Wintriss Shadow 8 User manual

Shadow 8
®
Safety Light Curtain
1139300
Rev. K March 201
UserUserUser
ManualManualManual
User
Manual
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
®
®

Requirements You Must Meet When Installing and Using
Shadow Safety Light Curtains
DO NOT USE SHADOW LIGHT CURTAINS ON FULL-REVOLUTION POWER PRESSES
• DO NOT use Shadow safety light curtains on full-revolution clutched machinery, which cannot be stopped in mid-stroke.
• Use Shadow safety light curtains only on machinery that can be stopped at any point in the stroke or cycle.
Failure to comply with these instructions will result in death or serious injury.
AVOID 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 a qualified person. Only a qualified person
should possess keys, special tools, or other means needed to gain access to the control and modify the configuration of the
Shadow light curtain.
• 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, using the test procedure shown on the Shadow safety light curtain
control enclosure and also included in this manual.
• Perform the checkout and test procedures 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.
MAKE SURE THAT MACHINERY IS CONFIGURED AND 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.
PREVENT 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.
UNPROTECTED EQUIPMENT MAY CONTINUE TO OPERATE AFTER GUARDED PRESS STOPS
• 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.
GUARD AGAINST ELECTRIC SHOCK HAZARD
Turn off and disconnect power from the Shadow safety light curtain and from the machinery it is connected to, including the
machine control and motor, before making any wiring connections.
Failure to comply with these instructions could result in death or serious injury.
DANGER
!
DANGER
!
DANGER
!
DANGER
!
DANGER
!
WARNING
!

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 our Board Exchange (EX) program. Call our
“800” number between 8 a.m. and 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.

Table of Contents i
Table of Contents
Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
UL, CSA, CE, OSHA, and ANSI Compliance . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Shadow 8 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Shadow 8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Shadow 8 Object Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Shadow 8 and Control Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Shadow 8 LED Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Shadow 8 Operating States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Shadow 8 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Programmable Fixed Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Floating Blanking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Other Shadow 8 Features and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Shadow 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Chapter 2. Installation and Checkout. . . . . . . . . . . . . . . . . . . . . .2-1
Calculating the Safety Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
OSHA and ANSI Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
OSHA Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
ANSI Safety Distance Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
European Safety Distance Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Increasing Safety Distance for Perimeter Guarding . . . . . . . . . . . . . . . . . . . . . . . 2-10
Increasing Safety Distance To Compensate for Blanking Windows. . . . . . . . . . . 2-10
Providing Pass-through Protection within the Safety Distance. . . . . . . . . . . . . . . 2-12
Height Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Special Requirements for Presence Sensing Device Initiation (PSDI) for Machines
Other Than Mechanical Power Presses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Designing and Installing Mounts for Optic Heads . . . . . . . . . . . . . . . . . . . . . .2-15
Universal Mounting Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Mounting Location Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Designing and Installing Mounting Brackets and Floor Stands . . . . . . . . . . . . . . 2-16
Aligning Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Maximum Openings for Side Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Using Mirrors with Shadow 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Reflective Surface Interference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Preventing Cross Talk between Two Sets of Shadow 8 Heads. . . . . . . . . . . . .2-27
Loosely Mounting Shadow 8 Transmitter and Receiver. . . . . . . . . . . . . . . . . .2-28
Mounting the Optional Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
Wiring Main Optic Heads to the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

1139300 Shadow 8 User Manual
ii Table of Contents
Connecting Extension Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Connecting Extension Heads Using Pigtails Only . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Connecting Extension Heads Using Interconnect Cables. . . . . . . . . . . . . . . . . . . .2-36
Connecting AC Wiring to the Optional Control . . . . . . . . . . . . . . . . . . . . . . . 2-37
Connecting Stop Circuits to the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Wiring Shadow 8 in a Single Normally Open (N/O) Emergency Stop Circuit . . .2-40
Wiring Shadow 8 to EDM Monitor Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-41
Wiring Shadow 8 Optional Control Box to a PLC. . . . . . . . . . . . . . . . . . . . . . . . .2-42
Wiring Shadow 8 Optional Control to a Wintriss Clutch/Brake Control . . . . . . . .2-43
Wiring Auxiliary Output(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Setting Option Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Setting Operating Mode (Receiver Switch 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Enabling External Device Monitoring (EDM) (Receiver Switch 2) . . . . . . . . . . .2-47
Setting Scan Codes (Receiver Switch 3, Transmitter Switch 1). . . . . . . . . . . . . . .2-47
Enabling Floating Blanking (Receiver Switch 4). . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Enabling Programmable Fixed Blanking (Receiver Switch 5). . . . . . . . . . . . . . . .2-48
Setting Scanning Range (Receiver Switch 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Enabling Machine Test Signal (MTS) (Transmitter Switch 2). . . . . . . . . . . . . . . .2-48
Connecting AC Wiring to Power Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Aligning and Tightening Down Shadow 8 Heads . . . . . . . . . . . . . . . . . . . . . . 2-49
Diagnosing Problems Before Using Shadow 8 . . . . . . . . . . . . . . . . . . . . . . . . 2-52
No Power to Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Interlock/Alarm LED Is Illuminated. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Machine Run/Stop LED Not Illuminated Green . . . . . . . . . . . . . . . . . . . . . . . . . .2-53
Machine Run/Stop LED Is Green But Machine Won’t Start . . . . . . . . . . . . . . . . .2-53
Shadow 8 Control Box or WPC Power LED Dims and Blinks . . . . . . . . . . . . . . .2-54
Performing Checkout and Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-55
Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56
Adding and Removing Extension Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Adding Extension Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-59
Removing Extension Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
Chapter 3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Shadow 8 LED Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Shadow 8 Operating States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Setting Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Automatic Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Start/Restart Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Programming a Fixed Blanking Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Setting a Floating Blanking Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Enabling Both Blanking Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Shadow 8 User Manual 1139300
Table of Contents iii
Chapter 4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Troubleshooting with Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Other Troubleshooting Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Machine Run/Stop LED Is Red and No Fault Code Displayed. . . . . . . . . . . . . . . . 4-5
Machine Run/Stop LED Not Green. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Machine Run/Stop LED Green but Press Won’t Start. . . . . . . . . . . . . . . . . . . . . . . 4-6
Every Other IBI Lit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Transmitter Status LED Is Flashing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Machine Run/Stop and Blanking Active LEDs Flash Simultaneously. . . . . . . . . . 4-6
Shadow 8 Control Box or WPC Power LED Dims and Blinks. . . . . . . . . . . . . . . . 4-6
Checking and Cleaning Lens Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Checking Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Checking and Replacing the AC Power Fuse in Optional Shadow 8
Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Checking and Replacing Control Relays in Optional Shadow 8 Control Box . .4-9
Performing a Resistance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Replacing the Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Checking for and Correcting Cross Talk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Appendix A. Wiring Shadow 8 Heads Directly to WPC . . . . . . . . .A-1
Appendix B. Checkout Procedure Log . . . . . . . . . . . . . . . . . . . . . .B-1
Appendix C. Test Procedure Log. . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Appendix D. Extracts from OSHA Regulations and ANSI
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Extracts from OSHA Regulation 1910.217. . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Extracts from ANSI Standards for Presence-sensing Devices . . . . . . . . . . . . . D-5
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Wintriss Manuals

1139300 Shadow 8 User Manual
iv Table of Contents
Figures at End of Manual
Figure A. Installing Shadow 8 Cabling in Liquidtight Conduit
Figure 1. Shadow 8 Transmitter and Receiver Head Wiring Diagram
Figure 2. Shadow 8 Connection for Simple N/O ESTOP Circuit Wiring Diagram
Figure 3. Shadow 8 Connection with External N/O and N/C Relays Wiring Diagram
Figure 4. Shadow 8 Connection with External N/O Relays Wiring Diagram
Figure 5. WPC 2000 and Shadow 8 Control Box Wiring Diagram
Figure 6. WPC 1000 Old Style and Shadow 8 Wiring Diagram
Figure 7. WPC 1000 New Style and Shadow 8 Control Box Wiring Diagram
Figure 8. WPC II and Shadow 8 Wiring Diagram
Figure 9. WPC I and Shadow 8 Wiring Diagram
Figure 10. Shadow 8 Control Option Wiring Diagram
Figure 11. WPC 2000 and Shadow 8 Wiring Diagram
Figure 12. WPC 1000 New Style and Shadow 8 Wiring Diagram
List of Figures
Figure 1-1. Shadow 8 Main Transmitter and Receiver ...................................................................1-3
Figure 1-2. Shadow 8 Main and Extension Heads .......................................................................... 1-4
Figure 1-3. Shadow 8 Control ......................................................................................................... 1-5
Figure 1-4. Shadow 8 Light Beams ................................................................................................. 1-6
Figure 2-1. Safety Distance: Distance between Pinch Point and Light Curtain ............................. 2-3
Figure 2-2. Plan View of Pass-through Protection ........................................................................2-12
Figure 2-3. Supplemental Guarding ..............................................................................................2-13
Figure 2-4. Shadow 8 Stand Dimensions (Shown with Mounting Brackets for Heads) ...............2-17
Figure 2-5. Light Curtain Mounting Bracket Types .....................................................................2-18
Figure 2-6. Shadow 8 Optic Heads: Mounting Dimensions .........................................................2-19
Figure 2-7. Shadow 8 Universal Mounting Brackets: Dimensions and Rotation (Top View) ..... 2-20
Figure 2-8. Shadow 8 Universal Mounting Brackets: T-Slot Configuration ................................2-20
Figure 2-9. Aligning Brackets Using Mounting Holes .................................................................2-21
Figure 2-10. Shadow 8 with Mirrors for Three-sided Guarding .....................................................2-23
Figure 2-11. Shadow 8 Mirror Dimensions ....................................................................................2-24
Figure 2-12. Correct Mounting Example with Proper Alignment ..................................................2-25
Figure 2-13. Unsafe Mounting, Example 1 .....................................................................................2-25
Figure 2-14. Unsafe Mounting, Example 2 .....................................................................................2-26
Figure 2-15. Minimum Distance: Worst Case Alignment Example ...............................................2-26
Figure 2-16. Minimum Distance from a Reflective Surface as a Function of Range ..................... 2-26
Figure 2-17. Reversing Transmitters (TX) and Receivers (RX) to Prevent Cross Talk .................2-27
Figure 2-18. Mounting an Optic Head with Shock Mounts ............................................................2-28
Figure 2-19. Shadow 8 Control Box: Mounting Dimensions .........................................................2-30
Figure 2-20. Shadow 8 Main Board: Location of Important Components .....................................2-32
Figure 2-21. Cable Being Threaded through Top of Gland Nut and Threaded Coupling ..............2-33
Figure 2-22. Shadow 8 AC Wiring Connections ............................................................................2-38
Figure 2-23. Relays Wired to Emergency Stop Circuit, N/O Configuration ..................................2-41
Figure 2-24. Shadow 8 Option Switches (Located in Main Receiver and Transmitter) .................2-46
Figure 2-25. Transmitter and Receiver Properly Aligned ............................................................... 2-50
Figure 2-26. Test Object Pattern .....................................................................................................2-57

Shadow 8 User Manual 1139300
Table of Contents v
Figure 3-1. Using Supplemental Guarding with Fixed Blanking Windows ....................................3-5
Figure 3-2. Coil Stock Unwinding Using a One-beam Floating Window ......................................3-8
Figure 4-1. Fault Code “34” Displayed on Individual Beam Indicators on Main Receiver ............4-2
Figure A-1. WPC Label for Program Off/On and Program/Run/Start Key Switches .....................A-1
List of Tables
Table 1-1. Shadow 8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Table 2-1. Shadow 8 Stand Height and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Table 2-2. Light Curtain Dimensions in Inches (Millimeters) (see Figure 2-6) . . . . . . . . . . . . . .2-19
Table 2-3. OSHA Table 0-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Table 2-4. Shadow 8 Mirror Dimensions (see Figure 2-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Table 2-5. Main Receiver Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Table 2-6. Main Transmitter Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Table 2-7. Operating Mode Settings: Receiver Switch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Table 2-8. External Device Monitor (EDM) Settings: Receiver Switch 2 . . . . . . . . . . . . . . . . . .2-47
Table 2-9. Scan Code Settings: Receiver Switch 3, Transmitter Switch 1 . . . . . . . . . . . . . . . . . .2-47
Table 2-10. Floating Blanking Settings: Receiver Switch 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Table 2-11. Programmable Fixed Blanking Settings: Receiver Switch 5 . . . . . . . . . . . . . . . . . . . .2-48
Table 2-12. Scanning Range Settings: Receiver Switch 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Table 2-13. Consecutive Beam Alignment Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
Table 3-1. Consecutive Beam Requirement for Programmable Blanking . . . . . . . . . . . . . . . . . . .3-6
Table 4-1. Shadow 8 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Table A-1. Shadow 8 Main Transmitter/Receiver Wiring Connections to WPC . . . . . . . . . . . . . A-2

1139300 Shadow 8 User Manual
vi Table of Contents
How To Use This Manual
This manual shows you how to install, operate, and troubleshoot Shadow 8 light curtains and
includes pertinent information about OSHA and ANSI requirements.
Chapter 1 provides an overview of Shadow 8 operation and features, including product
specifications.
Chapter 2 shows you how to install and wire Shadow 8, set Shadow 8 options, and perform
checkout and test procedures. The chapter also provides instructions for calculating the safety
distance for your light curtains.
Chapter 3 shows you how to operate Shadow 8 and explains Shadow 8’s operating modes,
LED displays, and programmable fixed blanking and floating blanking features.
Chapter 4 shows you how to troubleshoot Shadow 8. The chapter provides a table of actions
you can take to respond to Shadow 8 fault codes and explains how to check light curtain
alignment and check and replace safety relays.
Appendix A shows you how to wire Shadow 8 Main Receiver and Transmitter directly to a
WPC 2000 or “new-style” WPC 1000 clutch/brake control.
Appendix B provides a Checkout Procedure Log form that can be used to document the
results of the checkout procedure.
Appendix C provides a Test Procedure Log form that can be used to document the results of
the test procedure.
Appendix D provides extracts from OSHA regulation 1910.217 and ANSI standards
B11.1-2009 and B11.19-2003.
The Glossary provides definitions of terms used in the manual that may be unfamiliar to some
users.
Wiring diagrams at the end of the manual provide detailed wiring schematics to help you
install your Shadow 8.

Shadow 8 User Manual 1139300
Table of Contents vii
Important Highlighted Information
Important danger, warning, caution and notice information is highlighted throughout the
manual as follows:
A DANGER symbol indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
A WARNING symbol indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
A CAUTION symbol indicates a potentially hazardous situation, which, if not avoided, may result in
property damage.
A NOTICE symbol indicates important information that you should remember, including tips to aid
you in performance of your job.
DANGER
!
WARNING
!
CAUTION
NOTICE

1139300 Shadow 8 User Manual
viii Table of Contents
Wintriss Controls Group, LLC SHADOW 8 SAFETY LIGHT CURTAIN
100 Discovery Way USER MANUAL
Unit 110 1139300
Acton, MA 01720 ©2015 Wintriss Controls Group, LLC
Telephone: (800) 586-TECH (8324)
[phone]
Fax: [phone]
Internet: http://www.wintriss.com
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/
SFC 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.

Introduction 1-1
Chapter 1. Introduction
Shadow 8 is a compact, state-of-the-art light curtain consisting of Main Transmitter and
Receiver optic heads, which can be wired directly to a new Wintriss Clutch/Brake Control
(WPC) or to an optional Shadow 8 control. Main heads are capable of supporting up to three
additional pairs of Extension heads connected in series with two cables, as long as the total
length of the heads does not exceed 202 in. For either transmitters or receivers, the total
length of heads and interconnect cables cannot exceed 110 ft. Due to its expandability,
Shadow 8 is capable of safeguarding multiple sides of a machine with a single control.
Shadow 8 light curtains are designed to protect personnel working around dangerous
equipment. The system signals the machine to stop if a person’s hand (or any other part of the
body) comes too close to the hazardous area. However, the invisible light screen does not
interfere with normal operation. Unlike mechanical guards that physically block access to the
hazardous area, Shadow 8 safeguards personnel with this field of invisible infrared light.
DO NOT USE SHADOW LIGHT CURTAINS ON FULL-REVOLUTION POWER PRESSES
• DO NOT use Shadow safety light curtains on full-revolution clutched machinery, which cannot
be stopped in mid-stroke.
• Use Shadow safety light curtains only on machinery that can be stopped at any point in the
stroke or cycle.
Failure to comply with these instructions will result in death or serious injury.
OBSERVE SAFETY REGULATIONS AND STANDARDS WHEN INSTALLING EQUIPMENT
• Install and use Shadow safety light curtains according to applicable safety regulations and
standards.
• Install Shadow safety light curtains on presses according to the requirements and inspection
procedures of OSHA regulation 1910.217 and ANSI standard B11.1-2009.
• Install Shadow safety light curtains on other machinery 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.
USE EXTRACTS FROM SAFETY STANDARDS FOR REFERENCE ONLY
For your convenience, Wintriss has provided extracts from OSHA regulation 1910.217 and from
ANSI standards B11.1-2009 and B11.19-2003 in Appendix D. These extracts are provided for the
user’s convenience only, and may not reflect the current revisions of these documents. For the
most up-to-date information, refer to the latest versions of the original OSHA and ANSI documents.
DANGER
!
WARNING
!
NOTICE

1139300 Shadow 8 User Manual
1-2 Introduction
UL, CSA, CE, OSHA, and ANSI Compliance
Shadow 8 has undergone independent testing, certification, and/or approval by the following
bodies:
UL (Underwriters Laboratories) to UL CCN’s NIPF/ NIPF7 for Type 4, Light Curtain System
(Applicable Requirements: ANSI/UL 61496-1, -2, UL 508, UL 1998, the Standard for Safety
Related Software, CAN/CSA-C22.2 No. 14, CAN/CSA-C22.2 No. 0.8).
TÜV to the relevant Essential Health and Safety Requirements (EHSRs) of the European
Machinery Directive (98/37/EC) and the relevant requirements of the Low Voltage Directive
(73/23/EEC as amended by 93/68/EEC) and with the essential protection requirements of the
Electromagnetic Compatibility (EMC) Directive (89/336/EEC, 92/31/EEC and 93/68/EEC)
per EC Type-Examination Certification for Type 4 Safety Light Curtain (Applicable
Requirements: IEC EN 61496-1, -2, EN 954-1, EN 60204-1, EN 50178, IEC 62061, SIL 3 per
IEC 61508, EN ISO 13849-1, and 2002/95/EC – Restriction of the use of Certain Hazardous
Substances - RoHS).
Shadow 8 also complies with OSHA 1910.217, ANSI B11.1, ANSI B11.19, CSA Z142, and
CSA Z432.
These rules mandate that a single component failure cannot jeopardize operator safety.
Critical components must be duplicated and continually cross-checked during operation to
guarantee that a single component failure can never create an unsafe condition. Self-checking
circuitry must be capable of detecting the presence of any faults and of signalling the press to
stop.
Shadow 8 Components
Shadow 8 optic heads (see Figure 1-1, page 1-3) are constructed of rugged, heavy-gauge
extruded aluminum (0.10 in., 2.6 mm wall thickness). These compact heads (1.50 x 1.97 in.
cross-section) come in sizes ranging from 12.6 in. to 5 ft. in height and 9.4-in. extensions.
Optic heads have a keyed, threaded connector at one end and a 7-in. pigtail with connector at
the other. If the head is a Main Receiver or Transmitter, the connector on the pigtail is used to
connect the head to the cable wired to the control (see Figure 1-2, page 1-4). The other
connector can be used to connect a second pair of light curtains, called Extensions, to the
Main pair via the pigtail-and-connector on the Extension Receiver or Transmitter.
Up to three pairs of Extension Receivers/Transmitters can be connected in series to the Main
pair, but the total length of the heads cannot exceed 202 in. The total length of heads and
interconnect cabling cannot exceed 110 ft. for either transmitters or receivers. Additional
cabling for interconnections between Extension heads is available in various lengths.

Shadow 8 User Manual 1139300
Introduction 1-3
Figure 1-1. Shadow 8 Main Transmitter and Receiver
Transmitter
Operating state
LED Indicators
Receiver
Red or Green
(Curtains O structed or
Curtains Uno structed)
Yellow
(Interlock or Fault)
Am er
(Programma le Fixed
Blanking or Floating
Blanking Active)
In-series connectors
(for interconnect ca le
or pigtail connections
from other receivers/
transmitters)
Universal
mounting
rackets
7 pigtails with
connectors
(screw onto ca les
from press control
or optional remote
control ox).
Individual Beam Indicator (IBI) LEDs
Protective end caps
(screw into connectors)
Color-coded red
for receiver, lack
for transmitter.
ON
165432
ON
165432
Receiver switches
( ehind hinged
panel)
Transmitter status
LED Indicator
(Yellow)
ON
12
Transmitter switches
( ehind hinged
panel)

1139300 Shadow 8 User Manual
1-4 Introduction
Figure 1-2. Shadow 8 Main and Extension Heads
7 pigtail
Shadow 8 control
Main transmitter
Main receiver
Extension transmitters Extension receiver
End cap
Female
Male
FemaleMale FemaleMale
Male Female
Quick-disconnects
Quick-disconnects
Interconnect ca le
Transmitter ca le
Receiver ca le
7 pigtail
P
R
O
G
R
U
N
S
T
A
R
T
OSSD 1
OSSD 2
POWER
STROKE SELECT
O
F
F
I
N
C
H
S
I
N
G
L
E
C
O
N
T
MODE SELECT
1
H
A
N
D
2
H
A
N
D
F
O
O
T
MICRO-INCH
O
F
F
O
N
BRAKE WARNING
INTERRUPTED STROKE
TOP STOP ANGLE
AUTO CARRYUP
STOP TIME LIMIT
MICRO-INCH
STOPPING TIME
STOPPING ANGLE
90° STOP TEST
COUNTER
COUNTER PRESET
ANGLE / SPM
ca on angle ca off angle
WPC 2000 Honeywell
Wintriss® Clutch/Brake Control
WPC SETTINGSRESET/SELECT MUTE
New Wintriss Clutch/Brake
Control
or
O
F
F
P
R
O
G
O
N

Shadow 8 User Manual 1139300
Introduction 1-5
An optional control enclosure (see Figure 1-3) is available for Main Receiver and Transmitter
unless you are connecting Shadow 8 to a new Wintriss Clutch/Brake Control. The enclosure
can accommodate any-sized receiver and transmitter. No special settings are required. The
control contains a power supply and relay circuitry.
For added security, the control comes standard with two key switches. The Program/Run/
Start key switch is used alone to reset the light curtain after machinery has been stopped due
to a fault (see Figure 1-3). Simply turn the switch to the START position to clear the interlock
or alarm condition. The Program/Run/Start key switch can also be used with the Program
Off/On key switch to program a fixed blanking pattern. See Programming a Fixed Blanking
Window, page 3-4 for details. In addition, the clasp which secures the door of the control can
be padlocked to prevent unauthorized personnel from gaining entry. A screw-down latch for
securing the door is also provided.
Cables for connecting the control to the Main Receiver and Transmitter are available with the
light curtain. They are sized in various lengths and fitted with a keyed, threaded connector at
one end that screws easily into the pigtail-and-connector on the optic heads. The other end of
the cable is not terminated, allowing the cable to be wired to the appropriate terminal block in
the optional control (see Figure 2-20, page 2-32) or in the WPC. Receiver cables, which are
terminated by a connector with a red overmold, are eight-conductor, shielded. Transmitter
cables are five-conductor, shielded and have black connector overmolds.
Figure 1-3. Shadow 8 Control
OSSD 1
OSSD 2
Clasp
Program/Run/Start
key switch POWER
O
F
F
P
R
O
G
O
N
P
R
O
G
R
U
N
S
T
A
R
T
Program Off/On
key switch
Latch

1139300 Shadow 8 User Manual
1-6 Introduction
Shadow 8 Operation
The Shadow 8 light curtain is an optoelectronic presence-sensing device. Shadow 8 uses light
and electric current to detect any object penetrating its field, and when an object is detected,
the light curtain reacts by signaling the press, or other equipment, to stop.
Shadow 8’s transmitter and receiver are mounted on either side of the hazardous area. LEDs
(light emitting diodes) in the transmitter emit harmless, invisible, infrared light pulses when
electric current passes through them. These conical beams of light are aimed at
phototransistors in the receiver (see Figure 1-4), which produce an electrical signal whenever
a light pulse strikes them. An invisible light barrier is formed by these infrared light beams
passing between the transmitter and receiver. If one of the phototransistors in the receiver
does not “receive” its designated light pulse, as when the operator’s hand or another
obstruction penetrates the light field, Shadow 8 sends a stop command to the press.
UNPROTECTED EQUIPMENT MAY CONTINUE TO OPERATE AFTER GUARDED PRESS
STOPS
Ensure that all operators know which device(s) are protected by your Shadow safety light curtains
and which are not. Though a protected press will stop when the Shadow light curtain is
interrupted, associated feeds and conveyors not protected by Shadow will continue to operate
after the press stops.
Failure to comply with these instructions could result in death or serious injury.
Figure 1-4. Shadow 8 Light Beams
WARNING
!
Transmitter ReceiverLight beams

Shadow 8 User Manual 1139300
Introduction 1-7
Transmitter LEDs pulse in succession from end to end of the head. Each phototransistor in
the receiver detects only the single pulse of light aligned with it and is only enabled at the
instant that the beam is anticipated. Shadow 8’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 8 will send a stop command to the guarded machinery.
Between 7 and 9 consecutive beams on Main heads, depending on Shadow 8 model, and 2
consecutive beams on Extensions must be aligned and unobstructed at all times to allow
receiver(s) and transmitter(s) to synchronize their sequencing (see Shadow 8 LED Displays,
page 1-9 and Programmable Fixed Blanking, page 1-11).
Because the receiver only accepts infrared light pulses of a certain duration in proper
sequence, Shadow 8 does not respond to other light sources, continuous or pulsed. Neither
normal lighting near the curtain nor changes in area lighting nor even flashing strobe lights
affect Shadow 8 operation.
Shadow 8 Object Sensitivity
Shadow 8 light beams are on 0.79-in. (20-mm) centers, enabling the light curtain to detect any
object 1.18 in. (30 mm) in diameter or greater. An object smaller than 1.18 in. can pass
undetected through Shadow’s light field if it travels in a path directly between the light beams.
This measure of minimum detection diameter is called the light curtain’s “object sensitivity.”
Object sensitivity is used in calculating the “safety distance,” the distance from the hazardous
area of the press that the optic heads must be mounted to allow enough time for the light
curtain to react, and the press to stop, before the operator can penetrate the light curtain and
reach the hazard (see Calculating the Safety Distance, page 2-2).
Shadow 8 and Control Reliability
OBSERVE PROPER INSTALLATION PROCEDURES
• Install Shadow safety light curtains in compliance with applicable OSHA and ANSI safety
regulations (extracts are provided in Appendix D).
• 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 optional Shadow control box safety relays are used in any Shadow installation
and that they are connected directly to the press control’s stop circuit, to a PLC, or to another
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
!

1139300 Shadow 8 User Manual
1-8 Introduction
Shadow 8 is “control reliable” as defined by OSHA and ANSI. A control-reliable device must
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” (OSHA 1910.217 (c) (3) (iii) (c)).
All critical components in Shadow 8 are duplicated so that if one component fails, its
duplicate will still allow the guarded machinery to be stopped. When a component failure
occurs, Shadow 8 immediately detects it and sends a stop signal to the machinery. The light
curtain will not allow equipment to resume operation until repairs are made to the failed
component.
The Shadow 8 receiver has two solid-state PNP safety outputs that source 24 Vdc when the
sensing field is unobstructed. When an obstruction enters the field, Shadow’s circuitry
instantly de-energizes the outputs. Safety outputs must be wired to either the optional Shadow
8 control or to a new WPC.
The Shadow 8 control has two cross-checked “captive contact” safety relays, one N/O
(Normally Open), the other either N/O or N/C (Normally Closed). 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.
The new WPC clutch/brake control also has two “captive-contact” N/O safety relays. When
an obstruction enters the sensing field while the machine is energized, WPC instantly
de-energizes its relays, stopping the press.
Shadow 8’s response time from loss of light to relay contacts open (or de-energized) is 23 to
59 milliseconds, depending on configuration (see Table 1-1, page 1-13). Even if one of
Shadow’s control relay contacts fails closed (i.e., the contact welds shut), the second relay
will still de-energize and a stop signal will be sent to the machinery. Shadow 8 will also
detect the failed relay and will not allow further press operation until the relay is replaced (see
Checking and Replacing Control Relays in Optional Shadow 8 Control Box, page 4-9)
UNPROTECTED EQUIPMENT MAY CONTINUE TO OPERATE AFTER GUARDED PRESS
STOPS
Ensure that all operators know which device(s) are protected by your Shadow safety light curtains
and which are not. Though a protected press will stop when the Shadow light curtain is
interrupted, associated feeds and conveyors not protected by Shadow will continue to operate
after the press stops.
Failure to comply with these instructions could result in death or serious injury.
OSHA and ANSI have issued regulations for the use of presence-sensing devices such as
Shadows. Both organizations require control reliability. See Appendix D for more information.
WARNING
!
NOTICE

Shadow 8 User Manual 1139300
Introduction 1-9
Shadow 8 LED Displays
Shadow 8 provides the following LED displays on the Main Receiver and Transmitter and on
the optional control to provide information about light curtain operation.
•Three operating state LED indicators located on the pigtail end of the Main Receiver (see
Figure 1-1).
•One status LED indicator located on the pigtail end of the Main Transmitter. When this
yellow LED is lit, wiring connections between the Main Transmitter and the Wintriss
Clutch/Brake control or Shadow 8 control are good.
•Red Individual Beam Indicator (IBI) LEDs next to each phototransistor on the receiver.
•Green power and safety relay LEDs on the cover of the optional control (see Figure 1-3).
Operating state LEDs provide the following information about Shadow 8 operation (see
Shadow 8 Operating States, below):
•Machine Run/Stop (Green/Red) LED–When LED is green, light curtains are unobstructed.
When LED is red, light curtains are obstructed or Shadow 8 has experienced an internal
fault. The state of the yellow Interlock/Alarm LED (see next item) indicates which of these
conditions applies.
•Interlock/Alarm (Yellow) LED–Light curtains are obstructed (LED lit continuously) or
Shadow 8 has experienced an internal fault (LED flashing).
•Blanking Active (Amber) LED–Programmable fixed blanking and/or floating blanking
feature has been enabled (see Programmable Fixed Blanking, page 1-11 and Floating
Blanking, page 1-11). Fixed blanking is enabled by default.
The red Individual Beam Indicator LED next to each phototransistor on the receiver becomes
lit whenever the light pulse from the corresponding beam on the transmitter is not detected.
These LEDs indicate either a penetration of the light curtain or receiver/transmitter
misalignment. When the required number of consecutive beams are not in alignment (see
Table 2-13, page 2-50), alternate IBIs on the misaligned receiver(s) illuminate. Detailed
instructions for using IBIs during alignment of Shadow 8 optic heads is provided starting on
page 2-49.
Selected IBIs on the Main Receiver also illuminate whenever there is a fault condition, which
is indicated by a continuously lit red Machine Run/Stop LED and a flashing Interlock/Alarm
LED. Each digit of the fault code is represented by a string of consecutively illuminated,
flashing IBIs. Each digit is separated by an unlit IBI and terminated by a string of unlit IBIs
(see Figure 4-1, page 4-2 for an example). Fault codes are fully documented, including
suggested remedies for each fault, in Chapter 4 of this manual.
When the amber Blanking Active LED is lit, indicating that programmable fixed blanking or
floating blanking has been enabled, illuminated IBIs identify beams that have been
programmed as a fixed blanking window. When the obstruction being blanked is present, the
Machine Run/Stop LED is lit green. When the obstruction is removed, the IBIs defining that
area of the light curtain remain lit, but the Machine Run/Stop LED turns red.