Contrinex YBB Series User manual

SAFETINEX
SAFETY LIGHT CURTAINS
SAFETY ACCESS CONTROL BARRIERS
TYPE 4
YBB, YCA SERIES
INSTRUCTION MANUAL

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EN – This manual is available to download from our website in many language versions, including
English:
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darunter Deutsch, zum Download bereit:
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incluindo o português:
https://www.contrinex.com/download – Section “Safety User Manuals”
ORIGINAL INSTRUCTIONS

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TABLE OF CONTENTS 1. INTRODUCTION ............................................................5
1.1. Contrinex..................................................................................................5
1.2. Safetinex safety systems .........................................................................5
1.3. Active optoelectronic protective devices (AOPD) ................................... 5
1.3.1. Safeguarding function ........................................................................6
1.3.2. Hazardous area ..................................................................................6
1.3.3. AOPD detection capability .................................................................6
1.4. Advantages of AOPDs.............................................................................7
1.5. Operating principle..................................................................................7
1.6. Certification of Safetinex products........................................................... 8
2. EUROPEAN SAFETY STANDARDS ..............................8
2.1. Types of safety standards applicable in the EU ...................................... 8
2.2. Examples of safety standards..................................................................9
2.3. An approach to European standards ...................................................... 9
2.4. The user side .........................................................................................10
2.5. Machine manufacturer side ...................................................................10
2.6. Notified bodies.......................................................................................11
3. NORTH AMERICAN SAFETY STANDARDS ..............11
3.1. A different approach .............................................................................. 11
3.2. OSHA Regulations and U.S. Consensus Standards .............................12
3.3. North American Standards for safety issues: UL, ANSI and CSA.........13
3.3.1. American standard agencies ........................................................... 13
3.3.2. Canadian standard agencies ...........................................................13
3.4. International standard agencies ............................................................14
4. RISK ASSESSMENT......................................................14
4.1. Definition of hazards and risk reduction strategy .................................. 14
4.2. Risk assessment process ...................................................................... 14
4.3. Methods for determination of risk level.................................................. 17
4.3.1. Determination of risk level in North America ....................................17
4.3.2. Determination of required performance level (PLr)..........................17
4.3.3. Specific standards for safety distance calculation...........................19
5. INSTALLATION ............................................................19
5.1. Installation rules ..................................................................................... 19
5.1.1. Positioning the AOPD .......................................................................19
5.1.2. Minimum safety distance required ...................................................20
5.1.3. Minimum safety distance calculation (EU) ....................................... 21
5.1.4. Minimum safety distance calculation (US & Canada)......................23
6. OTHER COUNTRIES ....................................................24
7. ACRONYMS..................................................................25
8. TECHNICAL DOCUMENTATION ...............................26
8.1. Safetinex YBB for finger protection........................................................26
8.2. Safetinex YBB for hand protection.........................................................26
8.3. Safetinex YCA for access control .......................................................... 26

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8.4. Advantages of the Safetinex range .......................................................27
8.5. Scope of this technical documentation ................................................. 27
8.6. Self protected outputs............................................................................27
8.7. Resolution (R) of an AOPD ....................................................................28
8.8. LED status indicators.............................................................................29
8.9. Configurable functions........................................................................... 29
8.9.1. Transmission channel selection (YBB and YCA).............................. 29
8.9.2. Test Mode selection (YBB) ...............................................................30
8.9.3. Operating range selection (YCA) ..................................................... 30
8.10. Installation..............................................................................................30
8.10.1. Minimum safety distance..................................................................30
8.10.2. Recommended beam heights for access control devices (YCA) .... 31
8.10.3. Positioning the sender and receiver units ........................................ 31
8.10.4. Distance from reflective surfaces ..................................................... 32
8.10.5. Installation of multiple systems.........................................................33
8.10.6. Mechanical installation .....................................................................34
8.11. Connecting the protective device..........................................................36
8.11.1. Power supply ....................................................................................36
8.11.2. Electromagnetic compatibility (EMC) ............................................... 36
8.11.3. Light radiation................................................................................... 36
8.11.4. Pin assignment ................................................................................. 37
8.12. Safetinex safety relay YRB-4EML-31S ...................................................38
8.12.1. Response time from protective field intrusion
to switching of safety relay ...............................................................38
8.12.2. Connection examples for YRB-4EML-31S safety relay ....................39
8.13. Alignment of sender and receiver units.................................................40
8.14. Test before the first commissioning .......................................................41
9. TESTING AND MAINTENANCE .................................42
9.1. Daily functional test................................................................................ 42
9.1.1. Finger and hand protection devices (YBB models) .........................42
9.1.2. Access control devices (YCA models)............................................. 43
9.2. Troubleshooting .....................................................................................44
9.3. Preventive periodic inspections.............................................................45
9.4. Cleaning.................................................................................................45
9.5. Daily testing log file................................................................................ 45
10. AVAILABLE MODELS ..................................................47
11. DISCLAIMER ................................................................51
12. EC DECLARATION OF CONFORMITY .......................53

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1. INTRODUCTION
1.1. CONTRINEX
Contrinex, a multinational company with headquarters in Switzerland,
is specialized in the development, production and worldwide sales of
position sensors, RFID and safety systems. Contrinex employs over
500 people, including 25 highly qualified R&D engineers, operates
production units in Switzerland, China, USA, Sri Lanka and Brazil, has
its own sales offices in all the major markets and is represented in over
60 countries. Contrinex applies stringent management and production
principles, which are reflected in its ISO 14001:2004 and ISO 9001:2008
certifications. Additionally, Contrinex is subject to regular client-based
audits. Identical quality controls and equipment as well as staff recruit-
ment and training policies are implemented at the different production
sites, thus guaranteeing consistent product quality.
1.2. SAFETINEX SAFETY SYSTEMS
The Safetinex product lines produced by Contrinex offer high quality
safeguarding solutions for both personnel and machinery. Our specialists
in sensor technology have developed high-performance electro-sensitive
protective equipment. Our range of safety products comprises highly
sensitive devices for finger and hand protection as well as access control,
featuring various lengths and connection options.
Safetinex products have been developed in compliance with the appli-
cable international safety standards and have obtained the required
product certification for use in the European Union, the United States
of America and all other countries where the applicable IEC standards
have been adopted.
1.3. ACTIVE OPTOELECTRONIC PROTECTIVE
DEVICES (AOPD)
When looking to build a safety system around a danger zone, the first
consideration is whether or not optical protection is suitable at all. For
this to be the case, it must be possible for the machine control to be
electrically influenced by means of the AOPD’s semiconductor output.
Moreover, it must also be possible to instantly terminate or exit the
hazardous process in every operating phase. Further, there must be no
danger of injury due to heat, radiation or from materials or components
ejected by the machine. If such danger exists, then either the optical
system is not suitable, or the danger must be otherwise excluded by
applying additional safety measures.
The selection of a specific type of safeguard involves an evaluation of
the hazard, in order to determine the applicable category or required
performance level PLr.

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The choice of an active optoelectronic protective device (AOPD), such
as a safety light curtain, depends on:
–The relevant safety standards to be applied
–The definition of the safeguarding function
–The available space around the hazardous area
–The safety distance, as calculated by the appropriate formula and
depending on the AOPD’s resolution and position, as well as the
response times of the light curtain or access control barrier, the safety
relay and the machine stopping time
–Ergonomic factors (e.g. how often access is necessary)
–Commercial criteria
1.3.1. SAFEGUARDING FUNCTION
The AOPD resolution must be chosen according to the application and
the required safeguarding function. It is defined as the minimum size of
an object that can be reliably and safely detected at any position in the
protective field. Basically, two approaches can be considered:
–Point of operation: detection of fingers or hands entering the defined
hazardous area. The protective equipment immediately stops the
machine or renders it harmless. The Safetinex YBB range is best
suited for this type of application.
– Perimeter or entry-exit: once the entry of a person has been detected,
the hazardous motion of the machine is stopped. The control device
enabling the operator to restart the machine must be located outside
the hazardous area. From there, the operator must have a full view
of the hazardous area to verify that nobody is in it before restarting
the machine. The Safetinex YCA range is best suited for this type
of application.
In both cases, the primary function of the protective device is to stop the
machine before the hazardous point is reached and to prevent uninten-
tional machine start-up or restart. This function must comply with the
category or performance level of the safety-related components of the
machine’s control system.
1.3.2. HAZARDOUS AREA
The hazardous area can be defined in terms of:
–The dimensions of the zone that requires protection
–The different access points to accessible hazards
–The risk of an undetected presence in the hazardous zone, or risk of
bypassing the protective device
1.3.3. AOPD DETECTION CAPABILITY
The light curtain or barrier detection capability (or resolution) depends
on the distance between the centerlines of each beam emitted by the
sender. The choice for a specific resolution depends on the part of the
body which needs protection (finger, hand, whole body).

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1.4. ADVANTAGES OF AOPDS
Safeguarding devices are used where risks cannot be eliminated by
machine design. Rather than preventing access to a hazardous area,
safety light curtains or access control barriers detect the entry of a person
or part of a body and eliminate the hazard by triggering an immediate
stop of the hazardous machine motion. They present several advantages
over mechanical safeguarding devices:
– Access time to the machine is reduced, thereby increasing productivity
– Workplace ergonomics are greatly improved and less space is required
–The invisible infrared beams allow better visibility of the machine and
operating process
–Protection applies to any approaching person
1.5. OPERATING PRINCIPLE
A light curtain or access control barrier comprises two units, namely a beam
sender (or transmitter) and a receiver between which coded infrared beams
are sequentially exchanged. The protective field is the area enclosed by
these two components, the emitted light beams forming a permanent,
though invisible, shield between the two units. The receiver unit is connected
to a safety relay which transmits the signal to the machine control unit.
Synchronization between the sender and receiver devices is performed
optically, i.e. wired connection between the two units is not necessary.
FIG. 1: RESOLUTION OF THE ACCESS CONTROL BARRIER OR LIGHT CURTAIN
Beam resolution 30 mmBeam separation > 30 mm Beam resolution 14 mm
FIG. 2: OPERATING PRINCIPLE
Sender Receiver
Protective field
Resolution (R)
Protective height
Operating distance (d)

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When properly installed, the protective device detects any relevant entry
into the hazardous area. As soon as such an entry is detected, the pro-
tective device immediately triggers the safety relay, which in turn causes
the machine control system to bring the machine to a safe status and/
or complete stop, thus eliminating the hazard.
The size of the protective field depends on the dimension of the AOPD
and the distance between the sender and receiver units.
AOPDs are also commonly used as sensors to automate industrial
operations where no critical human safety issue is involved. However,
when directly linked to the safety of persons, their design and installation
are strictly regulated.
1.6. CERTIFICATION OF SAFETINEX PRODUCTS
Safetinex YBB/YCA products satisfy all the requirements of category 4,
PL e, according to EN/ISO 13849-1 (formerly EN 954-1) Type 4 accord-
ing to EN/IEC 61496-1 and -2 and SIL 3 according to EN/IEC 61508.
Before considering the use of Safetinex products in machine safety
applications, it must be verified that the product certifications are valid
in the country where the product is to be used.
The following chapters provide a brief introduction to the main standards
and regulations applicable in the European Community and in North
America. They are by no means a complete guide and only serve as a
reminder of the most important issues. For detailed information, please
refer to the original documents.
2. EUROPEAN SAFETY STANDARDS
This section is intended to provide help for designers and users of indus-
trial machinery. It summarizes the basic principles of European directives,
procedures and regulations in terms of protection against hazards in the
work environment. It is by no means a complete guide and only serves
as a reminder of the most important issues. For detailed information,
please refer to the original documents.
2.1. TYPES OF SAFETY STANDARDS
APPLICABLE IN THE EU
In the European Union, safety is legislated. The EU’s Machinery Direc-
tive requires that all machines and safeguarding devices operating in
EU countries meet essential safety standards. Harmonized European
standards regarding machine safety policies are prepared by the CEN
(European Committee for Standardization) or CENELEC (European
Committee for Electrotechnical Standardization) and finalized by the EU
Commission. Once ratified, these standards become European Standards
(EN) that take precedence over national laws. Thus, EU countries must
remove or modify any national standard that conflicts with the European
Standard. CENELEC and CEN cooperate closely with ISO and IEC, the
main bodies for international standards.

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Applicable standards usually have the prefix EN (“European Norm”), but
most also have international – ISO/IEC – equivalents. There are different
types of standards:
– A-type standards are basic safety standards applicable to all machin-
ery, e.g. EN/ISO 14121
–B1-type standards set out special safety aspects and procedures,
e.g. EN/ISO 13849-1
–B2-type standards set rules on safety equipment design, e.g. EN/
IEC 61496-1, EN/TS/IEC 61496-2/-3
–C-type standards set safety requirements for a specific machine or
type of machine
2.2. EXAMPLES OF SAFETY STANDARDS
In addition to the Machinery Directive 2006/42/EC and the Work Equip-
ment Directive 2009/104/EC, there are standards that specifically focus
on protective equipment, such as:
TYPE SCOPE EUROPEAN
STANDARDS
INTERNATIONAL
STANDARDS
ASafety of machinery
Basic principles
EN 12100-1
EN 12100-2
ISO 12100-1
ISO 12100-2
Risk assessment EN 14121-1
EN 14121-2
ISO 14121-1
ISO 14121-2
BInterlocking devices EN 1088 ISO 14119
Guards EN 953
Safety related parts of
control systems
EN 13849-1
EN 13849-2
ISO 13849-1
ISO 13849-2
Safety of machines:
Electro-sensitive
protective equipment
EN 61496-1
EN 61496-2
EN 61496-3
IEC 61496-1
IEC 61496-2
IEC 61496-3
Safety distance details EN 13855 ISO 13855
Positioning of protective
equipment
EN 13855 ISO 13855
TABLE 1: EXAMPLES OF SOME APPLICABLE SAFETY STANDARDS
For additional information regarding European standards, please refer to
www.din.de, www.iec.ch, www.iso.org.
2.3. AN APPROACH TO EUROPEAN STANDARDS
The European Union has chosen to regulate the production, installation
and use of old, modified and new machines within the European Union
territory by approaching the parties concerned separately, i.e. one legal
framework has been created for users and another for manufacturers.
The Work Equipment Directive sets out the rules applying to users of
machines on production sites, while the Machinery Directive sets out
those applying to machine constructors and safety equipment manu-
facturers. However, most subordinate standards apply to both parties,
as shown in the following chart.

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2.4. THE USER SIDE
The user side is regulated by the Work Equipment Directive, which
states that users of a machine are obliged to make sure that it complies
with the legal requirements. Hence, if the user buys a machine which
does not comply with the EU Machinery Directive, it is his responsibility
to take the necessary actions to bring the machine up to the required
quality and safety level.
Additionally, the Work Equipment Directive specifies what minimum
regulations must be observed for safety purposes when work equipment
is being used. The original text can be found on the relevant European
Union website.
2.5. MACHINE MANUFACTURER SIDE
The manufacturer side is addressed by the Machinery Directive. This
umbrella document refers to the specific requirements described in EN
standards, and stipulates that each danger zone of a machine must be
made safe. The method used to make different zones safe depends on
the type of hazard.
The Machinery Directive requires that, before placing machinery on
the market and/or putting it into service, the manufacturer ensures that
TABLE 2: EUROPEAN MACHINE SAFETY OVERVIEW – USER AND MANUFACTURER SIDE.