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.