STI QuadSafe RM-4 User manual

QuadSafe RM-4
Installation and Operating Manual
Scientific Technologies Inc.
Optical Sensor Division
Manufacturing and Sales Office
6550 Dumbarton Circle
Fremont CA 94555-3611 USA
1 / 888 / 510-4357
Tel: [phone]
Fax: [phone]
www.sti.com
STI Scientific Technologies GmbH
European Sales Office
Bötzinger Straße 29
79111 Freiburg, Germany
Phone: [phone]
Fax: [phone]
© STI 0802 PN99583-0010 Rev. B
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QuadSafe RM-4 Installation and Operation Manual
SCIENTIFIC TECHNOLOGIES INC.
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STI SCIENTIFIC TECHNOLOGIES GmbH
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Tel: [phone]
©STI 0802 PN99583-0010 Rev.B
RM4 for Light Curtains
Table of Contents
Section 1— Important Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 3
Section 2—
Description of QuadSafe RM-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
Section 3—
QuadSafe RM-4 Top Label and Indicators . . . . . . . . . . . . . . . . . . . page 6
Section 4—
Operating and Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . page 7
Section 5—
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Section 6—
Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 17
Section 7—
Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Section 8—
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Section 9—
QuadSafe RM-4 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Section 10—
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 24
Section 11—
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 26

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RM-4 Installation and Operation Manual
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I MPORTANT S AFETY W ARNINGS
Safety Warnings
QuadSafe RM-4 Installation and Operation Manual
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1 I MPORTANT S AFETY W ARNINGS 1
WARNING! Read and understand this section prior to installing the QuadSafe
RM-4 system.
1.1. S AFETY W ARNINGS
The QuadSafe RM-4 module is a “ Type 4 ” safety device. It is designed to work with
safety devices to guard personnel working around moving machinery.
Whether a specific machine application and QuadSafe RM-4 installation complies
with safety regulations depends on several items, including the proper
application, installation, maintenance and operation of the QuadSafe RM-4. These
items are the responsibility of the purchaser, installer and employer.
The employer is responsible for the selection and training of personnel to
properly install, operate, and maintain the machine and its safeguarding systems.
The QuadSafe RM-4 should only be installed, verified and maintained by a
qualified person, as “ a person or persons who, by possession of a recognized
degree or certificate of professional training, or who, by extensive knowledge,
training or experience, has successfully demonstrated the ability to solve
problems relating to the subject matter and work.
” (ANSI B30.2-1983)
To use a QuadSafe RM-4 module, the following requirements must be met:
— The guarded machine must be able to stop anywhere in its cycle. Do not use an
QuadSafe RM-4 on a press with a full-revolution clutch.
— The guarded machine must not present a hazard from flying parts.
— The guarded machine must have a consistent stopping time and adequate control
mechanisms.
— Severe smoke, particulate matter and corrosives may degrade the efficiency of
safety devices. Do not use the QuadSafe RM-4 module and safety devices system in
this type of environment.
— All applicable governmental and local rules, codes, and regulations must be
satisfied. This is the employer’s responsibility.
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D
ESCRIPTION OF
Q
UAD
S
AFE
RM-4
Description
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RM-4 Installation and Operation Manual
— All safety-related machine control elements must be designed so that a fault in the
control logic or failure of the control circuit does not lead to a failure or danger.
— Additional guarding may be required for access to dangerous areas not covered by
the QuadSafe RM-4 module and safety device system.
— Perform the STI test procedure at installation and after maintenance, adjustment,
repair or modification to the machine controls, tooling, dies or machine, or the
QuadSafe RM-4 and safety device system.
— Perform only the test and repair procedures outlined in this manual.
— Follow all procedures in this manual for proper operation of the QuadSafe RM-4.
The enforcement of these requirements is beyond the control of STI. The
employer has the sole responsibility to follow the preceding requirements and any
other procedures, conditions and requirements specific to his machinery.
2 D ESCRIPTION OF Q UAD S AFE RM-4 2
2.1. D ESCRIPTION
The QuadSafe RM-4 provides protection for machines with more than one
opening to guard. It produces a single pair of OSSD (OSSD A, OSSD B) safety
outputs by receiving safety and auxiliary outputs from up to four STI 4600 family
of light curtains. The QuadSafe RM-4 is enclosed in a 3"W X 5.8"L X 4.3"H DIN
box with two rows of removable terminal blocks. The mode and configuration DIP
switches are located inside the box. For DIP switch settings, see
“Section 4.3.”
on
page 13.
The QuadSafe RM-4 module works with up to four independent safety sensing
devices identified as safety device 1, safety device 2, safety device 3, and safety
device 4. Each safety sensing device (light curtain) has two solid-state, current
sourcing type OSSD outputs identified as OSSD 1 and OSSD 2. The OSSD signals
conform to 24 VDC indicating Machine Run and 0 VDC indicating Machine Stop.

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D ESCRIPTION OF Q UAD S AFE RM-4
Response Time
QuadSafe RM-4 Installation and Operation Manual
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The QuadSafe RM-4 is primarily intended to work with the 4600 family of light
curtains, but it can operate with other safety devices that test its OSSD output,
including the following other STI products: the MC4700 Light Curtain and the
BeamSafe II solid state unit (BS2RC24).
For the QuadSafe RM-4 to act as the primary safety device, the safety devices used
with the QuadSafe RM-4 module must be configured in the Automatic Start mode
and have their MPCE function disabled. The QuadSafe RM-4 also provides
connection for the safety device power, auxiliary, and start signals.
2.2. R ESPONSE T IME
The response time is less than 1 msec. The response time is measured from the
time when any safety device transitions to the MACHINE STOP state to the time
that the QuadSafe RM-4 OSSDs are in the OFF state. The QuadSafe RM-4 controls
it’s OSSDs according to the state of the safety device OSSD inputs. The QuadSafe
RM-4 outputs are only active when all the selected safety device OSSD inputs are
active.

Q
UAD
S
AFE
RM-4 T
OP
L
ABEL AND
I
NDICATORS
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RM-4 Installation and Operation Manual
3 Q UAD S AFE RM-4 T OP L ABEL AND
I
NDICATORS 3
3.1. Q UAD S AFE RM-4 D IN C ONTROLLER L ABEL
Figure 3-1 QuadSafe RM-4 Top Label
RM-4 QuadSafe
R
Lift Tab to Remove Lid
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
XMTR-2 XMTR-1 RCVR-1
RCVR-3
Input PowerMPCE Fault
Drain
0 VDC
+24 VDC Start
+24 VDC
0 VDC
Drain Drain
0 VDC
+24 VDC
Start
+24 VDC
0 VDC
Drain
XMTR-3 RCVR-4 XMTR-4 Output
+24 VDC
0 VDC
Drain Drain 0 VDC +24 VDC Start Drain 0 VDC +24 VDC Return MPCE In Start In
ST
Lamp
11
12
1314151617181920212223
RCVR-2
123
4
57
8
+24 VDC
0 VDC
Drain
+24 VDC
0 VDC
69102425
26
27
Diagnostic
Interlock
Machine Stop
Machine Run
y to
!
WARNING SAFETY DEVICE
Do not defeat or bypass. Severe injur
personnel could result.
Device #3 Clear Device #4 Clear
Device #1 ClearDevice #2 Clear
Start
Power
Diagnostic Codes: (see manual)
– 00: no faults
– 01: waiting for Start Input
– 2x: DIP switch fault
– 3x: OSSD fault
– 4x: MPCE fault
– 50: internal RM-4 fault
Auxiliary
OSSD 1 OSSD 2 OSSD 1 OSSD 2
Auxiliary
Auxiliary Auxiliary
OSSD 2 OSSD 1 OSSD 2 OSSD 1
OSSD B OSSD A
RM4-Aux
Aux-1
Aux-2 Aux-3
Aux-4
Control

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OPERATING AND WIRING INSTRUCTIONS
Configuration of 4600 Light Curtains
QuadSafe RM-4 Installation and Operation Manual
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4 O PERATING AND W IRING
I
NSTRUCTIONS 4
4.1. CONFIGURATION OF 4600 LIGHT CURTAINS
Configure each 4600 light curtain as follows:
• Set DIP switches A and B:
— Positions 1 and 2 to ON (Automatic Start)
— Position 3 to ON (MPCE inactive)
— Positions 4, 5, and 6 as required (Exact Channel Select and Floating Blanking)
• Connect each light curtain MPCE wire (pink) to the ground (0 VDC)
• Connect the conductors of the 4600 transmitter and receiver cables to a 10-
position terminal block as described in 4.2.Wiring Connections.
4.2. WIRING CONNECTIONS
4.2.1 REMOVABLE TERMINAL BLOCKS ARE DIVIDED AS FOLLOWS:
• Each light curtain receiver and transmitter is connected to a 10 position terminal
block.
• Power supply inputs, control input & lamp out are connected to a 7 position block.
• Outputs are connected to a 7-position terminal block.
4.2.2 T HE LIGHT CURTAINS MUST BE CONNECTED TO THE Q UAD S AFE RM-4 USING SPECIFIC
TERMINALS :
• one light curtain - connect to RCVR-1 terminals
• two light curtains – connect to RCVR-1 and RCVR-2 terminals
• three light curtains – connect to RCVR-1, RCVR-2, and RCVR-3 terminals

OPERATING AND WIRING INSTRUCTIONS
Wiring Connections
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4.2.3 THE CONNECTIONS TO THE QUADSAFE RM-4 TERMINAL BLOCKS ARE
SPECIFIED IN THE TABLE BELOW:
Table 4-1 Function Pin Assignment
PIN # FUNCTION ASSIGNMENT PIN # FUNCTION ASSIGNMENT
1 PE 54 OSSD A
2
Power Supply Input 0 VDC 53 OSSD B
3 +24 VDC 52 RM4-AUX
4 MPCE In 51 Outputs Aux-1
5 Control Input Return 50 Aux-2
6 Start In 49 Aux-3
7 Lamp Out Start Lamp Out 48 Aux-4
8 Drain 47 Drain
9 0 VDC 46 XMTR-4 0 VDC
10 +24 VDC 45 +24 VDC
11 RCVR-1 Start 44 OSSD 1
12 Auxiliary 43 OSSD 2
13 OSSD 2 42 Auxiliary
14 OSSD 1 41 RCVR-4 Start
15 +24 VDC 40 +24 VDC
16 XMTR-1 0 VDC 39 0 VDC
17 Drain 38 Drain
18 Drain 37 Drain
19 0 VDC 36 XMTR-3 0 VDC
20 +24 VDC 35 +24 VDC
21 RCVR-2 Start 34 OSSD 1
22 Auxiliary 33 OSSD 2
23 OSSD 2 32 Auxilliary
24 OSSD 1 31 RCVR-3 Start
25 +24 VDC 30 +24 VDC
26 XMTR-2 0 VDC 29 0 VDC
27 Drain 28 Drain

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OPERATING AND WIRING INSTRUCTIONS
Wiring Connections
QuadSafe RM-4 Installation and Operation Manual
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Figure 4-1 Connecting the RM-4 to Three Light Curtains
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54
XMTR-2 XMTR-1 RCVR-1
RCVR-3
Drain
0 VDC
+24 VDC Start
+24 VDC
0 VDC
Drain Drain
0 VDC
+24 VDC
Start
+24 VDC
0 VDC
Drain
XMTR-3 RCVR-4 XMTR-4 Output
+24 VDC
0 VDC
Drain Drain 0 VDC +24 VDC Start Drain 0 VDC +24 VDC Return MPCE In Start In
ST
Lamp
11
12
1314151617181920212223
RCVR-2
123
4
57
8
+24 VDC
0 VDC
Drain
+24 VDC
0 VDC
69102425
26
27
Start
Power
Auxiliary
OSSD 1 OSSD 2 OSSD 1 OSSD 2
Auxiliary
Auxiliary Auxiliary
OSSD 2 OSSD 1 OSSD 2 OSSD 1
OSSD B OSSD A
RM4-Aux
Aux-1
Aux-2 Aux-3
Aux-4
Control
RM-4
XMTR
XMTR
RCVR RCVR
+24VDC Supply
+
Return
+24VDC MPCE In
Start Switch
Start Required Lamp
+24VDC
XMTR
RCVR
**
**
MPCE In
** Normally Closed contacts
* Normally Closed momentary contact switch.
*

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Wiring Connections
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Figure 4-2 Connecting the RM-4 to BeamSafe

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OPERATING AND WIRING INSTRUCTIONS
Wiring Connections
QuadSafe RM-4 Installation and Operation Manual
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Figure 4-3 Connecting RM-4 to MS4600 Series Light Curtain

OPERATING AND WIRING INSTRUCTIONS
Wiring Connections
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RM-4 Installation and Operation Manual
Figure 4-4 Connecting to MC4700 Series Light Curtain with LCM-1 Controler.

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OPERATING AND WIRING INSTRUCTIONS
Setting QuadSafe RM-4 Configuration Switches
QuadSafe RM-4 Installation and Operation Manual
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4.3. SETTING QUADSAFE RM-4 CONFIGURATION SWITCHES
The following table defines the setting of the redundant 7-position DIP switches
(labeled SWA and SWB) used on the QuadSafe RM-4 module to select from the
configuration options.
4.3.1 ACCESS TO CONFIGURATION SWITCHES
Switches to configure the QuadSafe RM-4 system operating features are located
inside the controller. Access is gained by lifting the controller cover tab provided
on the label.
WARNING! Isolate power before removing controller cover.
4.3.2 FIELD CONFIGURATION SWITCH SETTINGS
Function SelectionDescription
Switch Function Selection Description
1
2
Operating Mode Automatic: 1=Closed, 2=Closed
Start Interlock:: 1=Closed, 2=Open
Invalid:1=Open, 2=Closed
Start/Restart Interlock:1 =Open,2=Open
3 MPCE Monitoring Enabled = Open
Disabled = Closed
4
5
Number of Light Curtains One device: 4 = Closed, 5 = Closed
Two devices: 4 = Closed, 5 = Open
Three devices: 4 =Open, 5 = Closed
Four devicess: 4 = Open, 5 = Open
6 QuadSafe RM-4 Auxiliary
Output Mode
Follow OSSD indication =Closed
Fault Indication =Open
7 QuadSafe RM-4 Auxiliary
Output Type
Current Source (PNP) = Closed
Current Sink (NPN) = Open
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General Considerations
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RM-4 Installation and Operation Manual
4.4. GENERAL CONSIDERATIONS
4.4.1 INPUT POWER REQUIREMENTS/CONNECTIONS
The QuadSafe RM-4 system operates directly from 24 VDC ±10%. Power to the
QuadSafe system must come from a dedicated power supply which must meet the
requirements of IEC 60204-1 and IEC 61496-1, STI part number 42992 or
equivalent.
4.4.2 START REQUIRED LAMP
When connected, the Start Required Lamp indicates when the QuadSafe RM-4
module is waiting for a signal from the start switch. The Start Required Lamp is
an option and is not required for operation of the QuadSafe RM-4.
4.4.3 SYSTEM COMMON RETURN
The QuadSafe RM-4 power input return must be connected to the overall system
component returns. At the installation site, the power return of the QuadSafe RM-
4 Start switch, MPCE monitor, Start Required lamp, OSSD loads and Aux loads
must all be connected in common for proper system operation.
4.4.4 MPCE MONITORING SET TO DISABLED
When MPCE monitoring is set to the inactive position, the MPCE In terminal
block, contact 4, must be connected to the system common return.

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SYSTEM OPERATION
Operating States
QuadSafe RM-4 Installation and Operation Manual
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5 S YSTEM O PERATION 5
The QuadSafe RM-4 module receives ouputs from up to four safety devices and
produces a single pair of OSSD outputs. The system consists of a DIN box with
two rows of removable terminal blocks, and is wired to up to four safety devices.
5.1. OPERATING STATES
The Output Signal Switching Devices (OSSD A and OSSD B) are QuadSafe RM-4
components that connect to the machine control system. When a safety device
detection zone is interrupted, the QuadSafe RM-4 OSSD responds by going to the
off state.
The operating condition of an QuadSafe RM-4 safety device system is described in
terms of states. The following operating states exist for the QuadSafe RM-4
module.
5.1.1 MACHINE RUN
The green MACHINE RUN indicator is lit, the OSSD outputs are on, and the
AUXILIARY output responds in a manner consistent with its set operating mode.
The protected machine is allowed to operate. Pressing and releasing the START
button has no effect.
5.1.2 MACHINE STOP
The red MACHINE STOP indicator is lit, the OSSD outputs are off, and the
AUXILIARY output is off. The protected machine is not allowed to operate.
Pressing and releasing the START button has no effect.
5.1.3 INTERLOCK
The yellow INTERLOCK indicator is lit, and the Start Required Lamp output is
on. The AUXILIARY output is off. The INTERLOCK state does not allow the
protected machine to operate until the START button is pressed and released.

SYSTEM OPERATION
Operating States
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5.1.4 LOCKOUT (FAULT)
The yellow INTERLOCK indicator is blinking, and the Start Required lamp is
blinking. The AUXILIARY output responds in a manner consistent with its set
operating mode. This state does not allow the protected machine to operate until
the fault is removed and the START button is pressed and released or power is
cycled.
Table 5-1 QuadSafe RM-4 operating states and corresponding outputs
Output
Machine
Run
Machine
Stop Interlock Lockout
Green LED: Machine
Run
On Off Off Off
Red LED: Machine Stop Off On On On
Yellow LED: Interlock Off Off On Blinking
Start Required Lamp
Output
Off Off On Blinking
OSSD A Output On Off Off Off
OSSD B Output On Off Off Off
QuadSafe RM-4
Auxiliary Output:
– Follow OSSD
Indication Mode
On Off Off Off
– Fault Indication Mode Off Off Off On

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CABLE LENGTHS
Input Signal Cable Lengths
QuadSafe RM-4 Installation and Operation Manual
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6 C ABLE L ENGTHS 6
6.1. INPUT SIGNAL CABLE LENGTHS
— Safety Device OSSD inputs: Use 20 AWG shielded wire with cable capacitance < 100
pF/ft., max length 60m (198 ft)
— MPCE Monitor input: Use 22 AWG unshielded wire, max length 10m (33 ft)
— Start input: Use 22 AWG unshielded wire, max length 60m (198 ft)
6.2. OUTPUT SIGNAL CABLE LENGTHS
— OSSD A and OSSD B outputs and return: Use 20 AWG unshielded wire with cable
capacitance < 100 pF/ft., max length 10m (33 ft)
— QuadSafe RM-4 Auxiliary outputs (PNP Out and NPN Out): Use 20 AWG unshielded
wire, max length 10m (33 ft)
— Start Required lamp output: Use 20 AWG unshielded wire, max length 60m (198 ft)

SAFETY DISTANCE
Output Signal Cable Lengths
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RM-4 Installation and Operation Manual
7 S AFETY D ISTANCE 7
WARNING! Never install a QuadSafe RM-4 safety device system without regard
to the safety distance. If the safety devices connected to the QuadSafe RM-4
system are mounted too close to the point of operation hazard, the machine
may not stop in time to prevent an operator injury.
A safety device system must be mounted far enough from the machine danger
zone so the machine will stop before a hand or other body part reaches the
hazardous area. This distance is called the safety distance. It is a calculated
number based on a formula. See the user’s manual for the 4600, 4700 or
BeamSafe safety device for safe mounting distance formulas.
▲
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