Wintriss Shadow VI User manual

Shadow VI
®
Safety Light Curtain
1107200
Rev. E July 2010
Tech Support Hotline [phone] EST
www.wintriss.com
®
®
Wintriss Controls Group, LLC
100 Discovery Way
Unit 110
Acton MA 01720 USA
Phone [phone]
Fax [phone]
PRINTED IN USA DA46072

Requirements You Must Meet When Installing and Using
Shadow Safety Light Curtains
DANGER
!
FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID-
STROKE OR MID-CYCLE
•DO NOT use Shadow safety light curtains on full-revolution clutched machinery or other equipment that cannot be stopped
at any point in its stroke or cycle.
•Use Shadow safety light curtains only on machinery that can be stopped at any point in its stroke or cycle.
Failure to comply with these instructions will result in death or serious injury.
DANGER
!
IMPROPER INSTALLATION, USE OR MAINTENANCE
•Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-supplied
replacement parts.
•Wire, install and maintain Shadow safety light curtain in accordance with OSHA lockout/tagout regulation 1910.147.
•Ensure that Shadow safety light curtain is installed, tested and repaired by qualified personnel.
•Ensure that all metal stamping presses on which Shadows are used meet the requirements and inspection procedures of
OSHA regulation 1910.217 and ANSI standard B11.1-2009, which govern the use of presence-sensing devices on metal
stamping presses. Ensure that all other machinery, or other devices on which Shadows are used, meet the general
machine guarding requirements in OSHA standard 1910.212 and any other regulations and standards that apply.
•Ensure that guarding is installed to prevent access to the machine over, under or around the light curtains.
•Test the operation of your Shadow safety light curtain daily using the checkout sequence shown on the Shadow safety
light curtain units and also listed in this manual. If your Shadow safety light curtain is installed so the warning and test
procedure labels are not clearly visible, call the factory for extra warning labels to affix to your machinery in a visible area.
•Perform the checkout sequence after any maintenance is done on the Shadow safety light curtain.
•Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, or any others responsible for the
proper operation of the machinery have read and understood all instructions for use of the Shadow light curtain.
Failure to comply with these instructions will result in death or serious injury.
DANGER
!
MACHINERY NOT CONFIGURED OR WORKING PROPERLY
•Ensure that the machinery and devices on which Shadow safety light curtains are used meet the general machine
guarding requirements of OSHA standard 1910.212 and any other regulations and standards that apply.
•Inspect all stopping mechanisms of the machinery regularly to be sure they work properly.
•DO NOT operate a machine equipped with Shadow safety light curtains if the machine or any of its stopping mechanisms
is not in proper working order.
Failure to comply with these instructions will result in death or serious injury.
DANGER
!
STOPPING MECHANISM FAILURE
•Install and maintain stopping mechanisms of machinery or other devices according to the applicable regulations or
standards.
•Regularly inspect all stopping mechanisms of the machinery to ensure proper functioning.
Failure to comply with these instructions will result in death or serious injury.
DANGER
!
OTHER EQUIPMENT CONTINUING TO OPERATE
•Equipment that operates with the machinery connected to Shadow safety light curtain may continue to operate after the
machinery has received a stop signal.
•Ensure that all operators and other affected personnel know which equipment is connected to Shadow safety light curtain
and which is not.
Failure to comply with these instructions will result in death or serious injury.
WARNING
!
ELECTRIC SHOCK HAZARD
Turn off and disconnect power from Shadow safety light curtain and from the machinery it is connected to before making
any wiring connections. This includes power to the machine control and motor.
Failure to comply with these instructions could result in death or serious injury.

Changes for Revision E of the
Shadow VI User Manual
(1107200)
This revision of the Shadow VI Safety Light Curtain User Manual covers Shadow VI models
with response times of 30 to 40 ms, maximum.
The changes include:
•The Remote Interrupt button has been removed from the Shadow VI Control board (see
page 44) , and, as a result, all references to the button have been removed from the
manual.
•AC power is now grounded to the set screw terminal on the Shadow VI enclosure rather
than to pin #3 on TB 1 (see page 51).
•The procedure for replacing Shadow VI safety relays has been updated. Instead of
replacing individual relays in the event of a relay failure, you now must replace the
Shadow VI Control board. See page 91.
•References to and excerpts from ANSI standards B11.1 and B11.19 have been updated to
their current versions, B11.1-2009 and B11.19-2003. See Appendix A.

Thank you for purchasing a Wintriss Product. We appreciate your business and want to do whatever
we can to ensure your satisfaction. Wintriss products are built to stay on the job day after day, and are
backed by an ironclad guarantee, international standards approvals, and unbeatable support. Whenever
you need assistance or service, we back all our products with excellent spare parts inventories, training
programs, and prompt repair service. We would like to share with you a list of service options–probably
the largest number of service options offered in the industry.
• Technical Assistance
We offer a toll-free line for technical assistance. Call our Wintriss Technical Support Hotline at
1-800-586-TECH (8324) should you have any questions about your equipment. Our technical
staff is ready to assist you Monday through Friday, 8 a.m. to 5 p.m. EST. In many cases our
experienced technical staff can resolve your inquiry right over the phone.
• Return Authorization
Please call our “800” number for a return authorization (RMA) number to return a product for
repair. Returned goods must arrive freight prepaid. In order to process your return quickly, we
ask that you provide us with the following pertinent information when you call: purchase order
number, shipping address, contact name and telephone number, and product type. The assigned
RMA number should appear on all packages returned to Wintriss Controls Group to ensure prompt
service.
At the time of requesting an RMA, you will be quoted a flat-rate repair price for the product you
are returning. We ask that you either fax us a PO for that amount or enclose the PO with the
returned item. This will enable us to ship the item back to you as soon as the repair has been
completed. If the item cannot be repaired or there are additional charges, you will be contacted for
approval.
Please be sure to carefully pack all returned items and ship to our Acton, MA location.
• Expedited Repair Program
Rush service providing 48 hour turnaround is available for most products upon request. An
Expedite Fee will be applied to our standard repair rate.
• Board Exchange Program
If your needs are urgent, you can take advantage of out Board Exchange (EX) program. Call our
“800” number between 8 a.m. to 5 p.m. EST and we will send a replacement to you overnight. A
fee does apply to this service. Contact Wintriss Technical Support at 800-586-8324 for details.
• Service Center
Our Service Center for product service is located at our headquarters in Acton, MA. If your
equipment requires repair, please contact us at 800-586-8324 to obtain a return authorization
number.
Nationwide field service is also available. Contact the Wintriss Technical Support group at
800-586-8324.
• Product Training
We also offer both product training and maintenance/troubleshooting courses at our Acton, MA
and Chicago-area facilities. On-site training is available from the factory or through your local
Wintriss representative.
• Restocking Charge
Returned goods are subject to a 20% restocking charge if returned for credit. The minimum charge
is $50, not to exceed $250 per item.
Whatever the product, we are committed to satisfying you with innovative engineering, quality
construction, reliable performance, and ongoing, helpful support. Call us whenever you need assistance.

Shadow VI User Manual 1107200
Table of Contents page i
Table of Contents
Chapter 1 – Introduction to Shadow®VI Safety Light Curtain ........................1
OSHA and ANSI Compliance....................................................................................................................2
About Shadow VI.......................................................................................................................................2
How Shadow Works...................................................................................................................................4
Shadow and Control Reliability .................................................................................................................6
Description of Shadow VI indicators .........................................................................................................7
At the Optic Heads.................................................................................................................................7
At the Control ........................................................................................................................................8
Inside the Control...................................................................................................................................8
Object Sensitivity .......................................................................................................................................8
Size and Scanning Distance........................................................................................................................8
Shadows Are Easy to Maintain ..................................................................................................................9
Shadow VI Features and Options.............................................................................................................10
Weld Shield Kit........................................................................................................................................11
Chapter 2 – Installation and Checkout............................................................15
Installation overview................................................................................................................................16
Calculating the safety distance........................................................................................................16
Mounting location for your Shadow transmitter and receiver ........................................................16
Wiring, aligning, mounting, and making proper settings................................................................16
Ensuring that the Shadow light curtains are working properly.......................................................16
Installation Procedure...............................................................................................................................17
Calculating the Safety Distance................................................................................................................18
OSHA and ANSI Requirements ..........................................................................................................19
The OSHA Safety Distance Formula..............................................................................................20
The ANSI Safety Distance Formula................................................................................................21
Perimeter Guarding.........................................................................................................................24
Blanking Windows Affect Safety Distance ....................................................................................24
Pass-through Protection ..................................................................................................................25
Height Considerations..........................................................................................................................26
Designing and Mounting Brackets...........................................................................................................26
Universal Mounts............................................................................................................................26
Mounting Location Requirements...................................................................................................27
How to Design and Mount Brackets or Floor Stands .....................................................................28
Alignment Considerations...............................................................................................................33
Maximum Openings for Side Guards .............................................................................................35
Using Mirrors with Shadows ..........................................................................................................36
Using Weld Shields.........................................................................................................................39
Mounting Shadow Light Curtains Upside Down............................................................................39
Avoiding Cross Talk When Mounting 2 Sets of Shadows .............................................................39
Loosely Mounting Shadow VI Transmitter and Receiver........................................................................40
Mounting the Control...............................................................................................................................42

1107200 Shadow VI User Manual
page ii Table of Contents
Connecting RF (Radio Frequency) Ground ....................................................................................42
Wiring the Transmitter and Receiver to the Control ................................................................................45
Terminating Shields of the Head Cables..............................................................................................46
Connecting the Head Cables to the Control.........................................................................................47
If You Have a Second Set of Shadow Optic Heads.............................................................................49
Connecting AC Wiring to the Control......................................................................................................50
Connecting Stop Circuits to the Control...................................................................................................52
8A. Wiring Shadow to the WPC (One or Two Control Boxes)......................................................55
8B. Wiring Shadow to a PLC..........................................................................................................56
Optional Wiring........................................................................................................................................57
Indicator Outputs..................................................................................................................................57
MPCE Monitor Inputs..........................................................................................................................58
Making Settings Inside the Control..........................................................................................................59
S1 settings............................................................................................................................................60
S4 Settings ...........................................................................................................................................60
J12 Setting............................................................................................................................................61
Plug in Connector and Replace Cover.................................................................................................61
Aligning and Tightening Down Shadow VI Components........................................................................61
Alignment Procedure ...........................................................................................................................62
Diagnostic Steps to Perform Before Using Shadow.............................................................................63
No Power to Unit ............................................................................................................................63
The Light Curtain Is in a "Reset Required" Condition....................................................................63
If the Transmitter Has No Power or Is Not Functioning.................................................................63
Check Power and Indicator Lights..................................................................................................63
Check Lens Window.......................................................................................................................64
Bring Shadow Heads Close Together .............................................................................................64
Green Light On ...............................................................................................................................64
No Green Light ...............................................................................................................................65
If You Have Two Sets of Shadow Heads........................................................................................65
Green Light On But Still Cannot Start Press...................................................................................65
Final Checkout Sequence .........................................................................................................................66
Chapter 3 – Fixed and Floating Blanking........................................................69
Blanking Windows Affect Safety Distance..............................................................................................70
Adding to Safety Distance for Fixed Blanking....................................................................................71
Adding to Safety Distance for Floating Window.................................................................................71
Installing Blanking Windows...................................................................................................................72
Installing the Master.............................................................................................................................72
Installing Slave Windows ....................................................................................................................75
Floating Window......................................................................................................................................77
Adding to Safety Distance for Floating Window.................................................................................78
How to Enable the Floating Window...................................................................................................78
Chapter 4 – Troubleshooting Shadow VI ........................................................79
How to use this chapter ............................................................................................................................79
Description of Shadow VI Indicators.......................................................................................................80

Shadow VI User Manual 1107200
Table of Contents page iii
At the Optic Heads...............................................................................................................................80
At the Control ......................................................................................................................................80
Inside the Control.................................................................................................................................81
External MPCE Monitoring: Checking DS5 and DS6.........................................................................85
Shadow VI Optic Head Connector...........................................................................................................86
Checking and Cleaning Lens Window(s).................................................................................................87
Checking Alignment.................................................................................................................................87
Alignment Problem or Bad Phototransistor.........................................................................................87
Checking and Replacing Fuses.................................................................................................................88
Checking and Replacing Control Relays..................................................................................................89
If the Relay Has Failed Completely.....................................................................................................89
Checking Relays with a Voltmeter ......................................................................................................90
Replacing Safety Relays ......................................................................................................................91
Checking and Correcting Cross Talk........................................................................................................92
Appendix A – Extracts from OSHA Regulations and ANSI Standards.........93
Extracts from OSHA Regulation 1910.217..............................................................................................93
Extracts from ANSI Standards for Presence-sensing Devices.................................................................97
Daily Tests in English ............................................................................................................................113
Tests Quotidiens du Rideau de Lumiere.................................................................................................114
Daily Tests in French..............................................................................................................................114
Appendix B – Shadow VI Panel Mount..........................................................115
Standard Enclosure Versus Optional Panel Mount ................................................................................115
Preparation for Mounting Shadow Using Your Enclosure.....................................................................115
About Shadow VI Panel Mount Labels .............................................................................................116
Appendix C – Installation of Shadow VI-WPC Control Board.....................119
Mounting Dimensions and Required Clearance.....................................................................................119
About Shadow VI-WPC Control Board Labels.................................................................................120
Wiring Shadow VI optic heads to the board ..........................................................................................124
Connecting AC wiring to WPC..............................................................................................................125
Connecting Stop Circuits to WPC..........................................................................................................126
Making settings on the control board.....................................................................................................127
Floating window setting.....................................................................................................................127
J12 Setting..........................................................................................................................................128
Reset button............................................................................................................................................129
Appendix D – Replacement Parts..................................................................131
Index ................................................................................................................133
Wintriss Manuals ............................................................................................137

1107200 Shadow VI User Manual
page iv Table of Contents
List of Figures
Figure 1-1. Illustration of Shadow Transmitter and Receiver...............................................................................3
Figure 1-2. Illustration of Shadow Control ...........................................................................................................4
Figure 1-3. Showing Light Beams with Shadow Light Curtain............................................................................5
Figure 2-1. Distance Between Pinch Point and Light Curtain.............................................................................19
Figure 2-2. Plan View Illustrating "Pass Through" Protection............................................................................25
Figure 2-3. Brackets for Shadow Light Curtains.................................................................................................29
Figure 2-4. Shadow VI Optic Heads Mounting Dimensions...............................................................................31
Figure 2-5. Top Views of Shadow VI Optic Heads (Universal Mounts)............................................................32
Figure 2-6. Transmitter and Receiver Properly Aligned .....................................................................................34
Figure 2-7. Using Laser Alignment Tool to Properly Align Shadow..................................................................34
Figure 2-8. Aligning Brackets Using Mounting Holes So Shadow Light Beams Line Up Later
When Mounted .................................................................................................................................35
Figure 2-9. Shadow VI Mirror Dimensions.........................................................................................................37
Figure 2-10. Representation of Shadow with Mirrors for Three-sided Guarding...............................................38
Figure 2-11. One Way to Avoid Cross Talk - Reversing Transmitters (TX) and Receivers (RX) .....................40
Figure 2-12. Mounting an Optic Head with Shock Mounts ................................................................................41
Figure 2-13. Shadow VI Control Enclosure Mounting Dimensions ...................................................................43
Figure 2-14. Location of Components, Shadow VI Control ...............................................................................44
Figure 2-15. Terminating Drain Wires to Set Screw Terminal ...........................................................................46
Figure 2-16. Terminal Block TB1 Connections..................................................................................................50
Figure 2-17. Setting Voltage Selector Switch S2................................................................................................51
Figure 2-18. Connecting to Protective Earth Ground Set Screw Terminal.........................................................51
Figure 2-19. Relays Wired to Emergency Stop Circuit, Typical.........................................................................54
Figure 2-20. Wiring "Upper" TB4 Connector in Control....................................................................................55
Figure 2-21. Example of MPCE Usage...............................................................................................................58
Figure 2-22. Setting MPCE Jumpers...................................................................................................................59
Figure 2-23. Factory Settings for Switch Blocks S1 and S4 ...............................................................................59
Figure 2-24. Jumper Position for "1 SET" and "2 SET" .....................................................................................61
Figure 3-1. Connecting Master Blanking Window .............................................................................................73
Figure 3-2. Close-up — Installing Blanking Window ........................................................................................74
Figure 3-3. Coil Stock Unwinding Using Floating Window...............................................................................77
Figure 4-1. Optic Head Connector Pinout Orientation and Chart .......................................................................86
Figure B-1. Daily Tests Label (left) and Operator instructions Label (right)....................................................117
Figure B-2. Shadow VI Panel Mount Control Dimensions...............................................................................118
Figure C-1. Shadow VI - WPC Labels..............................................................................................................121
Figure C-2. Mounting Dimensions and Required Space for Control Board .....................................................122
Figure C-3. Important Components - Shadow VI-WPC Control board.............................................................123
Figure C-4. TB1 Power Terminal......................................................................................................................125
Figure C-5. Setting Voltage Selector Switch S2 ...............................................................................................126
Figure C-6. Floating Window Switch S1 ..........................................................................................................127
Figure C-7. Jumper Position for "1 SET" and "2 SETS"...................................................................................128
Figure C-8. Reset Button...................................................................................................................................129

Shadow VI User Manual 1107200
Table of Contents page v
List of Tables
Table 1-1. Shadow VI Specifications..................................................................................................................12
Table 1-2. Shadow options and functions ...........................................................................................................14
Table 2-1. Light Curtain Dimensions: inches (cm).............................................................................................30
Table 2-2. OSHA Table 0-10..............................................................................................................................36
Table 2-3. Connecting Light Curtain Receiver Head to TB2 in Controller ........................................................48
Table 2-4. Connecting Light Curtain Receiver Head to TB3 in Controller .........................................................49
Table 4-1. Shadow troubleshooting guide for 1 or 2 sets....................................................................................82
Table 4-2. Shadow Troubleshooting Guide for 2 Sets........................................................................................85
Table C-1. Connecting Light Curtain Receiver Head to TB2 in Controller......................................................124
Table C-2. Connecting Light Curtain Transmitter Head to TB3 in Controller ..................................................125
Table C-3. Shadow-WPC Board TB1 to WPC .................................................................................................126
Table C-4. Shadow-WPC Board TB4 to WPC .................................................................................................127
Table D-1. Replacement Parts List....................................................................................................................131
Wiring Diagrams at End of Manual
Figure 1. Dual Light Curtain Wiring Diagram
Figure 2. Simple Connection to N/O Machine ESTOP Circuit
Figure 3. Connection for Simple N/O ESTOP and Auxiliary Circuit
Figure 4. Wiring Diagram Showing External N/O and N/C Relays with Captive Contacts
Figure 5. External Indication Wiring Diagram
Figure 6. Wintriss Clutch/Brake Control Shadow VI Wiring
Figure 7. Wintriss Clutch/Brake Control Dual Shadow Wiring
Figure 8. Wintriss Clutch/Brake Control Integrated Shadow VI Wiring
Figure 9. Older Model Wintriss Clutch/Brake Control Shadow VI Wiring
Figure 10. WPC 1000 Shadow VI and Cam Output Wiring

1107200 Shadow VI User Manual
page vi Table of Contents
How to Use the Manual
This is the installation and reference manual for the Shadow Safety Light Curtain. It has
information about how to install, use and troubleshoot Shadow, as well as pertinent
information about OSHA and ANSI requirements.
Chapter 1, Shadow Safety Light Curtain, introduces you to Shadow, tells how it works
—specifically about control reliability—and explains how to use this product.
Chapter 2, Installation and Checkout, gives the instructions for installing Shadow.
This chapter also includes installation of the mirrors, as well as installation information
when installing for different applications. At the end of the chapter is a diagnostic and
checkout section. Be sure to check out your Shadows prior to operating the machinery.
Chapter 3, Floating and Blanking Windows, tells what you need to know about using
blanking and floating windows, including installation and safety distance.
Chapter 4, Troubleshooting, provides information to help diagnose and correct
problems you may encounter when using a Shadow Light Curtain.
Appendix A, OSHA Regulations, ANSI Standards and Daily Tests gives excepts from
documents related to presence-sensing safety devices, and instructions for tests that
should be run every day.
Appendix B, Shadow VI Panel Mount explains how to install Shadow VI as a panel
mount. Mounting and "cutout" dimensions are provided.
Appendix C, Installation of Shadow VI-WPC Control Board explains how to install,
wire, and operate the optional Shadow VI-WPC control board assembly in conjunction
with your Wintriss Clutch/Brake Control (WPC). This control board replaces the
standard Shadow VI control box.
Appendix D, Replacement Parts lists the replacement parts available for the Shadow VI
from the factory.

Shadow VI User Manual 1107200
Table of Contents page vii
Important Highlighted Information
Important danger, warning, caution and notice information is highlighted throughout the
manual as follows:
DANGER
!
A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will
result in death or serious injury.
WARNING
!
A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could
result in death or serious injury.
CAUTION
A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may
result in property damage.
NOTICE
A NOTICE symbol indicates important information that must be remembered and aids in job
performance.

1107200 Shadow VI User Manual
page viii Table of Contents
Warranty
Wintriss Controls warrants that Wintriss electronic controls are free from defects in
material and workmanship under normal use and service for a period of one year (two
years for Shadow light curtains) from date of shipment. All software products (LETS
and SBR), electro-mechanical assemblies, and sensors are warranted to be free from
defects in material and workmanship under normal use and service for a period of 90
days from date of shipment. Wintriss’s obligations under this warranty are limited to
repairing or replacing, at its discretion and at its factory or facility, any products which
shall, within the applicable period after shipment, be returned to Wintriss Controls
freight prepaid, and which are, after examination, disclosed to the satisfaction of
Wintriss to be defective. This warranty shall not apply to any equipment which has
been subjected to improper installation, misuse, misapplication, negligence, accident,
or unauthorized modification. The provisions of this warranty do not extend the
original warranty of any product which has either been repaired or replaced by
Wintriss Controls. No other warranty is expressed or implied. Wintriss accepts no
liability for damages, including any anticipated or lost profits, incidental damages,
consequential damages, costs, time charges, or other losses incurred in connection
with the purchase, installation, repair or operation of our products, or any part thereof.
Please note:
It is solely the user’s responsibility to properly install and maintain Wintriss controls
and equipment. Wintriss Controls manufactures its products to meet stringent
specifications and cannot assume responsibility for consequences arising from their
misuse.
U.S. patent numbers 4,266,124 and 3,805,061 apply
Wintriss Controls Group, LLC SHADOW®VI SAFETY LIGHT CURTAIN
100 Discovery Way USER MANUAL
Unit 110 1107200
Acton, MA 01720 ©2010 Wintriss Controls Group, LLC
Telephone: (800) 586-TECH (8324)
[phone]
Fax: [phone]
Internet: http://www.wintriss.com

Shadow VI User Manual 1107200
Introduction to Shadow VI Chapter 1 page 1
Safety Light Curtain
Chapter 1 – Introduction to Shadow®VI
Safety Light Curtain
Shadow VI is a compact, state-of-the-art, 3-box light curtain which contains transmitter and
receiver optic heads plus a separate control.
Shadow protects personnel working around dangerous machinery. The system signals the
press to stop if a person's hand (or any other part of the body) gets too close to the hazardous
area. However, the invisible light screen does not interfere with normal operation. Unlike
mechanical guards which physically block access to the hazardous area, Shadow safeguards
personnel via this field of invisible infrared light.
DANGER
!
FULL REVOLUTION MECHANICAL POWER PRESSES CANNOT BE STOPPED IN MID-
STROKE
•DO NOT use Shadow safety light curtains on full-revolution clutched machinery.
•Use Shadow safety light curtains only on machinery that can be stopped at any point in its
stroke or cycle.
Failure to comply with these instructions will result in death or serious injury.
WARNING
!
IMPROPER INSTALLATION
•Install and use Shadow safety light curtains according to applicable safety standards.
•Install presses used with Shadow safety light curtains according to the requirements and
inspection procedures of OSHA regulation 1910.217 and ANSI standard B11.1-2009.
•Install other machinery or devices according to OSHA regulation 1910.212 for general
machine guarding and any other regulations that apply.
Failure to comply with these instructions could result in death or serious injury.
NOTICE
USE EXCERPTS FROM SAFETY STANDARDS FOR REFERENCE ONLY
Refer to the latest versions of the documents from which Wintriss has provided excerpts for
your convenience. An excerpt from OSHA regulation 1910.217 appears in the appendix of
this manual. Excerpts from the American National Standards Institute (ANSI) standards for
safety devices are also included in Appendix A.
ANSI is a federation of trade and professional organizations which sets standards for the
industry based on a national consensus of manufacturers, scientists, technical and
professional groups.

1107200 Shadow VI User Manual
page 2 Chapter 1 Introduction to Shadow VI
Safety Light Curtain
OSHA and ANSI Compliance
Shadow complies with OSHA CFR 1910.212 "General Machine Guarding" and 1910.217
"Mechanical Power Presses", ANSI B11.1-2009 "Mechanical Power Presses", ANSI B11.19
"Performance Criteria for Safeguarding"; ANSI B11.20 "Manufacturing Systems/Cells"; and
ANSI/RIA 15.06 "Industrial Robots and Robot Systems".
These regulations require that a single component failure cannot jeopardize operator safety.
Critical components are duplicated and continually cross-checked during operation to
guarantee that a single component failure can never create an unsafe condition. Self-
checking circuitry detects the presence of any faults and signals the press to stop.
About Shadow VI
DANGER
!
INCORRECT INSTALLATION
•Ensure that presses equipped with Shadow light curtains meet the requirements and
inspection procedures of OSHA regulation 1910.217 and ANSI standard B11.1-2009.
•Ensure that other machinery or devices meet OSHA regulation 1910.212 for general
machine guarding and any other regulations that apply.
Failure to comply with these instructions will result in death or serious injury.
NOTICE
EXCERPTS FROM OSHA REGULATIONS AND ANSI STANDARDS
Excerpts from OSHA regulation 1910.217 and from the American National Standards Insti-
tute (ANSI) standards for safety devices are also included in Appendix A. ANSI is a fed-
eration of trade and professional organizations which sets standards for the industry based
upon a national consensus of manufacturers, scientists, technical and professional groups.
Shadow safety light curtains provide excellent protection. Once properly installed,
Shadow VI does not require additional adjustment, and no maintenance is required. You do
not have to worry about personnel forgetting to close gates or replace barriers.
The optic heads are constructed of rugged, heavy-gauge extruded aluminum (0.12-inch wall
thickness). These compact heads (2" x 2.85" cross-section) come in sizes ranging from 6
inches to 5 feet in height. The transmitter and receiver (see Figure 1-1) are optionally
available in explosion-proof enclosures.
Shadow also includes a control enclosure (Figure 1-2) to which any-sized receiver and
transmitter can be wired. No special settings are required. The control contains a power
supply, relay circuitry, and switch block assemblies where you can easily enable or disable
Shadow's options.
For added security, the control comes standard with an enclosure keylock and a reset
keyswitch. Simply turn the reset keyswitch to the right when resetting is required.

Shadow VI User Manual 1107200
Introduction to Shadow VI Chapter 1 page 3
Safety Light Curtain
The cables join the control with the transmitter and receiver and are interchangeable between
each optic head. These cables have connectors that plug into the optic head end and screw
terminations that connect at the control end. They come in various lengths.
Receiver
LEDs:
Red
(curtain obstructed)
Orange
(floating window enabled)
Green
(curtain unobstructed)
universal
mounting
brackets
LED:
A
mber
(power on)
end caps
"quick-connect"
cable connectors
mating connector
for blanking
window cable
Transmitter
Figure 1-1. Illustration of Shadow Transmitter and Receiver

1107200 Shadow VI User Manual
page 4 Chapter 1 Introduction to Shadow VI
Safety Light Curtain
reset keyswitch
LED Indicators for
curtain clear,
floating window enabled,
curtain blocked and
reset required
(key pointed
toward "operate"
during normal
operation)
enclosure
keylock
cover latches
LIGHT CURTAIN
RESETOPERATE
CURTAIN
CLEAR STOP
SIGNAL RESET REQUIRED
FLOATING
WINDOW
Figure 1-2. Illustration of Shadow Control
How Shadow Works
WARNING
!
IMPROPER INSTALLATION
•Connect the Shadow safety light curtain stop relays to the machine’s stop circuit. If you do
not use the stop relays, you will not have the maximum protection afforded by these light
curtains.
•DO NOT attempt to connect Shadow safety light curtains to any control until you have
carefully read the installation instructions.
Failure to comply with these instructions could result in death or serious injury.
WARNING
!
UNPROTECTED MACHINERY MAY CONTINUE TO OPERATE
Ensure that all operators know which device(s) your Shadow safety light curtain protects and
which it does not. The press Shadow is wired to will stop when the light curtain is
interrupted and sends a stop signal to the press. However, the associated feeds and
conveyors, to which Shadow is not wired, will continue to operate after the press stops.
Failure to comply with these instructions could result in death or serious injury.
You cannot see the actual light curtain emitted by Shadow. However, the invisible curtain of
light automatically prevents access to hazardous areas while the press is operating.

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Safety Light Curtain
receiver
transmitter light beams
Figure 1-3. Showing Light Beams with Shadow Light Curtain
Shadow's transmitter and receiver are not "matched sets". In other words, a Shadow VI
transmitter will work with any same-sized Shadow VI receiver. You mount the units on the
machinery on either side of the hazardous area.
Shadow can be described as an optoelectronic presence-sensing device. Presence-sensing
means the light curtain detects an object that penetrates its field and reacts to it by signaling a
press to stop when an intrusion occurs. Optoelectronic means Shadow works using light and
electric current.
The transmitter's LEDs (light emitting diodes) emit a harmless, invisible, infrared light pulse
when an electrical pulse passes through them. These LEDs transmit light towards the
receiver. The receiver's phototransistors detect each light pulse and produce an electrical
signal whenever the light pulse hits them. An invisible light barrier is formed by infrared
light beams sent from the transmitter to the receiver. Reacting to the loss of light, Shadow
sends a stop command to the press when there is an obstruction, such as when you put your
hand into the light field.
As the light curtain is operating, each transmitter LED pulses in succession from top to
bottom, in the form of a conical beam. The phototransistors in the receiver detect these light
pulses instantly and produce an electrical signal (turn on) when the light strikes them. Each
phototransistor detects the one pulse of light designated to it. It is only enabled at the instant
that the beam is anticipated. Shadow's electronics must "see" the phototransistor turn "on"
then "off" as the beam hits it and disappears. Each phototransistor must turn on, then off in
sequence, or Shadow will send a stop command to the machinery.

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Safety Light Curtain
Because the receiver only accepts infrared light pulses of a certain duration in proper
sequence, Shadow cannot be affected or fooled by other light sources. All other continuous
light sources and even pulsed light sources are "tuned out." Therefore, the light curtain is not
affected by normal lighting near the light curtain. Also, changes in area lighting or even
flashing strobe lights will not affect operation.
This pulsed sequence is so fast that, where we mark time in units no smaller than a second,
the effect is a continuous light field across the guarded area. You would have to move the
point of your finger across an LED in the transmitter in less than 5/1000th of a second (5 ms
or milliseconds) to evade the light pulses coming from that LED. Therefore in our world of
seconds and minutes, the light curtain is really always there even though only one light beam
is actually produced at a time. The actual light pulse lasts for only 1/100,000th of a second
(10 microseconds). Consequently it does not take long to create a whole series of pulses one
after the other.
Shadow and Control Reliability
WARNING
!
IMPROPER INSTALLATION
•Install Shadow safety light curtains in compliance with applicable safety regulations from the
Occupational Safety and Health Administration (OSHA) and the American National
Standards Institute (ANSI). See excerpts in the appendices.
•Refer to the latest revision of all applicable documents.
•Ensure that your installation meets the control reliability requirements of the applicable
regulations.
•Ensure that both Shadow control relays are used in any Shadow installation, including
connection directly to the press control's stop circuit, to a PLC, or to other type of machine
control. Wiring is explained in Chapter 2.
•Read carefully and understand the installation instructions before attempting to install and
wire Shadows to any control
•Ensure that installation is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.
WARNING
!
UNPROTECTED MACHINERY MAY CONTINUE TO OPERATE
Ensure that all operators know which device(s) your Shadow safety light curtain protects and
which it does not. The press Shadow is wired to will stop when the light curtain is
interrupted and sends a stop signal to the press. However, the associated feeds and
conveyors, to which Shadow is not wired, will continue to operate after the press stops.
Failure to comply with these instructions could result in death or serious injury.
Shadow is control reliable. Control reliability is a term used and defined in the same way by
the Occupational Safety and Health Administration (OSHA) and the American National
Standards Institute (ANSI).

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Introduction to Shadow VI Chapter 1 page 7
Safety Light Curtain
NOTICE
The Occupational Safety and Health Administration (OSHA) and the American National
Standards Institute (ANSI) have issued regulations for the use of presence-sensing devices
such as Shadows. Both of them require control reliability. See Appendix A for more
information.
Control reliability means "the device shall be constructed so that a failure within the system
does not prevent the normal stopping action from being applied to the press when required,
but does prevent the initiation of a successive stroke until the failure is corrected."
Control reliability is another reason why Shadow is an excellent machine guard. All critical
components in Shadow are duplicated so that if one fails, the other will still allow normal
operation to stop the machinery. If a component failure does occur, Shadow will immediately
detect the failure and send a stop signal to the machinery. The light curtain will not allow
operation until the repairs are made.
Another example of control reliability are Shadow's control relays. The control contains
captive-contact relays (2 stop and 1 status relay). The N/O outputs are connected in series to
the press's emergency stop circuit and are always energized (contacts held closed) when the
light field is not broken. When an obstruction enters the field, Shadow's control circuitry
instantly de-energizes the relays, which results in opening the contacts and breaking the stop
circuit of the press. Shadow's response time from loss of light to relay contacts open is 30 to
40 milliseconds (depending on the size of the optic heads). Even if one of Shadow's control
relay contacts fails closed (contact welds shut), the second relay will still de-energize and a
stop signal will be sent to the machinery. Shadow will also detect the failed relay. It will not
allow further press operation until the relay is replaced. It is highly unlikely that the relay
contacts will fail simultaneously.
Description of Shadow VI indicators
Shadow includes several indicators. Figure 1-1 shows the indicators on the transmitter and
receiver, and Figure 1-2 illustrates the control.
These indicators communicate Shadow's operating status. Use them to troubleshoot your
light curtain (see Chapter 4 troubleshooting guides). If any contradiction exists between the
indicator lights at the receiver and those at the control, make sure you compare your findings
with the information in these troubleshooting guides to solve the problem immediately.
At the Optic Heads
The transmitter has an amber-colored power indicator which remains illuminated when
Shadow has power. There are three indicators on the front of the receiver. The red
indicator means that the light curtain has been interrupted. The orange indicator flashes
when the floating window option is turned "on" at the control (see Chapter 2). The green
indicator means the light curtain is unobstructed.

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Safety Light Curtain
At the Control
Four indicators appear on the front cover of the control and are clearly labeled. The green
"curtain clear" indicator means that the light curtain is unobstructed and the machinery will
be allowed to operate (the control relay contacts are held closed or in the unobstructed/
energized state). The "floating window" indicator lights up amber when this blanking
feature is enabled inside the control (see Chapter 2). The "stop signal" indicator goes red
when the light curtain is obstructed, the control relay contacts are open (or in the de-
energized
state) and the press is disabled, if there is misalignment, or when Shadow has detected an
internal malfunction. The yellow "reset required" signifies that a “reset required” or
condition exists. This could occur during power-up if “power up reset” settings are
enabled at the control (see Chapter 2), or if Shadow detects an internal malfunction with any
of the components (transmitter, receiver, or control).
Inside the Control
There are four indicators inside the control (refer to Figure 2-14 in Chapter 2 for location of
components). DS1 and DS2 are red indicators that are located just above the TB2 receiver
connectors at the lower right-hand corner of the board. They light up red if you are using
only 1 set of optic heads and there is an obstruction, misalignment, or internal problem. If
you have 2 sets, DS1 lights up red when Set 1 (wired to the upper connectors of TB2 and
TB3) is interrupted, the optic heads are misaligned, or an internal problem exists. DS2
corresponds with Set 2, which are wired to the lower connectors. Refer to the
troubleshooting guides in Chapter 4 for more details.
DS3 and DS4, located in the upper right-hand corner of the control near the power supply,
light up green all the time to indicate that power is going to the receiver and transmitter
respectively.
Chapter 4 provides troubleshooting guides which reference the indicators at the control and
the optic heads. They suggest how to solve a problem with the light curtains when certain
conditions exist.
Object Sensitivity
Object sensitivity is the minimum diameter object that Shadow can detect. Object sensitivity
for Shadow is 11/4" (3.2 cm), which means that it will detect any object of this diameter or
larger anywhere in the sensing field. Shadow light beams are on 3/4" (1.9 cm) centers. An
object smaller than 11/4" diameter could pass undetected through the light field if it traveled
in a path directly between the light beams.
Size and Scanning Distance
Shadow is available in a wide array of standard sizes from 6" to 60". Shadow's standard
scanning distance is 25 feet (7.6 meters), and optionally 50 feet (15.3 meters). The "standard
range" units cannot be modified for "extended range" capability.