STI BS3-C User manual

BS3-C/L Safety Sensor System
Installation and Operating Manual
Scientific Technologies Inc.
Optical Sensor Division
Manufacturing and Sales Office
6550 Dumbarton Circle
Fremont CA 94555-3605 USA
1 / 888 / 510-4357
Tel: [phone]
Fax: [phone]
www.sti.com
© STI 1203 PN99306-0020 Rev. B
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BeamSafe BS3-C/L Safety Sensor System
Table of Contents
Section 1— Important Safety Messages . . . . . . . . . . . . . . . . page 2
Section 2—
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 4
Section 3—
BS3-C/L System Description . . . . . . . . . . . . . . . page 9
Section 4—
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Section 5—
Mechanical Mounting . . . . . . . . . . . . . . . . . . . . page 12
Section 6—
Electrical Installation . . . . . . . . . . . . . . . . . . . . page 13
Section 7—
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Section 8—
Diagnostics, Maintenance & Warranty . . . . . . page 20
Section 9—
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . page 23
Section Appendix A—
— Checkout Procedure Log . . . . . . . page 33
Section Appendix B—
— Test Procedure . . . . . . . . . . . . . . . page 34

IMPORTANT SAFETY
MESSAGES
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1 I MPORTANT S AFETY M ESSAGES 1
The BS3-C/L and associated sensors are an active opto-electronic protection
device (AOPD). The safety module BS3-C/L meets the requirements of the IEC
1496 (prEN 50100) and is certified to safety category 4.
A single-beam safety light switch is designed to guard dangerous areas working
areas on machinery. The BS3-C/L Sensor AOPD system must not be used for
point-of-operation guarding. The point of operation is defined as “
the location in
the machine tool where material is positioned and a process performed.
”
The primary task of the BS3-C/L is to enhance the safety of both the operator of
the dangerous machinery and other persons nearby.
Whether a specific machine application and BS3-C/L Sensor installation fully
complies with safety regulations depends on several items, including: the proper
application, installation, maintenance and operation of the BS3-C/L Sensor
system. These items are the sole responsibility of the purchaser, installer and
employer.
The employer is responsible for the selection and training of the personnel
necessary to properly install, operate and maintain the machine and its
safeguarding systems. The BS3-C/L Sensor must only be installed, checked out
and maintained by a qualified person, defined as “
a person or persons who, by
possession of a recognized degree or certificate of professional training, or who,
by extensive knowledge, training and experience, has successfully demonstrated
the ability to solve problems relating to the subject matter and work.
” (ANSI
B30.2-1983)
The following is a list of additional requirements which must be met before using
the BS3-C/L Sensor system:
• Never use a BS3-C/L Sensor system for point-of-operation guarding. The point-of-
operation is defined by ANSI as “ The location in the machine tool where material
is positioned and a process performed ”.
• Additional guarding such as mechanical guards may be required if the BS3-C/L
Sensor system does not protect all points of entry into the hazardous area.

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I
MPORTANT
S
AFETY
M
ESSAGES
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• The machine on which the BS3-C/L Sensor system is installed must be capable of
stopping motion anywhere in its stroke or cycle. Do not use a BS3-C/L Sensor
system on a power press with a full-revolution clutch.
• Do not use an BS3-C/L Sensor system:
— where the guarded machine presents a hazard from flying parts.
— where the guarded machine has inconsistent stopping times or inadequate control
devices or mechanisms.
— where the environment, such as severe smoke, particulate matter, or corrosive
chemicals may degrade the efficiency of the BS3-C/L Sensor system.
• When a BS3-C/L Sensor system is used as a safety device, the employer has the
responsibility to ensure that all applicable federal, state and local requirements
and other such rules, codes and regulations are satisfied.
• All safety-related machine control circuit elements, including pneumatic, electric
or hydraulic controls must be control reliable. Control reliable is defined as:
“
...the device, system or interface shall be designed, constructed and installed
such that a single component failure within the device, interface or system
shall not prevent normal stopping action from taking place, but shall prevent
a successive machine cycle...
”
• All brakes, other stopping mechanisms and controls must be in proper working
order. If the machine stop mechanisms and associated controls are not working
properly, the machine may not stop safely even though the BS3-C/L/Sensor system
is functioning properly.
•The STI test procedures must be performed after any maintenance is performed on
the machine controls or on the BS3-C/L Sensor system. The test procedure is
contained in this manual. The user must perform (at least every three months,
more often with continuous use) the preventive maintenance procedures
recommended in this manual.
• Do not perform any test or repairs other than those outlined in this manual.
• The user must follow all procedures in this manual for proper operation of the
BS3-C/L Sensor system.
The enforcement of these requirements is beyond STI’s control. The employer
has the sole responsibility to follow the preceding requirements and any other
procedures, conditions and requirements specific to his machinery.

INTRODUCTION
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2 I NTRODUCTION 2
2.1. T HEORY OF O PERATION
A BS3-C/L Sensor system is a single-beam infrared safety control. A BS3-C/L
Sensor system employs up to two separate sets of single-beam safety sensors
connected to a central control module. Interruption of a beam sends a stop signal
to the guarded machine. The BS3-C/L Sensor system design provides control
reliable operation.
The BS3-C/L controller has been designed to meet industrial demands for
flexibility and includes the following features:
• DIN rail mounting
• Short-circuit protected sensor power supply
• Manual or automatic reset
• Prepared for muting (with optional module)
2.1.1
A
REAS OF
A
PPLICATION
:
The unit can be connected to various machinery such as:
• Robotic Systems
• Cutting Machines
• Revolving Machines
• Conveyor Systems
• Production Lines
• Graphic Machinery
• Sample installation shown in the following page.

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NTRODUCTION
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Figure 2-1 BeamSafe III Application
IMPORTANT! Please read this manual completely before beginning
installation. Installation and maintenance must be performed by qualified
personnel. Machine operator safety training is also important.
BeamSafes
Hard Guarding
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INTRODUCTION
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2.2. T ECHNICAL S PECIFICATIONS
2.2.1
BS3-C/L C
ONTROLLER
Table 2-1 BS3/L Controller
Supply Voltage 24VDC ±20%
Power Consumption 600 mA with two sets of sensors connected
Enclosure Rating IP20
Max. Conductor Area 2 x 1.5 mm
2
with end sleeve, 2 x 2.5 mm
2
with
solid connectors
Safety Relay Outputs
Response Time
Max. Switching Frequency
Max. Switching Voltage
Max. Switching Current
Max. Switching Power
Min. Switching Current
Two potential free change-over N.O. outputs
each protected with 4A fuse
< 30 mS relays with force guided contacts
1/s
DC 60V, AC250V
2A
50W, 500VA
20 mA
Auxiliary (Non-Safety) Outputs
Max. Switching Voltage
Max. Switching Current
Two potential-free opto-coupler outputs
DC 30V
30 mA
Inputs Two sensors, two manual reset, two automatic
reset, two MPCE test
Diagnostics Two red-green LED
Safety Category Type 4, self-monitoring system
Requirements IEC 61496-1, -2; prEN 954-1
Operating Temperature 0° to + 55°C (32 to 131°F)
Storage Temperature -25° to +55°C (-13 to 131°F)
Weight Approx. 300g (0.7 lbs)
22
BS3-C
Sensor 2 Sensor 1
Out A Out B
17 18 19 20 21
28
23 24
25 26 27 29 30 31 32
22
17 18 19 20 21
28
23 24
25 26 27 29 30 31 32
Status
6
12345 78
14
910 11 12 13 15 16
6
1234 578
14
910 11 12 13 15 16
R
58.9
2.32
71.6
2.82
89.9
3.54
SIDE VIEW TOP VIEW
43.6
1.72

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NTRODUCTION
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Figure 2-2 BS3-C Mechanical Drawing
2.2.2 B EAM S AFE BS3-X/BS3-R S ENSOR S ET
Table 2-1 BS3-X/BS3-R Sensor Set
Figure 2-3 BeamSafe III-C Sensor Mechanical Drawing
Operating Range
14m (45 ft.)
Reversed Polarity
Protected
Yes
Short Circuit Protection
Yes
Maximum Cable
100 m
Angle of Aperture
<± 2°
LIght Source
Light Emitting Diode 880nm
Sensitivity Adjust
Two turn with indicator
Environmental Rating
IP67
Operating Temperature
-20° to 60°C (10 to 143°F)
Weight
60 g (0.14 lbs)
Specifications are subject to change without notice.
17
46 44
16
13.5
4M12 x 1
4.3
4
50
2
44
40
4
4.3
1
50
27.5
17
46 44
16
13.5
4M12 x 1
4.3
4
50
2
44
40
4
4.3
1
50
27.5
34

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2.2.3 BEAMSAFE III-L SENSORS
Figure 2-4 BS3-L Mechanical Drawing
Operating Range 25m (82 ft.)
Reversed Polarity
Protected Yes
Short Circuit Protection Yes
Maximum Cable 30 m
Angle of Aperture <± 2°
LIght Source Red laser, 650 mm, class 1 per EN60825-1
Connection 4-pole M12 connectors
Environmental Rating IP67
Housing Material ABS
Operating Temperature -10° to 50°C (14 to 122°F)
Weight 30 g (0.066 lbs)
Specifications are subject to change without notice.
8
0.31
4
0.16
22
0.87
23.4
0.92
1.5
0.06
R2.1
0.083
Ø15
0.59
Ø18.2
0.72
R2.1
0.083
30°
Stability LED
BS3L-SV18BS3L-MP18BS3L-SP18
Output LED 3.9
0.154
42.5
1.67
18
0.71
Mx1
M18
M12
Ø16.6
0.654
Ø16.6
0.654
66
2.6
18.8
0.74
45
1.77
28
1.10
7
0.28
31
1.22
16
0.63
5
0.2
9.5
0.374
1.3
0.05
7
0.28
6
0.24
14
0.55
2
0.08
5
0.2
50
1.97
50
1.97
30
1.18
42
1.65
30
1.18
28
1.10
34
1.34 44
1.73
55
2.17
4.2
0.166
18
0.71
20.3
0.8
10.5
0.413
1
0.04
38.3
1.51
5.5
0.216

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BS3-C/L SYSTEM DESCRIPTION
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3 BS3-C/L S YSTEM D ESCRIPTION 3
3.1. BEAMSAFE III SENSOR DESCRIPTION
Via the transmitter, the BS3-C/L controller sends out a pulsed, coded light.
Figure 3-1 BeamSafe III-C & L Sensor Transmitter and Receiver
If the light is not interrupted, it will be received by the receiver which sends the
detected pulses back to the BS3-C/L controller. The BSC-3 controller contains
redundant circuits which monitor each other and the system. If a critical
component should fail, or if a cable is damaged, this will be detected and a stop
signal will be sent to the guarded machine.
A reset function in the BS3-C/L blocks its outputs after an interruption in the
safety light field and after power up. In order to have a new machine run signal,
activation by an external reset button is necessary.
Transmitter Receiver
Transmitter Receiver

INSTALLATION
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4 I NSTALLATION 4
WARNING: Read this information as well as the Important Safety Message at
the front of the manual completely before starting the installation procedure. A
BS3-C/L Sensor system should only be installed, checked-out, and maintained
by a qualified person (as defined in section 1). It is important that the user be
familiar with the installation requirements, safe mounting distance, controls
and features before using a BS3-C/L Sensor system.
4.1. USER RESPONSIBILITY
The user has the responsibility to perform all testing (as outlined in appendix A and B)
and maintenance as required by STI on the BS3-C/L Sensor system and to insure that
the guarded machine is properly tested, guarded and inspected as specified by its
manufacturer.
4.2. SAFETY DISTANCE
The optical sensors of the BS3-C/L must be installed so that an interruption of the
sensing beam, during dangerous motion, results in the machine stopping before
the area can be reached by the affected personnel.
This implies that there must be a fixed safety distance between the nearest point
of hazardous operation and the BS3-C/L’s sensing beam.
Figure 4-1 Safety Distance
4.3. STOPPING PERFORMANCE
The overall system stopping performance is the exact time, in seconds, it takes
from the interruption of the sensing beam until the dangerous movement of the
machine has stopped completely.
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INSTALLATION
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4.4. CALCULATING THE SAFETY DISTANCE
WARNING: The proper calculation of the safe mounting distance is an
important installation step. Never just install a BS3-C/L Sensor system at any
convenient location without regard to the safety distance. If the transmitter
and receiver are mounted too close to the point of hazardous operation, the
machinery may not stop in time to prevent operator injury.
The best information available on safe mounting distance and mounting height
comes from the preliminary European standard prEN999:1997. Where the risk
assessment allows a single-height beam to be used alone, then the minimum
distance shall be calculated using the following formula:
S = (K x T) + C
Where:
S = the minimum distance from the danger zone to the detection point, line,
plane or zone in mm;
K = Approach Sppeed
— Mutiple Beams: 1600 mm/s
— Single Beams: 1600 mm/s
T = the overall system stopping performance. T must include the response time
of controls, clutches, braking systems and the BS3-C/L Sensor system (30mS)
and the time for the machine to cease hazardous motion.
C = Additional distance
— Mutiple Beams: 850 mm
— Single Beams: 1200 mm
When using a single beam, a mounting height of 750mm from the ground or
reference plane has been found in industry to be a practical solution to the
problems of inadvertent access from stepping over or bending under the beam.
When two beams are employed, industry experience suggests that mounting
heights of 400 mm and 900 mm are practical.
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MECHANICAL MOUNTING
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5 M ECHANICAL M OUNTING 5
WARNING: conditions below must be fulfilled to ensure a proper
installation:
The danger area must only be accessible through the safety beam of the optical
sensors.
The safety distance must be fulfilled.
Additional mechanical guarding must always be installed according to valid
regulations.
5.1. MOUNTING THE BS3-C/L CONTROLLER
The BS3-C/L controller is designed to be mounted on a standard 35mm DIN rail.
It should be installed in such a way that any risk of cable damage is minimized.
5.2. MOUNTING THE OPTICAL SENSORS
Both the sensor transmitter and receiver can, depending on applications, be
mounted directly to the machinery or may be mounted to a suitable floor stand.
The sensors should be mounted so that the fixing screws are easy to reach in
order to ease alignment.
When mounting, it is important to secure the sensors so that their horizontal and
vertical alignment cannot be disturbed by vibration. The conditions below must
be fulfilled:
– The light beam of the transmitter must be received only by its own receiver (in
cases where two sensors are operating).
–The light beam must not be reflected by any bright or otherwise reflective
surface.
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6 E LECTRICAL I NSTALLATION 6
Connect cables between the optical sensors and the BS3-C/L controller and, if
used, between the reset buttons and the BS3-C/L.
The maximum wire cross sections are:
• 1.5 mm2with end sleeve
• 2.5 mm2solid conductor
Two wires can be connected to each terminal of the BS3-C/L.
6.1. POWER SUPPLY
Check that the power supply corresponds to the technical data of the BS3-C/L.
The supply voltage is to be connected to terminals 1 or 8 (0V) and 25 or 32
(+24VDC +20%).
6.2. SENSOR SUPPLY
When the BS3-C/L is supplied with 24VDC it supplies the connected sensors with
a short-circuit protected supply voltage.
6.3. SENSOR INPUTS
The BS3-C/L controller provides “dynamic” monitored inputs for two sets of
sensors. See Figure 6-1 for connection details.
• T= Transmitter
• R= Receiver
6.3.1 SINGLE SENSOR
If a single transmitter and receiver are used the BS3-C/L must be set to the single
sensor mode by placing a jumper between terminals 2 and 3. See Figure 6-1. The
single sensor mode can only be set if the second sensor is not wired.
Connect the transmitter input to terminal 14 and the receiver output to terminal
6.

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6.3.2 DUAL SENSORS
Connect the test input of the transmitter 1 to terminal 14, and transmitter 2 to
terminal 11. See Figure 6-1.
The output of receiver 1 is wired to terminal 6 and of receiver 2 to terminal 3 of
the BS3-C/L.
Figure 6-1 Single or Double set of Sensors
6.4. SAFETY OUTPUTS
To connect the BS3-C/L to the machine control system the two potential-free
safety change-over relay outputs must be used. See Figure 6-2.
The machine control system must be wired to the supply of the control element
which will stop any dangerous movement of the machine.
The BS3-C/L has a response time of <30ms. There is a soldered fuse for each relay
output to protect against high current peaks.
T1 14 6 R1 412 11 32
T1 14 6R1412 11 3
T2 R2

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ELECTRICAL INSTALLATION
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Figure 6-2 Fused Safety Change-Over Relay Outputs
WARNING: Always use arc suppression of the RC circuit or varistor type for
the control elements (MPCE). Diodes may cause a delay.
6.5. SIGNAL OUTPUTS
The two opto-coupled signal outputs can be used for communication to a PLC to
indicate that the BS3-C/L has been reset. See Figure 6-3. These outputs are not
for safety.
Maximum capacity for each output is 30VDC and 30mA.
6.5.1 SEPARATE OUTPUTS
Separate signal (non-safety) outputs is a mode in which each output operates by
following its own sensor. Output A follows sensor 1, output B follows sensor 2.
See Figure 6-3.
Separate signal outputs will always operate if two sets of sensors are connected.
19 18 26 27 31 30 22 23
F2 F3
Relay A Relay B
Maximum Load 2A
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Figure 6-3 Signal Output
6.5.2 PARALLEL OUTPUTS
Parallel signal (non-safety) outputs is a mode in which both outputs follow the
single sensor connected.
Parallel signal outputs will always operate if one set of sensors is used.
6.6. RESET FUNCTION
The internal “reset function” blocks the outputs of the BS3-C/L after an
interruption of the safety light beam, after a power on or if the power supply is
failing.
6.6.1 MANUAL RESET
Manual reset is a mode in which the operator must verify that the dangerous area
of the machine has been cleared from all personnel by pressing a button for 0.5
sec.
After the “press and release” of an external reset button, the BS3-C/L activates its
outputs.
If one set of sensors is used, a single reset button will reset the BS3-C/L. See
Figure 6-4.
20
28 21 29
Output B
Output A
Micro Micro
BS3 Signal Output
0 V
Signal
+24 V +24 V
0 V
Sensor 1 Sensor 2
Signal

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ELECTRICAL INSTALLATION
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Figure 6-4 One Reset Button
When two sets of sensors are used, one or two reset buttons can be connected.
When two reset buttons are used, each button will reset its own sensor. See
Figure 6-5.
NOTICE: The reset button must not be able to be reached from the danger
area. The person resetting must have a clear view of the danger area.
Figure 6-5 Two Reset Buttons
6.6.2 AUTOMATIC RESET
Automatic reset is a mode in which the outputs of the BS3-C/L will be activated
as soon as the interrupted safety beam of the connected sensor is no longer
interrupted.
If automatic reset is used, the BS3-C/L must be set to the automatic mode using
two jumpers. One jumper between terminals 9 and 17 (output A) and the other
between terminals 16 and 24 (output B). See Figure 6-6.
NOTICE: If the automatic reset mode is set, the manual reset mode will no
longer operate.
4513
12
G+ G–
>0,5 s
L1 + L2
4513
12
G+ G–
>0,5 s
L1
>0,5 s
L2

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Figure 6-6 Jumper Settings for Automatic Reset
6.7. MPCE TEST INPUTS
The BS3-C/L provides two machine primary control elements (MPCE) test inputs
for monitoring external control contact elements (MPCE). See Figure 6-7.
One normally closed contact from each contact element is to be connected to the
BS3-C/L.
Should the external contact elements not return to their normal positions the
BS3-C/L will detect this and not allow itself to be reset until the fault is corrected.
Since there is a simultaneous action between the two test inputs, both MPCE
must be activated within 500mS.
Ensure that MPCE A will be connected to test input A and MPCE B to test input B,
otherwise the safety function will be out of order.
Figure 6-7 MPCE Test Output
NOTICE: Terminal 2 must be wired to terminal 10 and terminal 7 to terminal
15, if not used for monitoring as stated above.
917 24 16
0 V +24 V
Channel A Channel B
210 15 7
MPCE A MPCE B

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LED INDICATORS
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7 LED I NDICATORS 7
The BS3-C/L has LED indicators for each set of sensors, each relay output and for
the status of the power supply.
The Sensor 1 light will give information about sensor 1 and the Sensor 2 light
about sensor 2. If sensor 2 is not used, the sensor 2 light will be off.
When a sensor is connected and exactly aligned, its LED will start to blink with a
green light. See Figure 7-1.
This blink indicates that the actual sensor is prepared and waiting for a reset
button to be activated. When a sensor has been reset, its LED will change to a
stable green light.
Out A and Out B are red-green LEDs indicating the actual state of the output
relays. A red light indicates off and a green light indicates on.
The status LED indicates the actual status of the internal power supply. If no
short-circuit appears the LED will be green. If a short-circuit is detected, it will
turn to red.
Figure 7-1 Indicators of the BS3-C/L
Sensor 2 Status Sensor 1
12 3 45 67 8
910111213141516
17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
Out A Out B
BS3-C
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Scientific Technologies Inc.
Fremont, CA USA
Tel: [phone], Fax: [phone]
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Cat. 4 IEC61496