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Safety Lightcurtains

WITH CROSS MATRIX ARRAY TECHNOLOGY

2012
EDITION

MERLINO
Type4

RANGE
SIL3

Category Category4

Safetytec LLC. 143 Cady Street, Suite 317, Northville Michigan. 48167 248-4494311 www.safetytec.us

CONTENTS

2. CONTENTS 3. UNIQUE DESIGN FEATURES 4. SELECTION AND SIZES 14-38 5. SELECTION AND SIZES 76-114 6. LEGEND 7. INSTALLATION 8. INDICATORS AND SETTINGS FOR TX 9. INDICATORS AND SETTINGS FOR RX 10. ELECTRICAL CONNECTIONS 11. PHYSICAL DIMENTIONS 12. HOW TO ORDER 13. OTHER FEATURES 14. OTHER SAFETYTEC SERVICES 15. AFFILIATIONS

UNIQUE DESIGN FEATURES

NEW Cross Matrix Array Technology


Cross matrix is a unique patented technology, where each individual infrared transmitter within the TX column, transmits IR beams to each receiver er within the RX column. This creates a cross matrix array within the safety guarded area. This technology serves to create a better detection capability and completely eliminates any alignment problems seen in conventional lightcurtain types. This is because beca in conventional guards, the transmitter column must focus each transmitted beam using optical lenses, so that the beams accurately align with their corresponding receiver. If the beams are off align more than 2 , then the transmitted beams will see the he wrong receivers and the guard will trip to off. Cross matrix does not have this problem because each transmitted beam is meant to see all the receivers and so the problem off alignment is removed completely. Depending on the scan distance, Futura4 guards can be off alignment as much as 30 or more.

HJF

PLUG AND PLAY

The Merlino range, including the Futura4 Guard, is a fully contained design, incorporating all electronics within the Transmitter (TX) and receiver (RX) heads. Thus eliminating the need for any interface control boxes or modules. The guards are all supplied complete with w cables ready for termination to the machine. The cables are fitted with standard plug fit connectors.

SELECTION AND SIZES


FUTURA 14
560mm (22) 630mm (25) 705mm (27.8) 775mm (30.5) 125mm (5) 195mm (7.7) 270mm (10.6) 340mm (13) 415mm (16) 485mm (19) 14mm (0.55) Model H 5m up to 15m (49ft)

Protected cted Height (PH): Total Height (TH):

Object Detection Capability (ODC) All models Working Range: Model L PH up to 5m (16.4ft)

Scan range setting system: Response time: Protection degree: All models Temperature capability: All models Supply Voltage: All models Current consumption: OSSDs: Max Load: Enclosure housing: Protection:

manual or Automatic 18 78 ms IP65 0 - 50C 24Vdc 10% (12Vdc available on request) TX = 70mA RX = 50mA 2 Volt free switches 0.7A @ 40Vdc/ac 0.1 uF Yellow RAL 1021 Aluminum with cross section of 41mm (1.6) x 46mm (1.8) Polarity inversion. Short circuit outputs (F4). Current threshold (F4)

2 NPN open collectors. 0.7A @ 24Vdc (F4).

Additional functions standard: External device monitoring (EDM) (as required by type 4 EN13849), Start and restart interlock, interlo muting. Light beams: Modulated Infrared with wavelength = 950 nm

FUTURA
Protected Height (PH) in mm: Total Height (TH) in mm : 150 (6) 367 (14.4) 584 (23) 654 (26)

38
1018 (40) 1088 (43) 1235 (49) 1305 (51) 1452 (57) 1522 (60) 1669 (66) 1739 (68.5)

801 (31.5) 871 (34)

220 (8.7) 437 (17)

Object Detection Capability (ODC) All models Working Range: Model L PH up to 5m (16.4ft)

38mm (1.5) Model H 5m up to 15m (49ft)

Scan range setting system: Response time: Protection degree: All models Temperature e capability: All models Supply Voltage: All models Current consumption: OSSDs: Max Load: Enclosure housing: Protection:

manual or Automatic 10.5 63 ms IP65 0 - 50C 24Vdc 10% (12Vdc available on request) reques TX = 70mA RX = 50mA 2 Volt free switches 0.7A @ 40Vdc/ac 0.1 uF Yellow RAL 1021 Aluminum with cross section of 41mm (1.6) x 46mm (1.8) Polarity inversion. Short circuit outputs (F4). Current threshold (F4) (

2 NPN open collectors. 0.7A @ 24Vdc (F4).

Additional functions standard: External device monitoring (EDM) (as required by type 4 EN13849), Start and restart interlock, interlo muting. Light beams: Modulated Infrared with wavelength = 950 nm

SELECTION AND SIZES


FUTURA
Protected Height (PH): Total Height (TH): 295mm (11.6) 11.6) 365mm (14.3)

76
1163mm (45.8) 1233mm (48.5) 1597mm (63) ( 1667mm (65.6)

729mm (28.7) 799mm (31.5) 76mm (0.55)

Object ect Detection Capability (ODC) All models Working Range: Model L PH up to 5m (16.4ft)

Model H 5m up to 15m (49ft)

Scan range setting system: Response time: Protection degree: All models Temperature capability: All models Supply Voltage: All models Current consumption: OSSDs: Max Load: Enclosure housing: Protection:

manual or Automatic 10.5 33 ms IP65 0 - 50C 24Vdc 10% (12Vdc available on request) TX = 70mA RX = 50mA 2 Volt free switches 0.7A @ 40Vdc/ac 0.1 uF Yellow RAL 1021 Aluminum with cross section of 41mm (1.6) x 46mm (1.8) Polarity inversion. Short circuit outputs (F4). Current threshold (F4)

2 NPN open collectors. 0.7A @ 24Vdc (F4).

Additional functions standard: External device monitoring (EDM) (as required by type 4 EN13849), Start and restart interlo interlock, muting. Light beams: Modulated Infrared with wavelength = 950 nm

FUTURA
Protected Height (PH): Total Height (TH): 657mm (25.9) 727mm (28.6)

114
1525mm (60) 1595mm (63)

1091mm (43) 1161mm (45 (45.7) .7) 114mm (4.5)

Object Detection Capability (ODC) All models Working Range: Model L PH up to 5m (16.4ft)

Model H 5m up to 15m (49ft)

Scan range setting system: Response time: Protection degree: All models Temperature capability: All models Supply Voltage: All models Current consumption: OSSDs: Max Load: Enclosure housing: Protection:

manual or Automatic 13 23 ms IP65 0 - 50C 24Vdc 10% (12Vdc available on request) reques TX = 70mA RX = 50mA 2 Volt free switches 0.7A @ 40Vdc/ac 0.1 uF Yellow RAL 1021 Aluminum with cross section of 41mm (1.6) x 46mm (1.8) Polarity inversion. Short circuit outputs (F4). Current threshold ( (F4)

2 NPN open collectors. 0.7A .7A @ 24Vdc (F4).

Additional functions standard: External device monitoring (EDM) (as required by type 4 EN13849), Start and restart interlock, muting. Light beams: Modulated Infrared with wavelength = 950 nm

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Futura = Model of lightcurtain ESPE = Electro Sensitive Protection Device

LEGEND

OSSD = Output Signal Switching Device (Chanel 1 or Chanel 2) TX = Transmitter. Either transmitter column, or individual beams within the column. Futura range has IR beams at 950nm. RX = Receiver. Either receiver column or each receiver diode within the receiver column. EDM = External Device Monitoring. This is the s safety afety circuit that allows compliance to category 4 status as defined by ISO EN 13849. In Futura 4, this is achieved via a feedback loop system for cross checking of PCEs. 2-3 or 4 circuits, there will be 2. PCE = Primary control Element. For type 2

PH = Protected height. Distance between top beam and bottom beam. PD = Effective protected distance between transmitter (TX) and receiver (RX). ODC = Object Detection Capability. The size of the smallest object that will be detected within the beams. For Futura, this number is variable due to the cross matrix technology, but ranges from 0-14mm, 0 0-38mm, 0-76mm and 0-114mm 114mm WD = Working distance.

INSTALLATION

Plug and Play


The Merlino Futura range of Lightcurtains are designed to be so simple that they are virtually plug and play. Simply bolt to the machine with the TX facing towards the RX, plug in the cables to the guards, then apply power er supply, and terminate to the machine control. It couldnt be easier. Alignment is not a problem to consider, its automatic So long as the TX is generally in the direction of the RX, the guard alignment will be sufficient. However, there are still some considerations to incorporate during any selection, installation and commissioning of any new Merlino Futura Lightcurtain system.

Selection:

Ensure that the Lightcurtain selected is suited to the application. Give consideration to the scan height, the scan range and the line of sight making sure that there are no obstacles or reflective planes in line. Ensure that reaching to the hazard area is not possible when the lightcurtain is active. This may require addition additional guarding components. For advice, especially where safety requirements, regulations and standards are important, contact Safetytec or an approved agent for advice. Installation: The Futura range comes complete with plug in connectors for easy easy installation. The TX uses only 2 wires within the TX cable for 24Vdc connection. The RX also uses 24Vdc, but has an additional 7 wires within the cable for all other desired switching functions etc. Standard cables are 5m (16ft) or 10m (32ft) lengths. All guards are preset to the desired scan range for ease of installation, but are easily changed as needed using the range setting switches on the TX. (See page 8). Type 3 or 4: There are 2 types of lightcurtain available within the Futura range, to suit the different risk categories of machine risk. Type 4 Lightcurtains are suited to machinery with all risk categories including high risk applications. Such machines include robotic ic applications, power presses and other high risk machinery where safety integrity is crucial and legally required. Type 3 Lightcurtains are available for all other machines with a risk level of 1,2 or 3 categories. NOTE: For guidance on the legal requirements requir and technical aspects of application of guarding systems to machinery, contact Safetytec for advice.

INDICATORS AND SETTINGS FOR TX


LED Indicates Calibrated for MEDIUM Distance LED Indicates Calibrated for LONG Distance Pushbutton for decreasing scan range

LED Indicates Calibrated for SHORT Distance Pushbutton for increasing and decreasing scan range

Pushbutton for setting scan range

Inc = Increase. This button is used to increase the scan range of the lightcurtain. Continually pressing it causes the scan range to increase proportionately. SET = this button is used to set the desired scan range and lock it. Each time the guard is repowered up, this range will remain. DEC = decrease. This button is used to reduce the desired scan range. Just as with the INC button, continually pressing it will reduce the scan range accordingly. The LEDs on the top head are used to indicate the functionality conditions. TROUBLESHOOTING DEVICE STATUS No Power Possible Internal Fault

CASE MIN A MAX MIN B MAX MIN C MAX MIN D MAX MIN E MAX

LED STATUS TATUS OFF OFF OFF ON OFF OFF ON ON OFF ON ON OFF Slow Blinking

CHECK/SOLUTION Check Power Supply Check Connections Return to factory for service Check that this short setting is desired. Increase distance calibration if required Check that this medium setting is desired. Increase or decrease distance calibration if required Check that this maximum setting is desired. Decrease distance calibration if required Infrared beams have been inhibited while test circuit activated. Disconnect test circuit if not required.

Calibrated for minimum working distance

Calibrated for medium working distance

Calibrated for maximum working distance

TEST input activated.

INDICATIONS AND SETTINGS FOR RX


LED Indicates misalignment or obstacles are present

LED Indicates beams are aligned and there are no obstacles

LED Indicates lightcurtain has locked out due to a fault being detected Function selection control

MODE: Function selector. Removing the jumper located below the cover, switches the guard from automatic to manually controlled restart function. SRI: This LED indicates that the guard is in the manual restart configuration. With the jumper in, this LED remains off.

LED Indicates guard is in Mute state.

LED indicates Manual restart function selected

TROUBLESHOOTING CASE A
RUN ALT BLK MUTE RUN ALT BLK MUTE RUN ALT BLK MUTE RUN ALT BLK MUTE RUN ALT BLK MUTE RUN ALT BLK MUTE RUN ALT BLK MUTE RUN ALT BLK MUTE

LED STATUS
ON OFF OFF OFF OFF ON OFF OFF ON OFF OFF BLINKING OFF ON BLINKING BLINKING OFF ON BLINKING OFF OFF FAST SYMULTANIOUS BLINKING OFF OFF SLOW ALTERNATING BLINKING OFF OFF ON ON OFF

DEVICE STATUS
Optical alignment OK. No obstacles. No failures. No optical alignment or object detected. Possible internal fault. MUTING activated. Infrared detection temporarily suspended. Disparity between CH1 and CH2 on MUTING inputs, or object detected during MUTE activation.

CHECK/SOLUTION
No action. Guard is operating as expected.

Check for alignment. Ensure I.R. beams are clear of obstacles. Try reset. If not resolved, contact factory. Caution! Guard I.R. detection is disabled. Ensure application is safe and suitable to the application. Check Mute inputs are clear and operating. Check for obstacles. If unresolved, contact factory. Temporarily block and then clear beams to attempt a reset. If reset does not occur, contact factory. Check wiring and restart the guard.

Disparity between internal switching channels.

OSSD1 or OSSD2 connected to +24Vdc or OSSD1 short circuited with OSSD2. Load sink current connected to OSSD1 or OSSD2 higher than 0.7A, OR shorted to ground.

Check wiring and restart guard.

OSSD1 or OSSD2 connected to +24Vdc during power-on.

Check wiring and restart guard.

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Transmitter cable
5 PIN M12 STYLE FEMALE CONNECTOR

ELECTRICAL CONNECTIONS
TX (Transmitter) Futura 4
2. White: Reference voltage. (For testing only). 1. Brown: 24VDC 3.Blue: 0V 1)Brown = +24V 2)White = REF. 3)Blue = GND 4)Black = Test 5)Grey = Test
TEST INPUT. N.C. If this function is not to be used, then use a jumper to connect wires 4 and 5, then connect them to 0V on the PSU

Jumper

4. Black: 5. Grey:

POWER SUPPLY. 24VDC +/- 10%

If the function TEST is not used, then link conductors 4-5 and connect them both to ground.

5m standard cable length, with M12 5pin connector.

RX (Receiver) Futura 4
Mute 1 Mute 2

SCR=Over voltage discharger (suppressor). Recommended use.


24VDC

Pink 6 Grey 5

7. Blue

}8.Red
Shield

POWER SUPPLY. 24VDC +/+/ 10%

0V

Yellow 4
NC Switch K1 Link

1. White 2.Brown

OSSD1 OSSD2 Max current Max current 0.7A

Green 3
External Device Monitor

NC Switch K1

EDM circuit to be used to achieve higher safety categories. K1, K2 and other switches must be forced guided contacts.

0.7A

NC Switch Kn Start/restart Interlock Push-Button

5m standard cable length, with M12 8pin connector.

If the EDM circuit is not to be used, inset a link across the yellow and green connectors, and then connect both to 0V of the PSU.

D1 and D2: Diodes to suppress spikes generated in the inductive load. F1and F2: Quick blow Fuses

Receiver cable
8 PIN M12 STYLE FEMALE CONNECTOR

1)White = 2)Brown = 3)Green 4)Yellow 5)Grey = 6)Pink = 7)Blue = 8)Red = Shield =

OSSD1 OSSD2 EDM/ Start/Reset Mute 1 Mute 2 +24V Ground Ground

PHYSICAL DIMENTIONS Futura 4 TOP HEAD

11

Futura 4 BOTTOM HEAD

Futura 4 CROSS SECTION


Optional weld splatter filter Optional rubber shock mounts

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OTHER HOW TO FEATURES ORDER

FUTURA _ / _ _ _ / _ _ _ _ -PH PH _ _ _ _ / _ / _ _ _ _
Model type Safety Category 3 or 4 Detection capability in mm 14,38,76 or 114 Scan Height in mm L for scan range 0-5m 0 H for scan range 5-15m 5 If the actual scan range desired is known, enter range here in mm. Only for manual set guards. Guard will be preset for ease.

Auto if fully automatic scan range version is required. This item is an option.

All Futura Lightcurtains are preset to the desired scan range for ease of installation. However, the scan range can be changed at anytime by the user simply by use of the switches on the TX top head. (See page 8). In the event that a fully automatic version is required, the guard will automatically automatic self regulate the scan range each time it is powered on. This is a useful feature if the guard is to be used on one or more applications where the scan range is never certain, or where the lightcurtain is likely to encounter high degrees of dirt or dust dust build up, that can reduce the power of the beams. In such cases, the guard will constantly compensate for the reduction in beam strength by auto recalibrating itself during each power up. For Auto feature, simply show AUTO on the part number above. All All other guards although being adjustable, will be pre set to the desired scan range for ease of installation.

EXAMPLES: Futura3/76-PH729/H/7500 This lightcurtain is designed to protect a machine with a risk category of 3 or less according to ISO13849. It has a detection capability of 76mm (3 or Limb Detection) with an overall safety scan area of 729mm (28.7 from top beam to bottom beam). The scan sca range between TX and RX is set to 7500mm (24ft). This lightcurtain is designed to protect a machine with a high risk category of 4 according to ISO 13849. It has a detection capability of 14mm (1/2 or Finger detection) with the overall safety area ofn560mm (22 from top beam to bottom beam). The scan range ofn560mm between RX and TX is 900mm (3ft). This lightcurtain is designed to protect a machine with a high risk of category 4 or less in accordance with ISO 13849. It has a detection capability of 38mm (1.5 o or Hand detection) with an overall safety area of 801mm (31.5 from top beam to bottom beam). The scan range is automatically calibrated and set by the lightcurtain itself. Because it is an L model, it will auto set between approximately 500mm, and 5m (16.4ft) (16.4ft) between RX and TX.

Futura4/14-PH560/L/900

Futura4/38/AUTO-PH801/L

OTHER FEATURES AND ACCESSORIES ACCE


CROSS MATRIX ARRAY TECHNOLOGY

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Because of the cross matrix of the scanned beams, the Futura range is perfectly suited for use on close operation machinery such as power presses and indexing machines. Unlike standard Lightcurtains, the cross matrix array means objects as thin as paper will be reliably detected. TYPE 4. Futura Lightcurtains are certified to ISO/EN61496-1-2 ISO/EN61496 for use on high risk machinery such as power presses and automation machines. For such applications, guidance should be sought from Safetytec on the correct installation requirements such as safe working distances and wiring integration. MUTING All Futura guards are equipped as standard with built in mute facility. This allows for use on automated machinery such as conveyors and robot cells that require fully automated functionality including the lightcurtain integration. Muting allows the product produc or tool to pass through the beams without stopping the machine. Safety is maintained by additional signals that detect the tool or product, but does not allow for the passage of any other object or person. TYPICAL MUTE SUSTEM ON AN AUTOMATED CONVEYOR LINE CABLES All Futura guards are supplied with ith standard 5m cables with plug fit connectors. 10m lengths available on request. BLANKING

STANDARD FUTURA 4 GUARD ON PRESS BREAK APPLICATION

NEW

Newly available for 2012. Futura guards are now available with blanking facilities. Either floating blank or fixed blanking. This facility allows for multiple applications including bending machines, presses with fixed objects protruding through the guard, conveyors and forming machines. For details on applications, contact Safetytec for advice on selection and integration. Mirrors

Safetytec provides a series of reflective mirrors for use in multiple plane applications. For perimeter scanning applications, mirrors may be placed on each corner r in order to deflect the scanned beams along multiple planes. This allows for one lightguard to protect 1 or more sides of the machine or protected area. Floor mounting posts are available to suit each application.

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OTHER SAFETY SERVICES

CE MARKING Safetytec is a licensed body for the application and assistance of CE marking and accreditation of machinery and equipment for European conformity. Specializing in the requirements of all the major European directives and their applications. Safetytec also offers expert services relating to OSHA requirements and other international standards such as ANSI, ISO and IEC standards. Safetytec can assist with self certification OR third part accreditation requirements. Machine Guards Safetytec offers a full range of standard off the shelf machine guards for standard machine tools such as lathes, milling machines and drills. Safetytec also offers ers a full design and custom build facility to design and install guarding systems to suit unique applications. All Safetytec guards are manufactured and are designed to be installed in accordance with various safety standards such as ISO EN 953. Training Safetytec offers a varied range of accredited safety training courses. These se include EU certification courses, machinery safety awareness, practical hands on training courses in risk assessment, CE marking process, and workplace health and safety. Safetytec can provide tailored or modified courses to suit specific requirements s or to focus on specific aspects of legal issues, or technical issues.

Legal services As licensed health and safety practitioners, and as legal experts in machinery safety law, Safetytec offers many legal services in relation to the application of directives, standards and regulations, including domestic and international. Services include: o Direct assistance relating to real or potential violations or challenges of CE certification. o Accident investigations o Interaction and assistance with regards to relations with Insurance officials or government inspectors. o Preparation of corporate health and an safety policies or best practice technical manuals for the application of health and safety in the workplace or the application of safety requirements to machinery.

Affiliations

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I.I.M.S
Safetytec is registered with the International Institute of Risk and Safety Management Safetytec is a founding member of the International Institute of Machinery Safety Excellence Safetytec is registered by, and is licensed as a training provider for the National Examination Board for Occupational Safety and health Safetytec is licensed by the Construction Industry Training Board as safety Management Company licensed to provide training to construction workers.

Registered Distributors
Michigan

RMI Robotics, 6800 N. Silvery Lane,


Dearborn Heights, MI 48127 248-444-2078 www.rmirobotics.com

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Safetytec LLC. 143 Cady Street, Suite 317, Northville Michigan. 48167 248-4494311 www.safetytec.us

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