Banner S4B User manual

S4B Safety Light Curtain
Instruction Manual
Original Instructions
230287 Rev. A
15 February 2023
©Banner Engineering Corp. All rights reserved
230287

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 .......................................................................................................................................... 5
2.1 Applicable U.S. Standards ............................................................................................................................................................... 5
2.2 OSHA Regulations ...........................................................................................................................................................................5
2.3 International/European Standards ................................................................................................................................................... 5
3 Introduction ...................................................................................................................................................................7
3.1 Features ..........................................................................................................................................................................................7
3.2 System Description ......................................................................................................................................................................... 7
3.2.1 Components ............................................................................................................................................................................ 8
3.2.2 Models ..................................................................................................................................................................................... 8
3.3 Appropriate Applications and Limitations ........................................................................................................................................9
3.3.1 Appropriate Applications ..........................................................................................................................................................9
3.3.2 Examples: Inappropriate Applications .................................................................................................................................... 10
3.4 Control Reliability: Redundancy and Self-Checking ......................................................................................................................10
3.5 Operating Features ....................................................................................................................................................................... 10
3.5.1 Trip Output .............................................................................................................................................................................11
3.5.2 Scan Code Configuration ...................................................................................................................................................... 11
3.5.3 Weak Beam Strength Indication ............................................................................................................................................. 12
4 Specifications ............................................................................................................................................................. 13
4.1 General Specifications .................................................................................................................................................................. 13
4.2 Emitter Specifications ....................................................................................................................................................................13
4.3 Receiver Specifications .................................................................................................................................................................14
5 Mechanical Installation ............................................................................................................................................... 15
5.1 Mechanical Installation Considerations .........................................................................................................................................15
5.2 Calculating the Safety Distance (Minimum Distance) .................................................................................................................... 15
5.2.1 Formula and Examples ..........................................................................................................................................................16
5.2.2 Examples ...............................................................................................................................................................................17
5.3 Reducing or Eliminating Pass-Through Hazards .......................................................................................................................... 18
5.4 Supplemental Safeguarding ..........................................................................................................................................................18
5.5 Reset Switch Location ....................................................................................................................................................................19
5.6 Other Considerations .................................................................................................................................................................... 20
5.6.1 Adjacent Reflective Surfaces .................................................................................................................................................20
5.6.2 Use of Corner Mirrors ............................................................................................................................................................ 21
5.6.3 Emitter and Receiver Orientation .......................................................................................................................................... 22
5.6.4 Installation of Multiple Systems ............................................................................................................................................. 23
5.7 Mounting System Components ......................................................................................................................................................24
5.7.1 Mounting Hardware ............................................................................................................................................................... 24
5.7.2 Sensor Mounting and Mechanical Alignment Verification ...................................................................................................... 26
5.7.3 Mounting Dimensions and Defined Area ............................................................................................................................... 27
6 Electrical Installation and Testing .............................................................................................................................28
6.1 Routing Cordsets .......................................................................................................................................................................... 28
6.2 Scan Code Selection .....................................................................................................................................................................28
6.3 Initial Electrical Connections ......................................................................................................................................................... 30
6.4 Initial Checkout Procedure .............................................................................................................................................................30
6.4.1 Configuring the System for Initial Checkout .......................................................................................................................... 30
6.4.2 Apply Initial Power to the S4B System .................................................................................................................................. 30
6.4.3 Optically Align the System Components ............................................................................................................................... 31
6.4.4 Optical Alignment Procedure with Mirrors ............................................................................................................................. 32
6.4.5 Conduct a Trip Test ............................................................................................................................................................... 32
6.5 Electrical Connections to the Guarded Machine ...........................................................................................................................34
6.5.1 Protective Stop (Safety Stop) Circuits ................................................................................................................................... 34
6.5.2 Preparing for System Operation ............................................................................................................................................ 35
6.5.3 Sensor Interchangeability ....................................................................................................................................................... 36
6.5.4 Commissioning Checkout ......................................................................................................................................................36
6.6 Wiring Diagrams .............................................................................................................................................................................38
6.6.1 Generic Emitter Wiring Diagram ............................................................................................................................................38
6.6.2 Generic Receiver Wiring Diagram—Self-checking Safety Module, Safety Controller, Safety PLC .......................................39
7 System Operation ....................................................................................................................................................... 40
7.1 Security Protocol ...........................................................................................................................................................................40
7.2 Normal Operation ..........................................................................................................................................................................40
S4B Safety Light Curtain

7.2.1 System Power-Up ..................................................................................................................................................................40
7.2.2 Run Mode ............................................................................................................................................................................... 40
7.2.3 Emitter Indicators ...................................................................................................................................................................40
7.2.4 Receiver Indicators ................................................................................................................................................................41
7.3 Periodic Checkout Requirements ..................................................................................................................................................41
8 Troubleshooting ......................................................................................................................................................... 42
8.1 Lockout Conditions ........................................................................................................................................................................42
8.2 Receiver Error Codes ....................................................................................................................................................................42
8.3 Electrical and Optical Noise .......................................................................................................................................................... 42
8.3.1 Checking for Sources of Electrical Noise .............................................................................................................................. 42
8.3.2 Check for Sources of Optical Noise .......................................................................................................................................43
9 Checkout Procedures ..................................................................................................................................................44
9.1 Schedule of Checkouts ................................................................................................................................................................. 44
10 Product Support and Maintenance ......................................................................................................................... 45
10.1 Cleaning ......................................................................................................................................................................................45
10.2 Warranty Service .........................................................................................................................................................................45
10.3 Manufacturing Date .....................................................................................................................................................................45
10.4 Disposal ....................................................................................................................................................................................... 45
10.5 Banner Engineering Corp Limited Warranty ............................................................................................................................... 45
10.6 Contact Us ................................................................................................................................................................................... 46
11 Accessories ................................................................................................................................................................47
11.1 Safety Controllers .........................................................................................................................................................................47
11.2 In-Line Sensor Status Indicator ...................................................................................................................................................47
11.3 Literature .....................................................................................................................................................................................47
11.4 Brackets ...................................................................................................................................................................................... 47
11.5 Cordsets ......................................................................................................................................................................................48
11.6 Test Piece ................................................................................................................................................................................... 49
11.7 Universal (Input) Safety Modules ................................................................................................................................................49
11.8 Alignment Aids ............................................................................................................................................................................ 50
11.9 MSM Series Corner Mirrors ........................................................................................................................................................ 50
11.10 SSM Series Corner Mirrors .......................................................................................................................................................51
11.11 MSA Series Stands ...................................................................................................................................................................52
12 Glossary .................................................................................................................................................................... 54
S4B Safety Light Curtain

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 to ensure proper understanding of the operation, installation, and maintenance.
Please direct any questions regarding the application or use of the device to Banner.
For more information regarding U.S. and international institutions that provide safeguarding application and safeguarding
device performance standards, see Standards and Regulations on page 5.
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 S4B Safety Light Curtain. 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 S4B Safety Light Curtain 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. For the complete DoC, please go to
www.bannerengineering.com.
Product Directive
S4B Safety Light Curtain Machinery Directive 2006/42/EC
Representative in EU: Spiros Lachandidis, Managing Director, Banner Engineering BV. Address: Park Lane, Culliganlaan 2F,
bus 3,1831 Diegem, Belgium.
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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
NFPA 79 Electrical Standard for Industrial Machinery
ANSI/PMMI B155.1 Package Machinery and Packaging-Related Converting Machinery — Safety Requirements
2.2 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
2.3 International/European Standards
EN ISO 12100 Safety of Machinery – General Principles for Design — Risk Assessment and Risk Reduction
ISO 13857 Safety of Machinery – Safety Distances to Prevent Hazard Zones Being Reached
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 13849-1:2015 Safety-Related Parts of Control Systems
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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
ISO 3691-4 Industrial Trucks—Safety Requirements and Verification, Part 4 Driverless Industrial trucks and their Systems
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3 Introduction
3.1 Features
• A two-piece optoelectronic safeguarding device
•Creates a screen of synchronized, modulated infrared sensing beams that
extend from end-to-end of the sensors (no "dead zone")
• Compact package for smaller production machines, robust for large power
presses
• 30 mm resolution
• Defined areas of 300 mm (12 in) to 1800 (71 in) mm, in increments of 150
mm (6 in)
• 0.1 m to 12 m range (4 in to 39 ft); the range decreases with the use of
corner mirrors and/or lens shields:
◦ Lens Shields—an approximately 10% reduction in range per
shield
◦ Glass-surface mirrors—an approximately 8% reduction in range
per mirror
• Zone and Status indicators for diagnostics
• FMEA tested to ensure control reliability
• Highly immune to EMI, RFI, ambient light, weld flash, and strobe light
• Safety PLC input compatible (per OSSD specifications)
3.2 System Description
Banner S4B emitters and receivers provide a redundant, microprocessor-controlled, opposed-mode optoelectronic safety
light screen. S4B typically is used for point-of-operation safeguarding, and is suited to safeguard a variety of machinery.
The S4B emitters have a row of synchronized modulated infrared (invisible) light-emitting diodes (LEDs) in a compact
housing. Receivers have a corresponding row of synchronized photodetectors. The light screen created by the emitter and
receiver is called the defined area; its width and height are determined by the length of the sensor pair and the distance
between them. The defined area (sensing area) is equivalent to the height of the sensors. The maximum sensing range is 12
m (39 ft), which decreases if corner mirrors or lens shields are used. The sensing area extends from end to end of the
housing; there is no dead zone.
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 typically
connected to an external monitoring device such as a Banner XS26-2 Safety Controller.
Electrical connections (power, ground, inputs, and outputs) are made via M12 quick-disconnect connections.
All models require a supply voltage of +24 V DC ±15%.
Both the emitter and the receiver feature LEDs to provide continuous indication of operating status and error conditions.
All models include the ability to select between two scan codes.
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3.2.1 Components
An S4B “System” refers to a compatible emitter and receiver (equal length and resolution), and cordset(s) for each. RD to
M12 cordsets, side mounting brackets, and specified test pieces are sold separately.
Figure 1. Main Components
1
2
4
5
3
1. Receiver
2. Emitter
3. Defined area
4. Specified test piece
5. Location of the status indicators
3.2.2 Models
Emitter Receiver Defined Area
(mm)
Response
Time, Tr (ms)
Recovery Time, OSSDs OFF to ON (ms)
Non-Sync Beam
Blocked All Beams Blocked
S4BE30-300-S S4BR30-300-S 300 7.5 29 typical 49 typical, 295 maximum
S4BE30-450-S S4BR30-450-S 450 8.5 35 typical 65 typical, 337 maximum
S4BE30-600-S S4BR30-600-S 600 10.0 41 typical 75 typical, 379 maximum
S4BE30-750-S S4BR30-750-S 750 11.5 48 typical 85 typical, 421 maximum
S4BE30-900-S S4BR30-900-S 900 12.5 54 typical 98 typical, 463 maximum
S4BE30-1050-S S4BR30-1050-S 1050 14.0 60 typical 112 typical, 506 maximum
S4BE30-1200-S S4BR30-1200-S 1200 15.0 65 typical 122 typical, 544 maximum
S4BE30-1350-S S4BR30-1350-S 1350 16.5 71 typical 128 typical, 582 maximum
S4BE30-1500-S S4BR30-1500-S 1500 17.5 78 typical 141 typical, 620 maximum
S4BE30-1650-S S4BR30-1650-S 1650 19.0 84 typical 150 typical, 658 maximum
S4BE30-1800-S S4BR30-1800-S 1800 20.0 90 typical 172 typical, 697 maximum
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3.3 Appropriate Applications and Limitations
WARNING:
•Read this Section Carefully Before Installing the System
•Failure to follow these instructions could result in serious injury or death.
•If all mounting, installation, interfacing, and checkout procedures are not followed properly, this
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 Persons, in accordance with this manual and applicable safety
regulations. A Qualified person is 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.
The Banner S4B is intended for point-of-operation machine guarding and other safeguarding applications. 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 ability of the S4B 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 S4B cannot provide the protection for which it
was designed.
WARNING:
•Install System Only on Appropriate Applications
•Failure to follow these instructions could result in serious injury or death.
• Use Banner's S4B only on machinery that can be stopped immediately after a stop signal is issued
at any point in the machine's stroke or cycle, such as part-revolution clutched machines. Under no
circumstances may the S4B be used on full-revolution clutched machinery or in unsuitable
applications.
• If there is any doubt about whether or not your machinery is compatible with the S4B, contact
Banner Engineering.
3.3.1 Appropriate Applications
S4B is typically used for, but is not limited to, the following applications:
•Small assembly equipment
• Automated production equipment
• Robotic work cells
• Molding and power presses
• Assembly and packaging machines
• Lean manufacturing systems
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Figure 2. Typical Application
3.3.2 Examples: Inappropriate Applications
Do not use the S4B 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, NFPA 79, ANSI B11.19,
ISO 12100, IEC 60204-1, IEC 61496-1, or other appropriate standard)
If the S4B is installed for use as a perimeter guard (where a pass-through hazard may exist, see Reducing or Eliminating
Pass-Through Hazards on page 18), the dangerous machine motion can be initiated by normal means only after the
safeguarded area is clear of individuals and the external safety monitoring device has been manually reset.
3.4 Control Reliability: Redundancy and Self-Checking
Redundancy requires that S4B 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 S4B is designed with redundant microprocessors.
Redundancy must be maintained whenever the S4B is in operation. Because a redundant system is no longer redundant
after a component has failed, S4B 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 S4B into a Lockout condition.
A recovery from this type of Lockout condition requires:
• Replacing the failed component (to restore redundancy), and
• Performing the appropriate reset procedure.
3.5 Operating Features
The sensing resolution is determined by the emitter and receiver model.
WARNING:
•Use of automatic (trip) or manual (latch) start/restart
•Failure to follow these instructions could result in a serious injury or death.
• Applying power to the Banner device, clearing the defined area, or resetting a latch condition must
not initiate dangerous machine motion. Design the machine control circuitry so that one or more
initiation devices must be engaged to start the machine (a conscious act), in addition to the
Banner device going into Run mode.
Emitter Wiring Options—An S4B emitter can be connected either to its own power supply or to the receiver cable, color-for-
color. The color-for-color wiring allows the emitter and receiver positions to be interchanged without rewiring.
Status Indicators—Status indicators on both the emitter and receiver are clearly visible on each sensor’s front panel.
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For more information, see System Operation on page 40.
Emitter:
Key Description
1 Status indicator (red/green)—shows whether power is applied or the device is in a
lockout condition.
1
2
2 Scan Code indicator (red/green/yellow)—shows the scan code setting (1 or 2) at
power-up
Receiver:
Key Description
1 Status indicator (red/green)—shows System status:
• Outputs are ON or OFF (green ON or red ON)
• The System is in Lockout condition (flashing red)
12
3
2 Zone indicators (red/green/yellow)—each shows the status of approximately 1/3 of the
total beams:
• Aligned and clear (green ON)
• Blocked and/or misaligned (red ON)
• All beams are clear, but one or more beams have weak beam strength
(yellow ON)
The Zone 1 indicator, at the bottom of this view, represents the 1/3 of the unit that is
toward the RD end of the unit. The Zone 2 indicator is in the middle and represents
the middle 1/3 of the unit. The Zone 3 indicator is at the top and represents the 1/3 of
the unit closest to the end cap.
3Zone 1 Indicator—indicates beam synchronization status
3.5.1 Trip Output
The System is configured for Trip Output which allows the System to enter Run mode automatically. Other measures must
be taken to prevent a pass-through hazard; see Reducing or Eliminating Pass-Through Hazards on page 18 and the
warning below for more information.
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 Trip Output also automatically resets after all beams are cleared.
WARNING:
•Use of automatic (trip) or manual (latch) start/restart
•Failure to follow these instructions could result in a serious injury or death.
• Applying power to the Banner device, clearing the defined area, or resetting a latch condition must
not initiate dangerous machine motion. Design the machine control circuitry so that one or more
initiation devices must be engaged to start the machine (a conscious act), in addition to the
Banner device going into Run mode.
3.5.2 Scan Code Configuration
Use the scan code to allow operation of multiple pairs of emitters and receivers in close proximity without the effects of
crosstalk.
The emitter and receiver may be configured to use one of two scan codes (1 or 2); a receiver recognizes light only from an
emitter with the same scan code. Set the scan code switches of the removable disconnect of each sensor (see Scan Code
Selection on page 28). Both the emitter and its corresponding receiver must have the same setting.
The default setting is Scan Code 1.
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3.5.3 Weak Beam Strength Indication
Weak beam strength is indicated when one or more channels are made, but the beam strength is marginal. This indication
can be used to aid alignment of the sensor and also to indicate when window cleaning might be needed.
The Zone indicator representing the area of the channel(s) with the weak beam strength immediately turns yellow when the
marginal signal is detected.
The Weak Beam Strength Output, receiver pin 5, turns ON any time one or more channels are detected with a marginal
signal for longer than 1 minute. After the signal rises above the marginal level, the Weak Beam Strength Output turns OFF.
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4 Specifications
4.1 General Specifications
Short Circuit Protection
All inputs and outputs are protected from short circuits to +24 V DC or
DC common
Electrical Safety Class
III (per IEC 61140)
Safety Ratings
Type 4 per IEC 61496-1, -2
Category 4 PL e per EN ISO 13849-1:2015
SIL3 per IEC 61508
PFHd: 1.56 × 10-8
MTTFd: 71 years
Effective Aperture Angle (EAA)
Meets Type 4 requirements per IEC 61496-2
Operating Conditions
–20 °C to +55 °C (–4 °F to +131°F)
95% maximum relative humidity (non-condensing)
Storage Temperature
–30 °C to +65 °C (–22 °F to +149 °F)
Environmental Rating
For indoor use only
IP65 (EN 60529)
Resolution
30 mm
Operating Range
0.1 m to 12 m (4 in to 39 ft)
Enclosure
Anodized aluminum housing with well-sealed zinc die-cast end-caps,
polycarbonate window
Mounting Hardware
Mounting brackets are made from glass-filled polycarbonate
Vibration and Mechanical Shock
Components have passed vibration and shock tests according to IEC
61496-1 (Class 3M4). This includes vibration (30 cycles) of 5 Hz to 150
Hz at 3.5 mm (0.14 in) amplitude and 1 g acceleration, and shock of 15 g
for 6 milliseconds (600 cycles).
Certifications
4.2 Emitter Specifications
Supply Voltage at the Device
+24 V DC ±15% (use a SELV-rated power supply according to EN IEC
60950)
Power supply must meet the requirements of IEC 60204-1 and IEC
61496-1.
Status Indicators
One bi-color (red/green) Status Indicator: indicates operating mode,
lockout or power Off condition
Two tri-color (red/green/yellow) Scan Code Indicators: shows scan code
setting (1 or 2) at power-up
Supply Current
26 mA typical
40 mA maximum 1
Residual Ripple
± 10% maximum
Wavelength of Emitter Elements
Infrared LEDs, 860 nm at peak emission
Controls and Adjustments
Scan Code Selection: 2 dual-position switches, located in the removable
cordset assembly, to select between scan codes (code 1 or 2)
Factory default position is code 1
1Maximum current occurs at a supply voltage of 20 V DC.
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4.3 Receiver Specifications
Supply Voltage at the Device
+24 V DC ±15% (use a SELV-rated power supply according to EN IEC
60950)
Power supply must meet the requirements of IEC 60204-1 and IEC
61496-1.
Status Indicators
Bi-color (red/green) Status indicator: indicates general system and
output status
Tri-color (red/green/yellow) Zone Status indicators: indicate condition
(clear, weak, or blocked beam) of a defined group of beams and also
shows the scan code at start up
Output Signal Switching Devices (OSSDs)
Two redundant solid-state 24 V DC, 0.5 A maximum sourcing OSSD
(Output Signal Switching Device) safety outputs (use optional interface
solutions for AC or larger DC loads)
ON-State voltage: > Vin - 1.5 V DC
OFF-State voltage: 0 V DC typical, 1 V DC maximum (no load)
OFF-State, maximum allowed external voltage: 1.5 V DC 2
Maximum load capacitance: 1.0 µF
Maximum cable resistance to load: 5 ohms per wire
Maximum leakage current: 50 µA (with open 0 V)
OSSD test pulse width: 200 µs typical
OSSD test pulse period: 200 ms typical
Switching current: 0 A minimum; 0.5 A maximum (per OSSD)
Weak Beam Strength Output
Current-sourcing (PNP) solid-state output, 100 mA at 24 V DC
Supply Current (no load)
58 mA typical
82 mA maximum 3
Exclusive of OSSD1 and OSSD2 loads (up to additional 0.5 A each)
Residual Ripple
±10% maximum
Response Time
See Models on page 8
Recovery Time
Blocked to Clear (OSSDs Off to On; varies with total number of sensing
beams and whether Sync beam is blocked).
See Models on page 8
Controls and Adjustments
Scan Code Selection: 2 dual position switches, located in removable
cordset assembly, to select between scan codes (code 1 or 2). Factory
default position is code 1.
2The maximum voltage allowed on the OSSDs in the OFF-state without a lockout occurring. This voltage may occur, for example, from the input structure of a safety relay module
connected to the S4B OSSDs.
3Maximum current occurs at a supply voltage of 20 V DC.
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5 Mechanical Installation
The S4B 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
•Failure to follow these instructions could result in serious injury or death.
•If all mounting, installation, interfacing, and checkout procedures are not followed properly, this
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 Persons, in accordance with this manual and applicable safety
regulations. A Qualified person is 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.
5.1 Mechanical Installation Considerations
The two primary factors that influence the layout of the S4B system mechanical installation are:
•Safety Distance (Minimum Distance) (see Calculating the Safety Distance (Minimum Distance) on page 15)
• Supplemental safeguarding/eliminating pass-through hazards (see Reducing or Eliminating Pass-Through Hazards
on page 18)
Other considerations include:
• Emitter and Receiver Orientation (see Emitter and Receiver Orientation on page 22)
• Adjacent Reflective Surfaces (see Adjacent Reflective Surfaces on page 20)
• Use of Corner Mirrors (see Use of Corner Mirrors on page 21)
• Installation of Multiple Systems (see Installation of Multiple Systems on page 23)
WARNING:
•Position the System Components Carefully
•Failure to observe this warning could result in serious injury or death.
• Position the system components such that the hazard cannot be accessed by reaching over,
under, around, or through the sensing field. Additional and supplemental guarding may be
required.
5.2 Calculating the Safety Distance (Minimum Distance)
Safety Distance (Ds), also called Minimum Distance (S), is the minimum distance required between the defined area 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 S4B 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:
•Calculate the Safety Distance (Minimum Distance)
•Failure to establish and maintain the safety distance (minimum distance) could result in serious
injury or death.
• Mount the components at a distance from the nearest hazard such that an individual cannot reach
the hazard before cessation of the hazardous motion or situation. Calculate this distance using the
supplied formulas, as described by ANSI B11.19 and ISO 13855. Mount the components more
than 100 mm (4 in) away from the hazard, regardless of the calculated value.
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Figure 3. Safety distance (minimum distance) and hard (fixed) guarding
Hard (fixed) Guarding
Reset Switch
Nearest Hazard Point
Robot
Turn-
Table
Hard (fixed)
Guarding
Safety Light Curtain/Screen
5.2.1 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 (in inches)
K
1600 mm per second (or 63 in per second), the OSHA
29CFR1910.217, and ANSI B11.19 recommended hand-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, XS26-2 Safety
Controllers) and measured at maximum machine velocity (see Note
3 below)
Tr
the maximum response time, in seconds, of the S4B emitter/
receiver pair (depending on model)
Dpf
the added distance due to the depth penetration factor as
prescribed in OSHA 29CFR1910.217, and ANSI B11.19 for U.S.
applications. See Depth Penetration Factor (Dpf) table below or
calculate using the formula (in mm): Dpf = 3.4 × (S – 7) where S is
the resolution of the light curtain (for S ≤ 63 mm).
S
the Minimum Distance, in mm, from danger zone to light screen
center line; minimum allowable distance is 100 mm ( 175 mm for
non-industrial applications), regardless of calculated value
K
hand-speed constant (see Note 2 below); 2000 mm/s (for Minimum
Distances < 500 mm) 1600 mm/s (for Minimum Distances > 500
mm)
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 = 8 × (d - 14)
where d is the resolution of the light curtain (for d ≤ 40 mm), or use
850 mm for C.
Table 1: Depth Penetration Factor (Dpf)
30 mm Systems
78 mm (3.1 in)
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Notes:
1. The OSHA-recommended hand 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 hand 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.
WARNING:
•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, which can
lead to serious injury or death.
• 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.
5.2.2 Examples
U.S. Applications, Model S4BR30-600-S
K= 63 inches per second (the hand speed constant set by OSHA)
Ts= 0.31 (0.250 second is specified by the machine manufacturer; plus 20% safety factor; plus 13 ms for XS26-2
Safety Controller response time)
Tr= 0.010 seconds (the specified response time of a S4BR30-600-S System)
Dpf = 3.1 inches (30 mm resolution)
Substitute the numbers into the formula as follows:
Ds = K × ( Ts + Tr ) + Dpf
Ds = 63 × (0.31 + 0.010) + 3.1 = 23.3 in
Mount the S4B emitter and receiver so that no part of the defined area will be closer than 23.3 inches to the closest
reachable hazard point on the guarded machine.
European Applications, Model S4BR30-600-S
K= 1600 mm per second
T= 0.32 (0.250 second specified by machine manufacturer; plus 20% safety factor; plus 13 ms XS26-2 Safety
Controller response time), plus 0.010 seconds (the specified response time of a S4BR30-600-S System)
C= 8 × (30 – 14) = 128 mm (30 mm resolution)
Substitute the numbers into the formula as follows:
S = (K × T ) + C
S = (1600 × 0.32) + 128 = 640 mm
Mount the S4B emitter and receiver so that no part of the defined area will be closer than 640 mm to the closest reachable
hazard point on the guarded machine.
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5.3 Reducing or Eliminating Pass-Through Hazards
A pass-through hazard is associated with applications where personnel may pass through a safeguard, such as the S4B
Safety Light Curtain (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.
In the use of light screens, 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 after the safeguarding device is tripped, the corresponding safety monitoring device
latches and requires 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
S4B Safety Light Curtain does not provide a configurable Manual Start/Restart (Latch Output) function. For these
applications, this function must be implemented in the external safety monitoring device.
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 System 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. Lockout/Tagout procedures per
ANSI Z244.1 may be required, or additional safeguarding, as described by ANSI B11.19 safety
requirements or other appropriate standards, must be used if a passthrough hazard can not be
eliminated or reduced to an acceptable level of risk.
5.4 Supplemental Safeguarding
As described in Calculating the Safety Distance (Minimum
Distance) on page 15, position the S4B such that an
individual cannot reach through the defined area and access
the hazard point before the machine has stopped.
Additionally, the hazard cannot be accessible by reaching
around, under, or over the defined area. 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
defined area of the S4B 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 defined area. Any
openings in the hard (fixed) guarding must comply with the
safe opening requirements of ANSI B11.19 or other
appropriate standard.
Figure 4. An example of supplemental safeguarding
Hard (fixed) Guarding
Reset Switch
Conveyor
Opening
Area
Guarding
Robot
Turn-
Table
Hard (fixed)
Guarding
Area
Guarding
Safety Light Curtain/Screen
This is an example of supplemental safeguarding inside a robotic work cell. The S4B, 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).
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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).
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 S4B 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.
5.5 Reset Switch Location
The S4B has a trip output (auto power-up and automatic reset) that turns the OSSD outputs ON when the defined area is
unobstructed (clear). Per application requirements, a latch response requiring a manual reset to a power-up condition or after
an interruption has cleared the defined area might be required. The latch function can be provided by interfacing the S4B
OSSD outputs to the machine's safety-related control system, a safety controller (such as SC10-2roe or XS/SC26-2), or
safety module (such as the UM-FA-9A/11A).
The system or device providing the latch/reset function must conform to the level of performance required by the risk
assessment. In applications requiring Control Reliability and/or ISO 13849-1:2015 Categories 3 or 4 and PL d or e, it is
recommended that a monitored manual reset (for example, open-closed-open action), such that a shorted or tied-down
button cannot cause a reset be used.
The reset switch must be mounted 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.
WARNING:
•Install reset switches properly
•Failure to properly install reset switches could result in serious injury or death.
• Install reset switches so that they are accessible only from outside, and in full view of, the
safeguarded space. Reset switches cannot be accessible from within the safeguarded space.
Protect reset switches against unauthorized or inadvertent operation (for example, through the use
of rings or guards). If there are any hazardous areas that are not visible from the reset switches,
provide additional safeguarding.
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.
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5.6 Other Considerations
5.6.1 Adjacent Reflective Surfaces
A reflective surface located adjacent to the defined area may deflect one or more beams around an object in the defined
area. In the worst case, an optical short circuit may occur, allowing an object to pass undetected through the defined area.
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).
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) (see Figure 5 on page 20),
being careful to maintain adequate Safety Distance (Minimum 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 (see
Figure 6 on page 20) resulting from the optical short circuit and use the corresponding depth penetration factor (Dpf
or C) in the Safety Distance (Minimum Distance) formula (see Calculating the Safety Distance (Minimum Distance) on
page 15); 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 Trip Test under Initial Checkout Procedure on page 30) to verify these changes have
eliminated the problem reflection(s). If the workpiece is especially reflective and comes close to the defined area,
perform the trip test with the workpiece in place
Figure 5. Adjacent Reflective Surfaces
d
d
d
Operating Range (R)
Emitter Receiver
Do not position reflective
surfaces within the shaded area
top view side view
Reflective Surface
Reflective Surface
Operating range 0.1 m to 3 m (4 in to 10 ft): d = 0.13 m (5 in)
Operating range > 3 m (>10 ft): d = 0.0437 × R (m or ft)
Figure 6. Determining Worst-Case Resolution With Larger Test Piece
Reflective Surface
If an optical short circuit exists due to a reflective adjacent surface, a test piece (represented by the dark gray circle) with the
specified system resolution will not cause a blocked condition. In this situation, during the Trip Test, the Zone indicators and
Status indicator will be green and the OSSDs will be on.
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