667 mm (105 in) 2667 mm (100 in) 2673 mm (105.25 in)
(4) M10 Bolt
Pole
40 mm
(1.58") Square
Mounting
Channel
Spacing
20 mm
(0.79")
Useable
Stand
Height
127 mm
(5.0")
Base Plate Thickness
6.4 mm (0.25")
Note: One EZA-MBK-2 Adapter Bracket Kit is required per component.
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13 Glossary
A
ANSI (American National Standards Institute)
Acronym for the American National Standards
Institute, an association of industry representatives
that develops technical standards (including safety
standards). These standards comprise a consensus
from a variety of industries on good practice and
design. ANSI standards relevant to application of
safety products include the ANSI B11 Series, and
ANSI/RIA R15.06. See
Standards and Regulations
(p.
6).
Auto Power-Up
A safety light screen system feature that enables the
system to be powered up into Run mode (or recover
from a power interruption) without requiring a manual
reset.
Auto Start/Restart (Trip) Condition
The safety outputs of a safety light screen system
turn off when an object completely blocks a beam. In
an Auto Start/Restart condition, the safety outputs
re-energize when the object is removed from the
defined area.
Auto Start/Restart (Trip) Initiate
The resetting of a safeguard causing the initiation of
machine motion or operation. Auto Start/Restart
Initiate is not allowed as a means to initiate a
machine cycle per NFPA 79 and ISO 60204-1, and is
commonly confused with PSDI.
B
Blanking
A programmable feature of a safety light screen
system which allows the light screen to ignore certain
objects located within the defined area. See Floating
Blanking and Reduced Resolution.
Blocked Condition
A condition that occurs when an opaque object of
sufficient size blocks/interrupts one or more light
screen beams. When a blocked condition occurs,
OSSD1 and OSSD2 outputs simultaneously turn off
within the system response time.
Brake
A mechanism for stopping, slowing, or preventing
motion.
C
Cascade
Series connection (or "daisy-chaining") of multiple
emitters and receivers.
CE
Abbreviation for "Conformité Européenne" (French
translation of "European Conformity"). The CE mark
on a product or machine establishes its compliance
with all relevant European Union (EU) Directives and
the associated safety standards.
Clutch
A mechanism that, when engaged, transmits torque
to impart motion from a driving member to a driven
member.
Control Reliability
A method of ensuring the performance integrity of a
control system or device. Control circuits are
designed and constructed so that a single failure or
fault within the system does not prevent the normal
stopping action from being applied to the machine
when required, or does not create unintended
machine action, but does prevent initiation of
successive machine action until the failure is
corrected.
CSA
Abbreviation for Canadian Standards Association, a
testing agency similar to Underwriters Laboratories,
Inc. (UL) in the United States. A CSA-certified
product has been type-tested and approved by the
Canadian Standards Association as meeting
electrical and safety codes.
D
Defined Area
The "screen of light" generated by a safety light
screen system, defined by the height and the safety
distance (minimum distance) of the system.
Designated Person
A person or persons identified and designated in
writing, by the employer, as being appropriately
trained and qualified to perform a specified checkout
procedure.
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E
Emitter
The light-emitting component of a safety light screen
system, consisting of a row of synchronized
modulated LEDs. The emitter, together with the
receiver (placed opposite), creates a "screen of light"
called the defined area.
External Device Monitoring (EDM)
A means by which a safety device (such as a safety
light screen) actively monitors the state (or status) of
external devices that may be controlled by the safety
device. A lockout of the safety device will result if an
unsafe state is detected in the external device.
External device(s) may include, but are not limited to:
MPCEs, captive contact relays/contactors, and
safety modules.
F
Failure to Danger
A failure which delays or prevents a machine safety
system from arresting dangerous machine motion,
thereby increasing risk to personnel.
Final Switching Device (FSD)
The component of the machine’s safety-related
control system that interrupts the circuit to the
machine primary control element (MPCE) when the
output signal switching device (OSSD) goes to the
OFF-state.
FMEA (Failure Mode and Effects Analysis)
A testing procedure by which potential failure modes
in a system are analyzed to determine their results or
effects on the system. Component failure modes that
produce either no effect or a Lockout condition are
permitted; failures which cause an unsafe condition
(a failure to danger) are not. Banner safety products
are extensively FMEA tested.
G
Guarded Machine
The machine whose point of operation is guarded by
the safety system.
H
Hard (Fixed) Guard
Screens, bars, or other mechanical barriers affixed to
the frame of the machine intended to prevent entry
by personnel into the hazardous area(s) of a machine,
while allowing the point of operation to be viewed.
The maximum size of the openings is determined by
the applicable standard, such as Table O-10 of
OSHA 29CFR1910.217, also called a "fixed barrier
guard."
Harm
Physical injury or damage to the health of people,
which may result through direct interaction with the
machine or through indirect means, as a result of
damage to property or to the environment.
Hazard Point
The closest reachable point of the hazardous area.
Hazardous Area
An area that poses an immediate or impending
physical hazard.
I
Internal Lockout
A Lockout condition that is due to an internal safety
system problem. Generally, indicated by the red
Status indicator LED (only) flashing. Requires the
attention of a Qualified Person.
K
Key Reset (Manual Reset)
A key-operated switch used to reset a safety light
screen system to RUN mode following a Lockout
condition. Also refers to the act of using the switch.
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L
Lockout Condition
A safety light screen condition that is automatically
attained in response to certain failure signals (an
internal lockout). When a Lockout condition occurs,
the safety light screen’s safety outputs turn Off; the
failure must be corrected and a manual reset is
required to return the system to Run mode.
M
Machine Primary Control Element (MPCE)
An electrically powered element, external to the
safety system, which directly controls the machine’s
normal operating motion in such a way that the
element is last (in time) to operate when machine
motion is either initiated or arrested.
Machine Response Time
The time between the activation of a machine
stopping device and the instant when the dangerous
parts of the machine reach a safe state by being
brought to rest.
Manual Start/Restart (Latch) Condition
The safety outputs of a safety light screen system
turn off when an object completely blocks a beam. In
a Manual Start/Restart condition, the safety outputs
stay off when the object is removed from the defined
area. To re-energize the outputs, perform a proper
manual reset.
Minimum Object Sensitivity (MOS)
The minimum-diameter object that a safety light
screen system can reliably detect. Objects of this
diameter or greater will be detected anywhere in the
defined area. A smaller object can pass undetected
through the light if it passes exactly midway between
two adjacent light beams. Also known as MODS
(Minimum Object Detection Size). See also Specified
Test Piece.
Muting
The automatic suspension of the safeguarding
function of a safety device during a non-hazardous
portion of the machine cycle.
O
Off State
The state in which the output circuit is interrupted
and does not permit the flow of current.
On State
The state in which the output circuit is complete and
permits the flow of current.
OSHA (Occupational Safety and Health Administration)
A U.S. Federal agency, Division of the U.S.
Department of Labor, that is responsible for the
regulation of workplace safety.
OSSD
Output Signal Switching Device. The safety outputs
that are used to initiate a stop signal.
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P
Part-Revolution Clutch
A type of clutch that may be engaged or disengaged
during the machine cycle. Part-revolution clutched
machines use a clutch/brake mechanism, which can
arrest machine motion at any point in the stroke or
cycle.
Pass-Through Hazard
A pass-through hazard is associated with
applications where personnel may pass through a
safeguard (which issues a stop command to remove
the hazard), and then continues into the guarded
area, such as in perimeter guarding. Subsequently,
their presence is no longer detected, and the related
danger becomes the unexpected start or restart of
the machine while personnel are within the guarded
area.
Point of Operation
The location of a machine where material or a
workpiece is positioned and a machine function is
performed upon it.
PSDI (Presence-Sensing Device Initiation)
An application in which a presence-sensing device is
used to actually start the cycle of a machine. In a
typical situation, an operator manually positions a
part in the machine for the operation. When the
operator moves out of the danger area, the presence
sensing device starts the machine (no start switch is
used). The machine cycle runs to completion, and
the operator can then insert a new part and start
another cycle. The presence sensing device
continually guards the machine. Single-break mode
is used when the part is automatically ejected after
the machine operation. Double-break mode is used
when the part is both inserted (to begin the
operation) and removed (after the operation) by the
operator. PSDI is commonly confused with "Trip
Initiate." PSDI is defined in OSHA CFR1910.217.
Banner safety light screen systems may not be used
as PSDI devices on mechanical power presses, per
OSHA regulation 29 CFR 1910.217.
Q
Qualified Person
A person who, by possession of a recognized degree
or certificate of professional training, or who, by
extensive knowledge, training and experience, has
successfully demonstrated the ability to solve
problems relating to the subject matter and work.
R
Receiver
The light-receiving component of a safety light
screen system, consisting of a row of synchronized
phototransistors. The receiver, together with the
emitter (placed opposite), creates a "screen of light"
called the defined area.
Reset
The use of a manually operated switch to restore the
safety outputs to the On state from a lockout
condition.
Resolution
See Minimum Object Sensitivity.
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S
Self-Checking (Circuitry)
A circuit with the capability to electronically verify
that all of its own critical circuit components, along
with their redundant backups, are operating properly.
Banner safety light screen systems and safety
modules are self-checking.
Safety Distance
The minimum distance required to allow the
machine’s hazardous motion to stop completely,
before a hand (or other object) can reach the nearest
hazard point. Measured from the midpoint of the
defined area to the nearest hazard point. Factors that
influence minimum separation distance include the
machine stop time, the light screen system response
time, and the light screen minimum object detection
size.
Specified Test Piece
An opaque object of sufficient size used to block a
light beam to test the operation of a safety light
screen system. When inserted into the defined area
and placed in front of a beam, the test piece causes
the outputs to de-energize.
Supplemental Guarding
Additional safeguarding device(s) or hard guarding,
used to prevent a person from reaching over, under,
through or around the primary safeguard or
otherwise accessing the guarded hazard.
T
Test Piece
An opaque object of sufficient size used to block a
light beam to test the operation of a safety light
screen system.
U
UL (Underwriters Laboratory)
A third-party organization that tests products for
compliance with appropriate standards, electrical
codes, and safety codes. Compliance is indicated by
the UL listing mark on the product.
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Index
M
muting device requirements 13 R
requirements
muting device 13