Columbus McKinnon MAGNETEK LaserGuard Mini User manual
Yale®YK/Shaw-Box®SK Crane Kit
LaserGuard Mini Technical Manual
Part Number: 192088726 Rev AA
July 2021
© Copyright 2021 Magnetek
LaserGuard Mini Technical Manual
July 2021
Page 3 of 36
SERVICE INFORMATION
For questions regarding service or technical information contact:
1.866.MAG.SERV
(1.866.624.7378)
International Service
Outside the U.S. and Canada call 1.262.783.3500, press 3.
Columbus McKinnon Corporation
205 Crosspoint Parkway
Getzville, NY 14068 USA
Toll-free: 800.888.0985
Telephone: 716.689.5400
E-mail: [email protected]m
Fax: 716.689.5644
Website
https://www.columbusmckinnon.com
© 2021 Columbus McKinnon Corporation
All rights reserved. This notice applies to all copyrighted materials included with this product, including, but
not limited to, this manual and software embodied within the product. This manual is intended for the sole
use of the person(s) to whom it was provided, and any unauthorized distribution of the manual or dispersal
of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means
whatsoever without the expressed written permission of the Columbus McKinnon Corporation.
LaserGuard Mini Technical Manual
July 2021
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PREFACE AND SAFETY
Product Safety Information
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products,
adjustable frequency drives, and industrial braking systems for material handling applications. This manual
has been prepared by Magnetek to provide information and recommendations for the installation, use,
operation, and service of Magnetek's material handling products and systems. Anyone who uses,
operates, maintains, services, installs, or owns Magnetek products should know, understand, and follow
the instructions and safety recommendations in this manual for Magnetek Products.
The recommendations in this manual do not take precedence over any of the following requirements
related to cranes, hoists, lifting devices, or other material handling equipment which use or include
Magnetek Products:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
Magnetek Products are used,
• Plant safety rules and procedures of the employers and the owners of the facilities where the
Magnetek Products are being used,
• Regulations issued by the Occupational Health and Safety Administration (OSHA),
• Applicable local, state or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the industries in which Magnetek Products are used.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners, users
and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the
responsibility of the employer to make its employees aware of all of the above listed requirements and to
make certain that all operators are properly trained. No one should use Magnetek Products prior to
becoming familiar with and being trained in these requirements and the instructions and safety
recommendations for this manual.
LaserGuard Mini Technical Manual
July 2021
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Product Warranty Information
Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a
drive by untrained personnel. A drive should only be programmed by a trained technician who has read
and understands the contents of this manual. Improper programming of a drive can lead to unexpected,
undesirable, or unsafe operation or performance of the drive. This may result in damage to equipment or
personal injury. Company shall not be liable for economic loss, property damage, or other consequential
damages or physical injury sustained by the purchaser or by any third party as a result of such
programming. Company neither assumes nor authorizes any other person to assume for Company any
other liability in connection with the sale or use of this product.
WARRANTY INFORMATION
FOR INFORMATION ON MAGNETEK'S PRODUCT WARRANTIES BY PRODUCT TYPE, PLEASE
VISIT WWW.MAGNETEK.COM.
WARNING
Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or
performance of the drive.
LaserGuard Mini Technical Manual
July 2021
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DANGER, WARNING, CAUTION and NOTE Statements
Read and understand this manual before installing, operating, or servicing this product.
The following conventions indicate safety messages in this manual. Failure to heed these messages could
cause fatal injury or damage products and related equipment and systems.
DANGERS, WARNINGS and CAUTIONS
Throughout this document DANGER, WARNING and CAUTION statements have been deliberately placed
to highlight items critical to the protection of personnel and equipment.
NOTE: A NOTE statement is used to notify people of installation, operation, programming or maintenance
information that is important, but not hazard-related.
DANGERS, WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.
Registered Trademarks
Trademarks are the property of their respective owners.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the most extreme situations.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury. It may also be used to alert against unsafe practices.
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July 2021
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Collision Avoidance Unit Warnings
WARNING
Never disable the range detector electrically or mechanically to be ON or OFF for any crane motion. If
the unit is for any reason disengaged or turned off, notify the crane operating personnel immediately,
and take proper alternate precautions.
WARNING
Check the crane collision avoidance unit and limit switches, if any, at the beginning of each shift or
when a new operator takes control of the crane. When checking the collision avoidance unit and limit
switches, ensure that the hoist is centered over an area that is free of personnel and equipment.
WARNING
Never use the collision avoidance unit and limit switches as a regular stopping device. They are
intended to be protective devices.
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July 2021
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Table of Contents
1 LaserGuard Mini System Information ...................................................................................................9
1.1 Collision Avoidance Model Numbers............................................................................................9
1.2 Class 1 Laser Sensor ...................................................................................................................9
1.3 System Description ....................................................................................................................10
1.4 System Specifications ................................................................................................................11
1.5 Laser Support Unit Assemblies ..................................................................................................12
2 Electrical Installation ...........................................................................................................................14
2.1 Voltage Considerations ..............................................................................................................14
2.2 Wiring Considerations ................................................................................................................14
2.3 Wiring Instructions......................................................................................................................14
2.4 Laser Cable and Relay Wiring....................................................................................................15
2.5 Wiring .........................................................................................................................................16
2.5.1 Crane to Crane Wiring When Integrated to Crane Controls at Factory .................................16
2.5.2 Crane to Crane Wiring Example, Field Integration and Wiring Will Be Necessary ................17
2.5.3 Trolley to Trolley Wiring When Integrated to Crane Controls at the Factory .........................18
3 Mechanical Installation .......................................................................................................................19
3.1 Mounting Location Considerations .............................................................................................19
3.2 Laser Dimensions.......................................................................................................................19
3.3 Mechanical Installation and Alignment ....................................................................................... 20
3.3.1 Crane to Crane Collision Avoidance ......................................................................................20
3.3.2 Trolley to Trolley Collision Avoidance ....................................................................................25
3.4 Electrical Conduit Installation .....................................................................................................33
4 Functional Installation ......................................................................................................................... 34
4.1 Laser Distance Set-Point Adjustment.........................................................................................34
4.2 Troubleshooting..........................................................................................................................35
LaserGuard Mini Technical Manual
July 2021
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1 LaserGuard Mini System Information
1.1 Collision Avoidance Model Numbers
1.2 Class 1 Laser Sensor
Magnetek's LaserGuard Mini Collision Avoidance System contains a Class 1 laser with a 660 nm
wavelength. Although the laser is safe for eyes, do not look directly into the laser. Do not open the laser
sensor enclosure. There are no serviceable parts inside.
LaserGuard Mini: Crane to Crane or Crane to Wall Catalog Numbers
LaserGuard Mini System integrated inside bridge controls Configured on demand
Reflector assembly CRANE REFLECTOR
Laser cable assembly LGM-CRANE LASER
LaserGuard Mini System standalone (for use on existing cranes) LGM-CRANE LSU
LaserGuard Mini: Trolley to Trolley Catalog Numbers
LaserGuard Mini System integrated inside hoist controls Configured on demand
Reflector assembly for monorail hoist frames A - C REFLECTOR M1
Reflector assembly for monorail hoist frames D - E REFLECTOR M2
Laser cable assembly for monorail hoist frames A - C LGM-M1 LASER
Laser cable assembly for monorail hoist frames D - E LGM-M2 LASER
Reflector assembly for top running hoist frames A - D REFLECTOR TR1
Reflector assembly for top running hoist frames E REFLECTOR TR2
Laser cable assembly for top running hoist frames A - D LGM-TR1 LASER
Laser cable assembly for top running hoist frames E LGM-TR2 LASER
LaserGuard Mini Technical Manual
July 2021
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1.3 System Description
Magnetek's LaserGuard Mini Collision Avoidance System measures the distance between the laser
sensor's lens and its companion retro-reflective target by means of pulse-ranging technology. This allows
for very accurate measurements and energy efficiency. The laser used in the LaserGuard Mini system
measures distances from 8 in. to 164 ft (0.2-50 m). The laser has a visible red light beam, which makes
system alignment very easy. Two LEDs (balloon 1 and balloon 2) on the front and top of the laser indicate
power and alignment. A steady green light indicates power to the laser. In the event of a laser short circuit,
the green LED will flash at 4Hz. A yellow light indicates the target is acquired and reading a signal.
Figure 1-1: Laser Optical Unit
The system includes an adjustable mounting bracket and a reflective target. The reflective target is
mounted on the wall or other crane that is going to be protected by the collision avoidance system.
The two laser distance set points are adjustable to trip the relays from approximately 8 in. to 164 ft
(0.2-50 m). The first distance set point (typically a Slowdown point) signals for the crane to start
decelerating. The second distance set point (typically a Stop point) will signal the crane to apply its brakes.
The relationship between these points are as follows:
164 ft (50 m) Slowdown > Stop 8 in. (0.2 m)
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July 2021
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1.4 System Specifications
Specification Laser Sensor
LaserGuard Mini Models
LGM-OPEN-x-x LGM-4X
Operating Ambient
Temperature
-20° to 122°F
(-30° to 50°C)
-4° to 141°F
(-20° to 60°C)
-4° to 122°F
(-20° to 50°C)
Detection Range 8 in.-164 ft
(0.2-50 m) -
Input Voltage - 85-264VAC or 120-370VDC
Accuracy 1 in.
(25.4 mm) -
Hysteresis Approx. 12 in.
(0.3 m) -
Control Outputs - Two form C relays rated at 6A, 270VAC and 24VDC
Laser Class 1 -
Laser Wavelength 660 nm -
Ambient Light Limit 50000 Lux -
Enclosure (Standard) Plastic IP65 Open Chassis Fiberglass NEMA 4X
Dimensions
H x W x D
3.5 x 1.0 x 2.2 in.
(88 x 26 x 55 mm)
8.75 x 6.75 x 4.25 in.
(222 x 171 x 108 mm)
10.5 x 8.5 x 6.25 in.
(267 x 216 x 159 mm)
Weight 0.2 lb
(0.09 kg)
2.0 lb
(0.91 kg)
5.6 lb
(2.54 kg)
Reflector Dimensions - 2 x 2 ft
(0.61 x 0.61 m)
Laser Cable Length - 32.8 ft (10 m), 82 ft (25 m), 131.2 ft (40 m), or 246 ft (75 m)
LaserGuard Mini Technical Manual
July 2021
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2 Electrical Installation
2.1 Voltage Considerations
Check the specification table or system drawings for proper line input voltage and supported relay
voltages. If there are any questions, contact Magnetek before applying power to the system.
NOTE: The collision avoidance system should not be connected to lines containing excessive
power-up transients or continuous commutator noise. A line conditioner may be necessary in
some installations.
2.2 Wiring Considerations
1. Do not connect or disconnect wiring or perform circuit checks while the power is turned on.
2. Keep power supply wiring in a metal conduit and separate from any motor wiring.
3. Keep control wiring in separate conduit and as short as possible.
4. Observe National Electric Code (NEC) when wiring electrical devices.
5. When cutting holes in the cabinet, take care to prevent metal filings from shorting the circuitry. Remove
any metal screws, metal filings, and wire clippings from inside of the unit.
6. Inspect to make sure no exposed wire has contact with any other wiring or terminals.
7. If possible, use suppressors on all contactors.
2.3 Wiring Instructions
1. Connect power to the power supply (85-264 VAC or 120-370 VDC) terminals “+” and “-.”
2. Wire both relays according to Figure 2-1 and Figure 2-2 on page 15. The acceptable wire size is
24 to 14 AWG.
Please observe National Electrical Code (NEC) guidelines when wiring electrical devices.
3. Connect a ground wire to the dedicated ground terminal block.
4. Turn on the power and verify that the green LED on the laser sensor is on continuously after a few
seconds. If that does not occur, turn the power off and recheck all wiring.
WARNING
The unit must be wired to the correct voltage. Failure to do so may damage the system.
LaserGuard Mini Technical Manual
July 2021
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2.4 Laser Cable and Relay Wiring
Figure 2-1: Laser Cable Wiring Diagram
Figure 2-2: Relay Wiring Diagram
Pin No. Wire Color Connection Point on Laser Support Unit
1 Brown “+” Terminal of Power Supply
2 White “A1+” Terminal of Relay 2
3 Blue “-” Terminal of Power Supply
4 Black “A1+” Terminal of Relay 1
LaserGuard Mini Technical Manual
July 2021
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2.5 Wiring
The LaserGuard Mini is integrated inside the crane controls when ordered from the factory. In the case
where an existing crane requires a collision avoidance system, field integration and wiring will be
necessary. See Section 2.5.2 on page 17.
2.5.1 Crane to Crane Wiring When Integrated to Crane Controls at
Factory
Figure 2-3: Crane to Crane; Bridge Control Wiring from Factory
LaserGuard Mini Technical Manual
July 2021
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3 Mechanical Installation
3.1 Mounting Location Considerations
Ensure the mounting location is as far as possible from exposed trolley wires and sources of
electromagnetic or radiated noise.
If possible, avoid installation on a surface where high vibration or shock exists. If avoiding high vibration or
shock is not possible, use appropriate shock mounts.
3.2 Laser Dimensions
Figure 3-1: Laser Sensor (P/N: LGM-HEAD) Dimensions (mm)
CAUTION
The LaserGuard Mini Systems are not rated as explosion-proof. Never install the unit in explosive
environments unless taking appropriate secondary enclosure measures.
LaserGuard Mini Technical Manual
July 2021
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3.3 Mechanical Installation and Alignment
The LaserGuard Mini Collision Avoidance System measures the distance between the laser sensor’s lens
and the reflective target surface.
Make sure the laser is mounted so that no obstructions can come between the laser sensor and the
reflective target.
Determine the mounting position for the laser and the reflective target so that the visual laser point is
centered on the reflective target. Align the laser beam and reflector as perpendicular as possible. This
alignment is the most important part of a successful installation since the laser beam must stay on the
target for the entire range of 8 in.-164 ft (0.2-50 m).
Refer to the figures in this section for mounting information.
3.3.1 Crane to Crane Collision Avoidance
Use the factory-supplied brackets on the festoon side of the crane or on the non-festoon side, depending
on your needs. See Figure 3-2 on page 20 and Figure 3-3 on page 21 for mounting arrangements.
Figure 3-2: Reflector Mounting Festoon Side
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