Pinnacle microguard User manual

Installation Manual
for the
DIN-rail Controller Module

Rev. 5-0
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to
physical injury.
Safety Instructions (or equivalent) signs indicate
specific safety-related instructions or procedures.

DIN-rail Controller Module
Installation Manual
Pinnacle Systems, Inc.
3715 Swenson Avenue
St. Charles, IL 60174
P/N: 28-022r5-0
Customer Service: 630-443-8542 (CST)
(Please have Model #, Serial #, and Software Rev # Available)
Sales and Marketing: 800-569-7697 (EST)
www.pinnaclesystems.com •[email protected] •[email protected]

Proper Usage and Limitations
Theinformationdisclosedherein
includes proprietary rights of the manufacturer. Neither
this document nor the information disclosed herein shall
be reproduced or transferred to other documents, used
or disclosed to others for manufacturing purposes, or for
any other purposes, except as specifically authorized in
writing by the manufacturer. If this manual is supplied
in connection with the sale or delivery of manufacturer’s
equipment, it is to be used solely for maintenance, repair,
or installation of such equipment.
The MicroGuard was manufactured in the United States.
The Installation Manual was printed in the United States.
You must read and fully understand the following
information pertaining to the proper use and limitations of
your Microguard:
• The MicroGuard must be installed by qualified
personnel only.
• The MicroGuard must NOT be used on full
revolution presses or any machine that cannot be
commanded to stop at any time.
• You must NOT wire the Safety Output contacts of
the MicroGuard to an external relay unless you
use the External Relay Checking feature.
• The mechanical power press on which the
MicroGuard is installed must meet ANSI
B11.1-2009 and OSHA 1910.217 regulations.
These include inspection and maintenance
procedures that must be followed to comply with
the regulations. The manufacturer will NOT
take responsibility for improperly maintained
machinery.
• Point of operation safeguarding is defined in ANSI
B11.19-2010. This regulation is used to determine
a safe distance to place your MicroGuard. The
manufacturer takes no responsibility for injury as
a result of improper safeguarding or improper safe
distances.
• The MicroGuard may not be able to safely stop
a press which has a faulty stopping mechanism.
The manufacturer cannot be held responsible
for an improperly maintained or faulty stopping
mechanism.
• The MicroGuard must be checked before put into
operation. Follow instructions provided in this
manual for procedures on how to do this.
• The MicroGuard should never be modified or
repaired except by qualified personnel and upon
authorization of the manufacturer. Never operate
machinery that is not in full working order.
• Make sure that all maintenance people, machine
operators, die-setters, foreman, and supervisors
have read and understood this manual and all
procedures have been and will be followed.
• All procedures in this manual must be followed.
The manufacturer cannot take responsibility for
operation if all procedures and warnings in this
manual are not followed.
Warranty
Manufacturer warrants that this product will be free
from defects in material and workmanship for a period
of two years from the date of shipment thereof. Within
the warranty period, the manufacturer will repair or
replace (at our discretion) any product that is disclosed
as defective upon examination by the manufacturer and
is returned with shipping charges prepaid. This warranty
will not apply to any product that has been subjected to
misuse, negligence, accident, restriction, and use not in
accordance with manufacturer’s instructions or which will
have been altered or repaired by persons other than the
authorized agent or employees of the manufacturer.
Disclaimer
The provisions of the warranty are the sole obligations
of the manufacturer and exclude all other warranties of
merchantability, expressed or implied. Further, there are
no warranties that extend beyond the above warranty.
Limitation of Liability
In the event of any claim for breach of any obligations of
the manufacturer under any order, whether expressed
or implied, and particularly in the event of any claim
of a breach of the warranty or warranties contained in
the paragraph “Warranty” or of any other warranties,
expressed or implied which might despite the paragraph
entitled “Disclaimer,” be determined to be incorporated in
any order, the company shall under no circumstances be
liable for any consequential or special damages, either in
law or in equity, or for losses or expenses or claims for
the same arising from the use of, or inability to use, the
productsof themanufacturer forany purposewhatsoever.
We have designed our equipment to the very highest
performance and safety standards known to the current
technological state of the art. However, the installation,
usage, suitability, and fitness of our equipment for any
purpose, known or unknown, is interdependent upon
the performance of other equipment not manufactured,
installed, or secured or maintained by the manufacturer.
Wecannotand do not accept responsibilityfor anyoverall
system performance when factors, such as these, are
beyond our control.
Wewillnot supplyindividual component partsof anycircuit
board but will supply the individual circuit board complete.
Individualdetectors oremittersare availableas acomplete
tested unit.

Fill this Information out Immediately
(It will be needed in the event you need assistance)
Purchase Date: _______________________________
Purchased From:______________________________
Model No.:___________________________________
Serial No.: ___________________________________
Options:_____________________________________
Microprocessor Revision No.: ____________________
The entire machine safety
system must be tested at the start of every shift.
Machine testing should include: (1) proper machine
operation and stopping capability; and (2) verification
of proper installation and settings of all point of
operation guards and devices before the operation is
released for production.

- i -
Table of Contents
Introduction
Theory of Operation...............................................................................................................................................iv
The System............................................................................................................................................................iv
System Safety........................................................................................................................................................iv
Safety Features......................................................................................................................................................iv
Specifications .......................................................................................................................................................1
Standard Features
Auxillary Relay Output ............................................................................................................................................2
Emergency Stop Input ............................................................................................................................................2
External Relay Check .............................................................................................................................................2
Fault Relay Output..................................................................................................................................................2
Resettable Latching Relays....................................................................................................................................2
Remote Latching Reset ..........................................................................................................................................3
Safety Relay Outputs..............................................................................................................................................3
Optional Features
Analog Output.........................................................................................................................................................5
Auto Blank...............................................................................................................................................................5
Cincinnati Interface.................................................................................................................................................6
DeviceNet ...............................................................................................................................................................6
Floating Blank.........................................................................................................................................................6
Guarding Mute-Out.................................................................................................................................................7
Remote Diagnostics Display...................................................................................................................................7
Remote Indicator Lights..........................................................................................................................................7
Remote Key Switch.................................................................................................................................................7
Installation Procedures
Resetting Faults......................................................................................................................................................8
System Check.........................................................................................................................................................8
Aligning Pylons .......................................................................................................................................................9
Aligning Mirrors.......................................................................................................................................................9
Operations ............................................................................................................................................................10
ANSI Standard B11.19.2010.................................................................................................................................11
Safeguarding with Mechanical Guards.................................................................................................................12
Light Curtain Test Procedure.................................................................................................................................12
Wiring....................................................................................................................................................................13
Controller Module Setup.......................................................................................................................................16
Swivel Bracket Dimensions...................................................................................................................................17
Pylon Dimensions (by model) (Swivel) .................................................................................................................18
Additional cable information (Swivel)....................................................................................................................18
Fixed Bracket Dimensions....................................................................................................................................19
Pylon Dimensions (by model) (Fixed)...................................................................................................................19
Additional cable information (Fixed)......................................................................................................................19

- ii -
Dimensions
Controller Module..................................................................................................................................................20
RSD Mounting Dimensions...................................................................................................................................21
Accessories
Cornering Mirrors..................................................................................................................................................22
Pedestal Mounting................................................................................................................................................23
Swing-Arm Mounting Bracket ...............................................................................................................................23
Appendix A: Diagnostics & Troubleshooting
Obstruction or Misalignment...............................................................................................................................A-1
Error Conditions..................................................................................................................................................A-1
Status Display Messages....................................................................................................................................A-2
Fault Display Messages......................................................................................................................................A-2
Appendix B: Regulations and Guidelines
OSHA Regulations..............................................................................................................................................B-1
Machine Control Reliability Requirements..........................................................................................................B-1
Safety Guidelines and Management
Operational Safety..........................................................................................................................................B-2
Power Press Guarding....................................................................................................................................B-3
Power Press Care through Inspection and Maintenance................................................................................B-3
Safety Enforcement ........................................................................................................................................B-3
Supervisor Training.........................................................................................................................................B-3
Operator Training............................................................................................................................................B-3
Appendix C: Replacement Parts
Pylons.................................................................................................................................................................C-1
Appendix D: USB Diagnostic Codes
Master Controls USB Port........................................................................................................................D-1 to D-2
Table of Contents

- iii -
Figures
Figure 1: 4 Sided Guarding with Dual Stud Guard Brackets, TRM Mirrors and Model #8000 Pedestals...........9
Figure 2: Minimum Object Sensitivity and D(pf) ...............................................................................................11
Figure 3: DIN-rail Controller Module Wiring Diagram........................................................................................15
Figure 4: Internal Circuit Board View ................................................................................................................16
Figure 5a: Swivel Bracket Dimensions................................................................................................................17
Figure 5b: Swivel Bracket Dimensions, pylon dimensions (by model), and additional cable information...........18
Figure 6: Fixed Bracket Dimensions, pylon dimensions (by model), and additional cable information.............19
Figure 7: DIN-rail Controller Module Dimensions..............................................................................................20
Figure 8: RSD Plain Plate Dimensions .............................................................................................................21
Figure 9: RSD Plate with Floating or Auto Blank Dimensions..........................................................................21
Figure 10: Cornering Mirror Dimensions.............................................................................................................22
Figure 11: Pedestal Dimensions.........................................................................................................................23
Figure 12: Swing-Arm Mounting Bracket ............................................................................................................23
Tables
Table 2a: .5” Beam Spacing Pylons (Minimum Object Sensitivity, Depth Penetration Factor, Floating size)......6
Table 2b: 1” Beam Spacing Pylons (Minimum Object Sensitivity, Depth Penetration Factor, Floating size).......6
Table 3: Truth Table...........................................................................................................................................7
Table 4: Mechanical Guards............................................................................................................................12
Table 5a-f: Controller Module Wiring ...................................................................................................................13
Table 6: Internal Jumper Settings with Different Pylon Lengths......................................................................16
Table 7: Cornering Mirror Dimensions.............................................................................................................22
Table of Contents

- v -
Introduction
TheMicroGuardDIN-railController Module isaninfrared
safety light curtain that is designed to the European
IEC 61496 standard. IEC-61496 standard defines
requirements for infrared light curtains used in safety
applications. When properly installed, it protects the
machine operator by passing an invisible infrared light
beam across an area to be guarded and examining
whetheror notthe light beam(s)are blocked. Ifthe light
beams are blocked, safety outputs will automatically
open up and a “STOP” command will be sent to the
guarded machine.
The system is composed of a sending unit (Emitter), a
receivingunit (Receiver),and a Controller Module. The
entire system is control reliable (per IEC 61496) in that
a single fault anywhere within the MicroGuard DIN-rail
itself will not prevent the safety outputs from opening
up when anything blocks the infrared light beam(s). All
failures are reported on the Diagnostics Display and/or
via the RS-232 or RS-485 Serial Port.
The Diagnostics Display aids in installation by showing
where beam blockage is occurring, as well as reporting
selected installed options and fault reports.
Theoryof Operation. TheMicroGuard protectsanarea
byprojecting acurtain ofinfraredlight. It formsa curtain
by utilizing infrared Emitters in line on .5” or 1” centers.
This close spacing makes it impossible to place a body
part through the curtain without detection (assuming
properinstallationprocedures werefollowed). Forevery
infrared Emitter, there is an infrared Detector directly
opposite. When an obstruction is placed between
them,the beam isbroken and theabsence of a beam is
observed by the Controller Module which de-energizes
the safety relays and opens the connected circuit.
All the beams are scanned sequentially (one at a time)
until the entire curtain has been scanned. The two
computers compare data with each other every scan
of the light curtain and will drop out the safety relays if
any signal is incorrect or the compared data does not
match. Cooperationfrom both computers is requiredto
energize safety relays and either computer can disable
both safety relays if a fault is detected.
The System. The MicroGuard employs infrared
technologyina smallsealedNEMA4 aluminumhousing
which provides harmless invisible protection and an
unobstructedview of theguarded area. The Microguard
consists of three parts: an Emitter pylon(s), Receiver
pylon(s), and Controller Module. The Emitter pylon(s)
contains infrared light emitting diodes spaced .5” or 1”
apartdown the entirelength of thepylon. The Receiver
pylon(s)contains anequalnumber ofinfrared detector’s
and transistor receivers also spaced .5” or 1” apart.
The Controller Module contains diverse redundant
technologythat includestwo differentmicroprocessors,
self-checking circuitry, power supply, safety output
contacts, and a diagnostics display.
System Safety. The MicroGuard employs diverse
redundant technology that provides a backup for every
system that could cause an unsafe condition. Upon
power up, all systems are checked before activating
the output relays. Once the unit passes the initial
tests and activates the system, it is then tested by
both microprocessors and other circuits once per scan
of the light curtain. All signals are presented to both
microprocessors, but are isolated from one another
to prevent a failure of one microprocessor should the
other crash. Other circuits detect short circuits, open
circuits, proper voltage, proper oscillation, etc. The
use of special dual force-guided safety relays assure
that if one fails, the other can safely shut down the unit.
Additionally, watchdog circuits on the relays prevent an
unsafe condition even if both microprocessors failed.
All the standard and optional features that run on the
MicroGuard are designed with safety in mind:
The Floating Blank option allows only one object
to be placed into the light curtain’s field of view.
Evenif theobject is smallerthan theallowed size,
a second object will cause the unit to go RED.
The Auto Blank option programs in the exact size
and location of an object automatically and thus
can detect any movement in the object and shut
down the light curtain, which must be reset with
a key.
The External Relay Check can detect either an
opening or a short in the external relay or its
wiring. Thestandard Cincinnati Interfaceprovides
a means to assure that the light curtain can open
up its output relays between press cycles.
Safety Features. The MicroGuard was designed to
meet the European IEC 61496 standard parts 1 and 2,
CSA, UL1998, ULSubject 491, OSHA,ANSI, and RIA.
• Control-reliable design prevents a failure to
danger condition from ever occurring (assuming
all installation procedures are followed properly).
• Systemredundancyassuresthat there areatleast
two ways to detect a system failure, two ways
to shut down the safety outputs, and two safety
outputs. The redundant systems are configured
differentlytoprevent any possible inherent circuit
- iv -

- vi -
Introduction
problems from occurring simultaneously in both
redundant circuits.
• Force-guided relays allows dry relay contacts to
be monitored for contact welding and/or circuit
failure.
• Watchdog timers on both computers and both
safety relays assures that a system lock-up will
automatically drop out the safety relays.
• Through the use of shielded cables, chokes,
surge suppressers, and optically-coupled inputs,
immunity to EMI/RFI fields is greatly increased.
• The MicroGuard DIN-rail was designed to meet
the European IEC 61496 standard parts 1 and 2
(part 2 requires use of optional 2 degree pylons),
CSA,UL1998,UL491, UL991,OSHA,ANSI, and
RIA.
• Surface mount technology is used throughout for
increased reliability.
- v -

7
Specifications
DIN-rail Controller Module
Input Power
24vdc +/- 20% (7 watts max)
Input Fuse
1 amp fast blow (pico size)
Relay Outputs
K1, K2 Safety N.O.
8A@250v resistive
(4A@120vac recommended max)
130V surge suppression devices are installed
inside the Controller Module. This limits the
recommended maximum voltage to 120VAC.
Please consult factory if you need to switch higher
voltages.
K3 Aux N.O. & N.C.
8A@250v resistive
(4A@120vac recommended max)
K4 Fault N.O.
8A@250v resistive
(4A@120vac recommended max)
Indicators
External:
OK/CLEAR Green LED
BLOCK/FAULT Red LED
BLANKING ACTIVE Yellow LED
BLOCKED Red LED
Internal:
D1 +5v Yellow D3 +12v Red
D14 K2 relay Green D13 K1 relay Green
D16 K3 relay Green D15 K4 relay Green
D19 +5v Yellow D18 -5v Green
Construction
Controller Module: DIN-rail mountable
polycarbonate housing providing IP40 protection,
UL94V-1.
Pylons: Painted aluminum extrusion with
polycarbonate IR lens and Viton seals providing
NEMA 12, 13 protection. An optional polycarbonate
tube provides NEMA 4 protection.
Cables: Shielded PVC 22 AWG stranded.
Standard length: 20’ Emitter; 8’ Receiver
Temperature Range
0 to 50°C (up to 95% humidity, non-condensing)
Dimensions
Controller Module: 5.87” length X 2.95” width X
4.33” height DIN-rail mount is 35.5mm (1.4”) wide.
Pylons: 1.45” square.
Beam Spacing
.5” (12.7mm) standard
1” [25.4mm] (optional). The Floating Blank option
changes the effective beam spacing.
Minimum Object Sensitivity:
.5” (12.7mm) beam spacing is .55” (14mm)
1” (25.4mm) beam spacing is 1.18” (30mm)
Response Time < 30 mSec total
Scanning Frequency 5.9 KHz
Shock Tested to withstand high vibration applications
Self-Checking every 20 milliseconds
Scanning Distance All units are supplied standard
with a 20’ scanning capability. Extended range units
are available and must be specified (35’ maximum).
Maximum Operating Distance Stated as last two
digits in model number
1

3
Standard Features
DIN-rail Controller Module
Standard Features
Auxiliary Relay Output
Description: Usethis relayforhorns, lights,andsignals
back to PLC’s. Relay K3 is not monitored and driven off
oftheK2 relay. Itshould notbeplacedinto a“stop”circuit
by itself. Both N.O. and N.C. terminals are provided.
POWER / RELAY terminal #8: N.C., terminal #9:
common,terminal #10:N.O. Follow thesame directions
as for contact ratings.
Emergency Stop Input
Description: Abuilt-inhardwiredEmergencyStopSafety
Inputwhich utilizestwonormally-closed emergencystop
contacts to achieve a Category 4 safety level, per EN
954-1. If either or both emergency stop contacts open,
power to the safety output relays is removed, causing
the relays to de-energize and send a stop signal to the
guarded machine.
Application: This protects against a safety switch
contact failure or wiring fault. Acontact failure or wiring
short will inhibit the system reset, causing the system’s
DiagnosticsMessage Display to indicate anEmergency
Stop Input failure.
Usage: See Figure 3 DIN-rail Controller Module Wiring
Diagram for proper wiring of the E-Stop inputs. If you
choose not to use this feature, you must still wire the
two inputs closed (the DIN-rail is pre-wired from the
factory). To reset an E-Stop fault, hit the F1 key on the
top of the DIN-rail controller or Ground Terminal #3 on
the Input/Output connector (the same input is used for
the Latching Relay Reset).
External Relay Check
Description: This feature allows the MicroGuard
DIN-rail to monitor a pair of external relays in series.
The external relays must be force-guided and have an
extra pole that is normally closed. The primary pole of
a force-guided relay maintains identical position to the
secondary pole even when one of the poles is welded.
The secondary pole is used to monitor your external
relays.
Application: If your application requires you to switch
to high current in your “stop” circuit, then you will need
to use external relays. You will want to monitor those
external relays in case of contact welding.
To Activate Feature: Install Jumper (see Installation
Procedures, “Controller Module Setup”) on across pins
labeled EXT. The display should read “rdyE” when this
feature is active.
Usage: POWER / RELAY terminal #13: +pos input
(+24vdc max), terminal #14: -neg input (ground)
The secondary poles must be N.C. when the curtain is
in a “RED” condition. The monitored external contacts
must close and the primary contacts must open in a
“RED” condition within 250mSec’s or an error will occur.
If the curtain is “GREEN,” the monitored secondary
contacts should open up and the primary contacts will
close. An error will occur if the monitored contacts do
not open up. The primary poles of your external relays
must be N.O. (they are placed in your “stop” circuit).
Bring+24vdc toTerminal #13,run GNDthrough theN.C.
contact of both external relays in series to Terminal #14.
Messages: (see Appendix A: Diagnostics &
Troubleshooting for details)
“External contact welded or wire cut”
“External contact short”
NOTE: Useonly shieldedcable betweenexternal relays
and external relay checking input.
Fault Relay Output
Description: Relay K4 is not monitored and has its
own driver circuitry. It should not be placed into a “stop”
circuit by itself. The fault output is a dry contact N.O.
(held closed when clear, opens when there is a fault).
Usethisrelay forhorns,lights, andsignalsback toPLC’s.
POWER / RELAY terminal #11 & 12. Follow the same
note found above for contact ratings.
Resettable Latching Relays
Description: When power is applied to the MicroGuard
DIN-rail unit, it will stay in a “RED” condition until the
Latching Reset Input is reset.
Application: This is used for guarding an area against
intrusion; without this feature the curtain would stay
“RED” only as long as the curtain’s field of view was
blocked. If you are perimeter guarding, you may need
this.
To Activate Feature: Install Jumper (see Installation
Procedures, “Controller Module Setup”) on across pins
labeled CLOSE. The display should read “rdyL” when
thisfeatureis active.You maywantto removethisjumper
during installation.
Usage: Install your own N.O. push button between
ground and terminal #3 of INPUTS/OUTPUTS following
the Wiring section of this manual. You must cycle the
button to reset the curtain.
2
DIN-rail Controller Module

4
Standard Features
DIN-rail Controller Module
Remote Latching Reset
Description: When the curtain is blocked, the unit
will issue a “STOP” command and remain in this
condition until the curtain is clear and the Latching
Input is cycled. This feature must be enabled.
Usage: Install a N.O. button from I/O Terminal #3 to
Power/Relay Terminal #2.
To Activate: Install jumper across pins labeled
“close”.
Safety Relay Outputs
Description: Safety Relays are N.O. (closed when
green, open when blocked or power removed). Both
K1 and K2 relays each have their own driver circuitry
and relay monitoring circuitry, are fully independent
of each other, and have their own output terminals.
POWER / RELAY: K1 (Terminal #4 & 5)
K2 (Terminal #6 & 7)
Safetyrelays arerated at 8A
@ 250vac resistive at room temperature. Inductive
loads and high ambient temperatures de-rate that
value substantially. It is not recommended that more
than 4A@120vac be used through the internal safety
relay contacts.
3
Standard Features
DIN-rail Controller Module

5
Standard Features
DIN-rail Controller Module
4
Page Intentionally Left Blank

7
Optional Features
DIN-rail Controller Module
Analog Output
Description: Ouputcan beset up for either 0to 10Vor
–10V to 10V and proportional to the area blocked. You
must specify the details of the output (see Installation
Procedures, “Figure 3: Controller Module Wiring
Diagram”).
Application: Various
To Activate Feature: Thisfeaturemust beorderedand
requires exchanging computer chips (see Installation
Procedures, “Figure 3: Controller Module Wiring
Diagram”).
Auto Blank [patent # 5,243,183]
Description: With the obstruction in place, turn the
key switch from “OFF” to any mode of operation. If the
object(s)do notexceed the totalallowable size,the unit
will energize the safety outputs.
Application: Permits you to automatically program
the location of an obstruction (i.e., a conveyor, table,
work piece, etc.).
Standard Operation: If the obstruction is moved or
removed, the unit will issue a “MOVE” fault and will
re-energize the safety outputs when the obstruction
is returned to the original position. Standard operation
allowsfor atotalof eightbeams tobe blocked anywhere
inthe curtain (theydo nothaveto benext to eachother).
Optional Operation: If the obstruction is moved or
removed, the unit will issue a “MOVE” fault and lockup,
requiring you to re-program the obstruction.
Troubleshooting: If you get a “MOVE” fault when
the obstruction did not move, it is possible that you
are just barely covering a beam and either vibration or
reflectionsare causing thebeam tobecome uncovered.
The uncovered beam then causes a fault.
To Activate Feature: This feature must be ordered
and requires exchanging the computer chips (see
Installation Procedures, “Figure 3: Controller Module
Wiring Diagram”).
Leave key switch in OFF/
RESET position while installing, setting up, and
testing the light curtain. Use Auto Blank only after
you are able to get a clear signal from the curtain
with no obstruction.
MODE Description
OFF/
RESETNormal operation (no blanking)
#1 Mode 2, but guard must be reset if unit is
penetrated. Theauto blankobstructionmust
remainin its exactlocation permanently. Any
movement in theAuto Blank obstruction and/
or additional guard penetration will latch the
light curtain in a RED condition and must be
reset via the keyswitch.
NOTE: If no obstructions were programmed
in, the guard will still latch in a RED condition
should the guard be penetrated.
#2 Standard Auto Blank operation. The Auto
Blank obstruction must remain in its exact
location permanently. This works like Mode
1 except guard penetrations will not latch in
a RED condition.
#3 Mode 2, plus one beam float. This mode
works like Mode 2 with the addition of a
Floating Blank which is set to allow one
beam float (see Optional Features, “Floating
Blank”).
NOTE: If no obstructions were programmed
in, the guard will still allow one beam float.
Programming: To program, turn the keyswitch into
the OFF/RESET position and place the obstruction(s)
in the guarded area. Now, turn the keyswitch into the
desired mode of operation. The exact size and location
of the object(s) are now in memory. The Penetration
Depth Factor D(pf) must be set to account for the
one beam float (seeOptionalFeatures,“Floating Blank,
Tables 2a and 2b”).
Diagnostics Display
AB Auto Blank detected an object (the number
indicates the size of the object).
RDY No objects programmed in, keyswitch in
Mode 1 or 2.
FB No objects programmed in, keyswitch in
Mode 3
SIZE Obstruction size exceeded a total of eight
beams.
PENT Penetration of the light curtain occurred
while keyswitch was in Mode 1.
MOVE Auto Blank obstruction moved.
(CONTINUED ON NEXT PAGE)
5

8
Optional Features
DIN-rail Controller Module
To Activate Feature: Thisfeature mustbe ordered and
requires exchanging the computer chips.
Thesafetydistance musttake
intoaccountthemaximumblanking sizewhichalters
the Depth Penetration Factor.
Make sure that the diagnostics display does
not show blockage when there is none present.
Minimum Object Sensitivity indicates the minimum
size required to cause the light curtain to detect an
object even if it is moving (floating). If the obstruction
is slightly smaller (less than 0.25”) than the stated
number, the light curtain may blink RED/GREEN when
theobjectis movinginthe fieldofview. If theobstruction
issmaller thanthe stated number by atleast 0.25”,then
the light curtain will stay GREEN as long as there are
no additional obstructions.
Depth Penetration Factor is the number used to
compute the distance the light curtain should be placed
from the point of operation (see Installation Procedure,
“ANSI Standard B11.19-2010”).
Diagnostics Display
RDY Keyswitchis inthe lowestposition (Floating
Blank is off).
FB Indicates Floating Blank active and the
number of blocked beams.
OBST A second object found in the curtain (only
one obstruction is allowed to float).
Table 2a: .5” Beam Spacing Pylons
Table 2b: 1” Beam Spacing Pylons
(AUTO BLANK CONTINUED)
(CONTINUED ON NEXT PAGE)
Inches/Millimeters Inches/Millimeters Inches/Millimeters
RDY (float off) 0.55” / 14mm 0.935” / 23.8mm 0.00” / 0.0mm
FB1 (1 beam float) 1.18” / 30mm 3.077” / 78.2mm 0.45” / 11.4mm
FB2 (2 beam float) 1.75” / 45mm 5.015”/129.2mm 0.95” / 24.1mm
FB3 (3 beam float) 2.36” / 60mm 7.089”/180.2mm 1.45” / 36.8mm
FB4 (4 beam float) 2.95” / 75mm 9.095”/231.2mm 1.95” / 49.5mm
FB5 (5 beam float) 3.54” / 90mm 11.101”/282.2mm 2.45” / 62.2mm
FB6 (6 beam float) 4.13” /105mm 13.107”/333.2mm 2.95” / 74.9mm
Display Minimum
Object
Sensitivity, S
D(pf) Depth
Penetration
Factor
Max. Floating
object size
less than
Inches/Millimeters Inches/Millimeters Inches/Millimeters
Rdy (float off) 1.18” / 30mm 3.077” / 78.2mm 0.00” / 0.0mm
FB1 (1 beam float) 2.36” / 60mm 7.089” /180.2mm 0.95” / 24.1mm
FB2 (2 beam float) 3.54” / 90mm 11.101” /282.2mm 1.95” / 49.5mm
FB3 (3 beam float) 4.72” / 120mm 15.113” /384.2mm 2.95” / 74.9mm
Display D(pf) Depth
Penetration
Factor
Max. Floating
object size
less than
Minimum
Object
Sensitivity, S
6
Place Auto Blank keyswitch
into OFF/RESET position and remove any
obstructions while aligning light curtain. Do not
useAuto Blank until light curtain is correctly aligned
(see Installation Procedure, “Aligning Pylons” and
“Aligning Mirrors”).
The keyed selector switch is designated to be
supervisory controlled. After installation, the safety key
should be removed and controlled only by the safety
supervisor or authorized plant personnel.
Cincinnati Interface
Description: Asignal from the press control forces the
curtain into a blocked “RED” condition. This allows the
presscontrol toself check thewiring ofthe “stop”circuit.
Application: Cincinnati press that requires the light
curtain to open up the “stop” circuit every press cycle.
To Activate Feature: This feature is always active,
24vdc applied to the Cincinnati terminals will force the
curtain “RED” at any time.
Usage: POWER / RELAY terminal #15: +pos (+24vdc
max), terminal #16:-neg(ground). The signalfromyour
press will be either +24vdc or ground when it wants to
see the “stop” circuit open up (i.e., sinking or sourcing).
Sinking: If your press provides a ground signal to
generatea “stop”command, thenyou must provide
+24vdc to terminal #15 and apply the signal line to
terminal #16.
Sourcing: If your press provides a +24vdc signal to
generate a “stop” command, then you must ground
terminal #16 and apply the signal line to terminal
#15.
DeviceNet™
Optionalexternal board thatplugs into theRS-232 serial
port of the DIN-rail Controller Module. External board
comes with its own direction.
Floating Blank
Description: A key switch by default allows for 0, 1,
2, 3 beams to be blocked anywhere in the curtain as
long as all the blocked beams are next to each other.
The customer may request different blanking sizes for
different applications. The Minimum Object Sensitivity
and the Depth Penetration Factor (DPF) change when
the key switch position is changed. The DPF is used
to compute the safety distance.
Application: On a press brake, the Floating Blank
permitsthe workpiece to be placed inthe guardedarea
andcan bemoved aroundas longas itdoes notexceed
the object sensitivity selected.

9
Optional Features
DIN-rail Controller Module
Place Floating Blank
keyswitch into 0.5” position and remove any
obstructions while aligning light curtain. Do not use
Floating Blank until light curtain is correctly aligned
(see Installation Procedure, “Aligning Pylons” and
“Aligning Mirrors”).
The keyed selector switch is designated to be
supervisorycontrolled. After installation, thesafety key
should be removed and controlled only by the safety
supervisor or authorized plant personnel.
Guarding Mute-Out
Description: Two inputs (LS4 and LS5) are required
to use the Mute-Out feature. These inputs can come
from limit switches or PLC outputs that act as limits.
The signal to start Mute-Out should occur no sooner
than¼” fromramclosure andend beforethehazardous
portion of the machine cycle begins (see Installation
Procedures, “Figure 3: DIN-rail Controller Module
Wiring Diagram).
Application: Allowsanyobject topassthrough thelight
curtain without opening the stop circuit and interrupting
the machine cycle (i.e., the curtain stays GREEN).
Usage: The Mute-Out portion of the cycle occurs
between the pinch point and top stop (about 180° to
300°) or any non-hazardous portion of your machine
cycle.
You must power up the MicroGuard out of Mute-Out
condition, any other condition will cause an error to
occur and you will have to power down the guard to
reset it. When in Mute-Out, the MicroGuard will display
“MUTE.” If LS4 or LS5 limit switches are ever caught
out of sequence, the guard will fault and issue an error
message of “MUTE-OUT SWITCH FAULT” or “SLV
MUTE-OUT SWITCH FAULT.”
To Activate Feature: Thisfeaturemustbe orderedand
requiresexchangingthecomputerchips (seeInstallation
Procedures, “Controller Module Setup”).
Table 3: Truth Table
LS4 LS5 CONDITION DISPLAY
OPEN CLOSED GUARDED RdyM
CLOSED OPEN MUTE-OUT MUTE
OPEN OPEN FAULT Muteout switchfault
CLOSED CLOSED FAULT Mute out switch fault
LS4 = I/O Terminal #4 & LS5 = I/O Terminal #5
Ifbothsignals remaininthe samestate(i.e., bothclosed
or both open) for more than 100mSec, a fault will be
issued.
To by-passthis feature,jumper
LS5 (I/O terminal 4) to ground (Power/Relay terminal
#2).
Do not use one switch or one
relaytogenerate thetwoinputs needed—itisunsafe!
Make sure that Mute-Out occurs only on the non-
hazardous portion of the machine cycle.
Remote Diagnostics Display
Application: To view the display from the front panel
without having to open the door.
To Activate Feature: You must purchase the remote
display and cable.
Usage: The connector for the remote display is located
under the top cover of the Controller Module to the left
of the built-in display. Pull the boards out of the housing
and cut away the top cover to expose the connector.
Remote Indicator Lights
Application: To viewthe statusindicator lightsfrom the
front panel without having to open the door.
To Activate Feature: Purchase sealed LED indicator
lights from the manufacturer or use your own.
Usage: (see Installation Procedures, “Wiring”, and
“Figure 3: DIN-rail Controller Module Wiring Diagram”).
Remote Key Switch
Application: To control the blanking functions.
To Activate Feature: Purchasethekey switchandlabel
for the blanking style desired.
Usage: Refer to Floating Blank or Auto-Blank (see
Installation Procedures, “Figure 3: DIN-rail Controller
Module Wiring Diagram”).
(FLOATING BLANK CONTINUED)
7

11
Installation Procedures
DIN-rail Controller Module
The entire machine safety
system must be tested at the start of every shift.
Machine testing should include: (1) proper
machine operation and stopping capability; and
(2) verification of proper installation and settings
ofallpoint of operationguardsand devicesbefore
the operation is released for production.
The MicroGuard DIN-rail should be mounted in
a manner so that only authorized personnel can
change the mounting or location and that the safety
distance is recalculated each time its position is
changed.
Additional mechanical guards may be required
to prevent the operator from standing between,
reaching over, under, or around the light curtain to
the hazardous point of operation.
Otherinfraredsources(i.e.otherlightcurtains,etc)can
interfere with operation and prevent the light curtain
fromproperlyaligningandgivingaGREENindication.
MakesurethattheRECEIVERpyloncannotview oth-
erinfrared Emitters(exceptits ownEMITTER pylon).
The MicroGuard DIN-rail is
a low voltage device and operates with low voltage
and low current signals. Make sure to keep all parts of
this system as far away from high voltage devices as
possible.
1) Before installation, test the light curtain by
installing the cables between the pylons and
applying power to the Controller Module. Point
thepylonstoward eachotherand verifya“RDY”
orGREENindicator. Ifyoucannot get aGREEN
indicator, see Appendix A: Diagnostics and
Troubleshooting.
2) Determine the Safety Distance of the light
curtain from the hazardous point of operation
(see Installation Procedures, “ANSI Standard
B11.19-2003”). You must know the total stop
time of your machine.
3) Determine if any part of the Microguard is to
be directly subjected to either excessive shock
and/orvibration.If so, mountthesubjected parts
to your equipment using shock-mount devices
(suchas Part#21-019). Shock and/orVibration
damage is not covered under warranty.
4) Mount both pylons with the connector side
in the same direction (whether up or down)
across the hazardous area at a distance from
the hazardous point of operation, equal to or
greater than the calculated safety distance.
Shockmountthepylonsiftheyare
to be directly mounted onto a high vibration machine. Do
not lock down the pylons or mirrors until proper alignment
is obtained.
5) Mount the Controller Module inside your control
panel. The Controller Module should be placed
as far away from high voltage devices as possible
while remaining inside your control panel.
6) Usemirrorstoturn a corner90°ormorebutnoless.
If you are using pedestals, do not permanently
mountthem untilyou have finishedthe installation
procedure. When you have a GREEN indicator,
bolt the stands to the floor. Make sure the bottom
edge of the mirror(s) are below the bottom beam
of the curtain and the top edge of the mirror(s) are
above the top beam of the curtain.
7) Dress the pylon cables either inside their own
conduit, or tie-wrapped away from high voltage
devices. Even though the cables are shielded,
they carry low voltage, low current signals.
8) Either roll up excess cable inside the Controller
Module or cut the cable to proper length and re-
strip the wire ends (see Wiring section for further
details).
9) Wire power to the Controller Module and align
pylons for a GREEN indicator with no blockage
present. Lock down pylons, mirror(s), and
pedestalsatthispoint (seeInstallationProcedures,
“Wiring,”“AligningPylons,” and“AligningMirrors”).
10) Connect the Controller Module Safety Relay
Outputs into the hazardous machine’s STOP
circuit. Connect all other features that your
installation requires (i.e., mute-out, external relay
checking, etc.) (see Installation Procedures,
“Wiring”).
Resetting Faults
Press the FN1 button on top of the Controller Module to
reset faults.
System Check
11) Check the curtain’s field of view with a round
test piece (i.e., dowel rod) that has a diameter
equal to the minimum object sensitivity of the
curtain (see Specifications section for numbers).
When penetration into the curtain’s field of view
is performed, the guarded machine should shut
down. Move the test piece up and down the
curtain’s field of view to make sure there are
no spots where the curtain indicates a GREEN
condition.
8
Installation Procedures
DIN-rail Controller Module

12
Installation Procedures
DIN-rail Controller Module
Ifyougeta GREENindication
while the test piece is in the curtain’s field of view,
this may be due to any of the following reasons:
(1) an incorrectly sized test piece; (2) the Floating
Blank option is enabled and set larger than what
you believe it to be; or (3) there is a reflection from
adjacent reflective material. If #3 appears to be the
case, you must move the reflective material further
away from the curtain or the curtain away from the
material.
12) Install additional mechanical guards to prevent
anyone from getting to the hazardous point of
operationbyreachingaround, over,orunderthe
curtain.Also, to prevent anyone from getting in
between the curtain and the hazardous point
of operation, install L-shaped light curtains or
safety mats.
Aligning Pylons
Mechanically line up the pylons so they are looking
straight at each other. Twist the pylons to find the
center of their sweet spot (the point at which you get
a solid GREEN indicator). If you are trying to run the
pylons close to the maximum operating distance, you
may have to tip one end of the Emitter pylons to get a
GREEN indication.
The diagnostics display will show the location of the
first blocked beam. If you push the “FN1” button on the
ControllerModule, thedisplaywill showyou thelocation
of the next blocked beam. The last digit indicates how
manybeams areblocked (seeAppendixA: Diagnostics
& Troubleshooting for more details).
Aligning Mirrors (refer to Figure 1)
Every mirror you add reduces the maximum operating
distance by -10% and also increases the difficulty of
alignment. Because of the width of the mirrors and the
shoulders of the aluminum extrusion that protect the
mirror, you cannot turn a corner less than 90°.
The vertical height of the mirror with respect to the
vertical height of the pylons should be such that the
mirrormatchesthe beamareaof thepylons. Youshould
have some mirror showing above the top beam and
below the bottom beam.
All mirrors and pylons should be plumb. You should be
able to stand in front of one of the pylons, look straight
ahead, and see the other pylon through the center(s) of
themirror(s). Dependingonwhatthe diagnosticsdisplay
reads, you may have to tip one end of the mirror to get
the remaining blocked beams to come in.
Installation Procedures
DIN-rail Controller Module
9
Figure 1: 4 Sided Guarding with Dual Stud Guard Brackets, TRM Mirrors and Model #8000 Pedestals

13
Installation Procedures
DIN-rail Controller Module
Operations
Examine the MicroGuard on
a daily basis to make sure that no one has moved the
light curtain pylons closer to the pinch point or removed
any mechanical guards from around the curtain.
If it is possible for someone to go through the light
curtain and remain in a dangerous area without having
to block the light curtain, you must order the Resettable
Latchoutoption whichkeeps thecurtain REDeven after
you are no longer blocking the curtain. The Latchout
reset button is mounted away from the dangerous area
and must be cycled to reset the curtain.
1) Powerup thelight curtain.Ifa faultoccurred the
last time the unit was powered and was never
RESET, it will appear as a “SLAVE FOUND”
error message and you will have to push the
RESET button to clear the fault message and
start the curtain.
2) When GREEN the curtain display will say
“RDY” or “rdy “ depending on any options
that were set (see Appendix A: Diagnostics &
Troubleshooting for more details).
3) When RED due to blockage, the display will
indicate the location of the first obstruction(s)
and the total size of the obstruction(s) (see
Appendix A: Diagnostics & Troubleshooting
for more details). If you have Floating Blank,
then this is indicating that your object is too
large for the floating size you have selected. If
you increase the Floating Blank size, you must
recalculate the safety distance formula since
the object sensitivity will be larger. If you have
the Resettable Latchout option, the display will
show“PENT” toindicate penetration. Youmust
cycle the Latchout RESET button to clear the
curtain (see Standard Features, “Resettable
Latching Relays”).
4) When RED due to a fault, the display will scroll
the error message that caused the fault and
the board and beam number (if it can be pin
pointed). You must first correct the fault, and
then push the RESET button to clear the fault
from memory, even powering down the unit will
not clear the fault from memory (see Appendix
A: Diagnostics & Troubleshooting for more
details).
5) If you have the MUTE-OUT option, the display
will show “MUTE” during the up stroke. If you
have the Cincinnati Interface hooked up, the
display will show “CINN” during the up stroke
(see Optional Features, “Guarding Mute-Out”).
6) Auto Blank. The display will show “AB” to
indicate that an object is programmed in and
its size (in beams) is shown as the next digit.
If you keep getting a “MOVE” message and
your object is not moving, try repositioning the
object slightly (+- 1/4”) and reprogram it back
into memory. If you get a “SIZE” message, you
must either get new software to allow a larger
object or reduce your object size.
7) Floating Blank. The display will show “FB” to
indicate the allowed blanking size in beams.
Once an object penetrates the curtain, any
second object will cause the curtain to display
“OBST” to indicate that a second obstruction is
in the curtain. This is done in case you select a
Floating Blank size much larger than the actual
object size.
10
Installation Procedures
DIN-rail Controller Module