GAMMA SYSTEM GP02/E User manual

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 1/35
USE AND MAINTENANCE MANUAL
PRESSURE-SENSITIVE BUMPERS
TYPE GSBPS
IN COMBINATION WITH CONTROL UNITS
TYPE GP02/E –GP02R.T

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 2/35
Revisions
REVISION
DATE
DESCRIPTION
00
20-1-2010
First draft
01
20-05-2016
Legislative reference update

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 3/35
Sommario
1Introduction.............................................................................................................................4
2Important warnings about safety ..........................................................................................4
2.1 Improper use ..........................................................................................................................5
2.2 Environmental limits..............................................................................................................5
3Legislative Reference..............................................................................................................6
3.1 Approvals.................................................................................................................................6
3.2 Identification plate..................................................................................................................7
4Description and working principle........................................................................................8
5Description of the product......................................................................................................9
5.1 Force-travel relation.............................................................................................................10
5.2 Technical Specifications of sensors.....................................................................................15
5.3 Chemical resistance .............................................................................................................16
6Applications...........................................................................................................................17
7SELECTING THE BUMPER WHICH BEST SUITS YOUR REQUIREMENTS .......18
7.1 How to select the correct pressure-sensitive bumper...........................................................19
8Transport and Package ........................................................................................................21
8.1 Storage .................................................................................................................................21
9Installation.............................................................................................................................22
9.1 Sensor location.....................................................................................................................22
9.2 Fastening..............................................................................................................................22
9.3 Wire connection...................................................................................................................24
Wire connection to the connector 4 pole.......................................................................................24
Wires connection without connector.............................................................................................24
10 Commissioning......................................................................................................................25
10.1 Functional test......................................................................................................................25
10.2 Verification of the system integrity.....................................................................................25
10.3 Testing Procedure ................................................................................................................27
11 Control unit or control device for bumpers........................................................................28
12 Maintenance ..........................................................................................................................29
12.1 Periodical Maintenance........................................................................................................29
13 FAILURES AND POSSIBLE CAUSES .............................................................................31
14 Warranty................................................................................................................................33
15 EC Declaration of conformity..............................................................................................34

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 4/35
1 Introduction
This Manual should always be kept by the user in a safe and accessible place for further consultation by the
personnel.
Installation and maintenance procedures are to be carried out only by qualified, well trained personnel in all
safety procedures. The pressure-sensitive bumper is used as protection against the risk of accidents/injuries
which can be eliminated by switching off the electrical energy.
Global safety of either the machine and pressure-sensitive bumpers depends on the compatibility and
reciprocal integrity of these components.
Carefully take into consideration the risk assessment of the machine to protect in order to choose the correct
safety category in compliance with the requirements of the EN ISO 13849-1
2 Important warnings about safety
This Manual is intended for use in conjunction with the Manual of the control units. Please read this Manual
carefully and completely before doing any work on the bumper or on the control unit.
The pressure-sensitive bumper used together with the control unit is a safety component used to protect
persons from shearing movements which may become a source of danger or injuries.
The bumper can be used as a “tripping device”, which means it is capable of stopping the movement of the
hazardous element or as a device to detect the presence of a person or part of a person.
In order to ensure that a special application of the safety bumper with the control unit used to protect a
machine/installation meets the existing rules it is necessary to assess: the risk level of the
machine/installation and the compatibility with the safety level declared by GAMMA SYSTEM; furthermore, it
should also be borne in mind that the “performance level” in conformity with EN ISO 13849-1 Standard for
pressure-sensitive bumpers (safety bumpers) used on machines/devices is defined by Type C
Standards
Other fundamental elements are the installation, maintenance and verification of proper operation of the
pressure-sensitive bumper together with the control unit.
These assessments and elements are the sole responsibility of the purchaser, installer and employer.
The additional requirements indicated below are to be met with before using the pressure-sensitive bumper
together with the control unit:
The machine onto which the pressure-sensitive bumper and the control unit are installed must be
able to come to a safe stop at any point along its working cycle. If the pressure-sensitive bumper
(used to detect the presence of persons) and the relevant control unit are used as a safety device ,
the employer is responsible for ensuring that all requirements, rules, codes and regulations
applicable under current rules are fully satisfied.
All braking and locking mechanisms are to be checked regularly so to ensure their correct operation.
If the locking mechanisms do not work correctly, there is a risk that the machine stops in an unsafe
manner even if the pressure-sensitive device (bumper) and the control unit are working correctly.

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 5/35
The testing procedure is to be carried out while installing the device and after each maintenance or
adjustment operation carried out on the machine. The correct testing procedure is described in this
Manual.
All electrical wirings are to be carried out and installed in compliance with the existing regulations
and electrical local Standards.
The user must follow all procedures described in this manual so to ensure the correct use of the
pressure-sensitive bumpers type GSBPS01, GSBPS02 and GSBPS03, in conjunction with the
control units type GP02/E or GP02R.T.
The employer is responsible for the selection and training of the personnel charged with the
installation, use and maintenance of the machine and its relevant safety system. It is mandatory for
the user of the machine to report all and any malfunctioning of the machine, tools and safety
devices. DO NOT put the machine into operation if the safety device is not working correctly.
2.1 Improper use
THE BUMPER AND THE CONTROL UNIT SHALL NOT BE USED:
In control circuits and equipment featuring inadequate stop time or inadequate control
instruments/mechanisms.
In environments which can adversely affect the correct working of the bumper and/or of the control unit
(i.e.: environments with the presence of chemical, corrosive agents).
To start the machine movement.
In environments where there is a risk of explosion or a risk of flood (where devices risk to be covered
with water).
In places where there is the passage of heavy means (forklift trucks, motor vehicles and similar ones).
Beyond the use and storage temperature limits.
In applications where finger detection is required.
2.2 Environmental limits
The material of the sensor can resist the deteriorative effects of ozone, sun rays, water, acids, bases, oily
liquids, fats. Hydraulic oils and cutting oils do not cause any damage.
Very aggressive liquids such as phosphoric acid, nitric acid, Freon, etc… can cause the deformation and the
loss of the material characteristics. The exposure to very high temperatures damages the product (the
product should be stocked at a temperature in the range -10 and +50°C).

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 6/35
3 Legislative Reference
The safety device called
PRESSURE-SENSITIVE BUMPER
consisting of the sensor type: GSBPS01, GSBPS02, GSBPS03
In combination with the control unit type: GP02/E, GP02R.T
has been designed and manufactured in compliance with the essential safety and health requirements for
people’s safeguarding. In particular, the design and manufacture provisions prescribed by the Machine
Directive 2006/42/UE, and the Electromagnetic Compatibility Directive 2014/30/UE, as well as the
European harmonized Standards for risk prevention (EN ISO 12100:2010) have been complied with. Also
taken into account have been the domestic technical specifications, in consideration of the technological
level in force at the moment of construction as well as of the technical and economical requirements.
GAMMA SYSTEM PRESSURE-SENSITIVE BUMPERS also comply with the applicable requirements of the
following Standards:
EN ISO 13856-3:2013
Safety of machinery - Pressure-sensitive protective devices - Part 3:
General principles for design and testing of pressure-sensitive
bumpers, plates, wires and similar devices (ISO 13856-3:2013)
EN ISO 13849-1
Safety of machinery - Safety-related parts of control systems - Part 1:
General principles for design (ISO 13849-1:2015)
EN 60204-1
Safety of machinery - Electrical equipment of machines - Part 1:
General requirements
CEI EN 60529: 1997 + A1: 2000
Degrees of protection of casings ( degree of protection IP)
EN ISO 12100:2010
Safety of machinery - General principles for design - Risk assessment
and risk reduction (ISO 12100:2010)
Other European Directives
2012/19/UE
(RAEE)
2011/65/UE
(ROHS)
(EC) Standard (CE) n°1907/2006
(REACH)
3.1 Approvals
Pressure-sensitive bumpers formed by the sensor type GSBPS0x (x=1,2,3) and used in combination with the
control units type GP02/E or GP02R.T conform to the requirements of EN ISO 13856-3 Standard.
The sensor GSBPS0x (x=1,2,3) in combination with the control units type GP02/E or GP02R.T is a safety
component of class 3 PL “d” which meets the prescriptions of EN ISO 13849-1 Standard. According to the
destination of use and the limits of use defined by the manufacturer, it is excluded that a mechanical failure
of the sensor can lead to the loss of safety function of the devices, meaning that, even if triggered, the
internal contact of the sensor cannot make. Also excluded is the risk for cuts with the ingress of foreign
bodies inside the sensor chamber capable of impairing the sensor operation or modifying its sensitivity (force
of activation).

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 7/35
3.2 Identification plate
Sensors are identified by the identification plate shown below:
GAMMA SYSTEM S.r.l
10044 PIANEZZA (TO) Italy
Via Torino 24/I
Tel: [phone]; Fax: [phone]; E-mail: [e-mail]
PARAURTI SENSIBILI DI SICUREZZA
PRESSURE SENSITIVE BUMPER
Tipo/ Type
NUMERO DI
SERIE
SERIAL
NUMBER
DATA DI PRODUZIONE/ PRODUCTION
DATE
Mese / Month
Anno/year
1
2
3
4
5
6
2010
7
8
9
10
11
12
2011
As for the control units, please refer to the relevant Use and Maintenance Manual.

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 8/35
4 Description and working principle
Definition:
GAMMA SYSTEM PRESSURE-SENSITIVE BUMPER is a “safety device" used as an "electro-sensitive
protective device designed to detect persons or parts of person. It is described in Annex IV of the Machinery
Directive 2006/42/CE. In particular, it is classified as a "safety device equipped with a sensor, capable of
detecting a pressure, and a control circuit having a verification function according to the specified category
and an output interface”. The sensitive surface undergoes a local deformation which actuates the sensor”.
It consists of two essential parts:
A PRESSURE-SENSITIVE SENSOR
A CONTROL UNIT
Working principle:
When the pressure-sensitive bumper is actuated by an external force, after a defined deformation called
“pre-travel”, the two parts of the plastic material come into contact and the circuit makes. The change in state
of the internal sensor (from NO to NC) is processed by the control unit (sensor control device) which sends a
stop signal to the machine thereby eliminating the danger situation. After the pre-travel, the bumper still
allows for an extra depression called “over-travel” during which the hazardous movement is stopped.
Legend
1 Pressure-sensitive bumper
2 Sensor/s
3 Control unit (can be located inside the enclosure of the machine control system or be an integral part of the control
system itself).
4 Switching device(s) for the output signal (can be installed inside the enclosure of the machine control system or it can
be an integral part of the control system itself
5 Part of the machine control system for processing the output signal of the pressure-sensitive bumper
6 Actuation force
7 Sensor output signal
8 Signal for active state (ON)/inactive state (OFF)
9 Signal for manual reset (if appropriate, alternative to A)
10 Reset signal from the machine control system (if appropriate)
11 Monitoring signals (optional)
A Signal for manual reset of the machine control system (if appropriate, alternative to 9))
B Machine control system(s)

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 9/35
5 Description of the product
Bumpers are made of a polyurethane material (foam) exhibiting appropriate elasticity and are coated with
protective fabric. Inserted inside the bumpers is a sensitive element (“sensor”) properly secured inside the
foam. The whole is closed by a frame that is glued to the foams and the aluminum plates. Inserted inside the
bumpers is a sensitive element (“sensor”) properly secured inside the foam. The whole is closed by a frame
that is glued to the foams and the aluminum plate.
The power supply cable is a 4-pole cable - 4*0,35mm2FROR 300/500 –standard length 3 m. (CS). Different
lengths can be supplied upon request (max. 10 m); indicate the length you require when ordering.
In the standard version, the pressure-sensitive bumper comes with a black fabric coating, front side with
yellow and black oblique stripes.
Standard shapes available:
500
200
250
150
300
100
200
100
200
100
Type GSBPS03
Type GSBPS02
Type GSBPS01
Sensitive zone
Sensitive zone
Sensitive zone
Sensitive element
(“sensor”)
Frame
Plate
Polyurethane material
coated with protective fabric

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 10/35
Actual detection zone
The effective sensitive zone is the surface which can potentially come in contact with a person. This surface is shown in
figures above. Versions in any length can be supplied up to a maximum length of 3 mt and with shapes with
135° minimum angle
5.1 Force-travel relation
Key:
b travel, mm
a force N
1 reference forces
2 lowest actuating force
3 hazard speed
4 sensor
c sensor before contact
d point of contact
e point of actuation
f deformation at point B2
g deformation at point C
h reaction force
i established stopping travel of machine
j actuating travel
k overtravel
l working travel
m total travel
Note: Forces are related to test pieces 1
and are example only.
135°
Actuation direction