PDF User Manual

SensaGuard

TM

18 mm Plastic Barrel

Installation Instructions

Certifications

IMPORTANT:

SAVE THESE INSTRUCTIONS FOR FUTURE USE

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Table of Contents

Installation Instructions

3

Warnings

3

Technical Specification

3

Operating Characteristics

3

Outputs (internally fused)

3

Environmental

3

Protection

4

Dimensions

4

Mode of Operation

4

Status Indicators

4

Mounting Information

4

Nut Torque Specification

4

Minimum Distance Between Sensors

5

Misalignment Curve

5

Wiring Diagram

5

Recommended Mating Cable

5

Diagnostics

5

Troubleshooting

6

Application Wiring Examples

8

List of Recommended Relays

12

Maintenance

12

Repair

12

Declaration of Conformity

12

PA-75056-180-01(A), September 2006

2

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions

 

Installation Instructions

Installation must be in accordance with the following steps and stated specifications and should be
carried out by suitable competent personnel. The unit is not to be used as a mechanical stop. Guard
stops and guides must be fitted. Adherence to the recommended maintenance instructions forms part
of the warranty.

This device is intended to be part of the safety related control system of a machine. Before installation,
a risk assessment should be performed to determine whether the specifications of this device are suit-
able for all foreseeable operational and environmental characteristics of the machine to which it is to
be fitted. Refer to Technical Specifications for Certification information and ratings.

ATTENTION:

The presence of spare actuators compromise the integrity of the safety sys-
tems. Personal injury or death, property damage or economic loss can result.
Appropriate management controls, working procedures and alternative protec-
tive measures should be introduced to control their use and availability.

WARNING

: 

Do not defeat, tamper, remove or bypass this unit. Severe injury to personnel
could result. The sensor MUST be connected to a Class 2 SELV 24V DC,
+10% / -15% power supply.

Technical Specification

Safety Ratings 

CAT4/SIL3

Safety Certifications 

TÜV, CE

Safety Standards 

IEC60947-5-3, IEC61508, EN954

Certifications cULus
Standards

UL 508

PFHd 

1.119 - 10

-9

Operating Characteristics

Sensing Distance (Actuator) 

18 mm 

30 mm

Assured Make (mm) 

15 

25

Assured Break (mm) 

25 

35

Typical misalignment 

(±7 mm in both axes)

Maximum output current (all
outputs, mA)

200

Input Current 

50 mA (no load supply current)

Operational Current, Min.

≤ 

1 mA DC

Off-state Current

< 0.5 mA DC

Maximum # of switches, connected in series

Unlimited. See unit response time section 

Operating Voltage

24V DC +10% / -15%
Class 2 SELV power supply

Frequency of operating cycle 

1 Hz

Response Time (Off) 

54 ms

Case Material 

Valox

®

DR 48

Actuator Material 

Valox

®

DR 48

Outputs (internally fused)

OSSD 2
Auxiliary 1

Environmental

Operating Temperature 

-10…+55°C (+14…+131°F)

Operating Humidity 

5% -95% relative

Washdown rating 

NEMA 3, 4X, 12,13, IP 69K

Shock & Vibration

IEC68-2-27 30 g, 11 ms/IEC 68-2-6
10…55Hz

Radio Frequency

IEC 61000-4-3
IEC 61000-4-6

PA-75056-180-01(A), September 2006

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions     

3

 

Protection

Short-Circuit Protection 

Incorporated

Current limitation 

Incorporated

Overload Protection 

Incorporated

False Pulse Protection 

Incorporated

Transient Noise Protection 

Incorporated

Reverse Polarity Protection 

Incorporated

Overvoltage protection 

Incorporated

Thermal shutdown/restart 

Incorporated

Electrical Life 

10 x 10

6

Dimensions - mm (inches)

Mode of Operation

Status indicators:

• 

“Power/Fault” LED illuminates Green - 

The unit is ready for operation.

• 

“Power/Fault” LED illuminates Red: - 

Door/Guard open. The unit is not ready for operation.

• 

“Power/Fault” LED illuminates flashes Red or Green: - 

Unit failure. See Diagnostic section below.

Mounting Information

Use non-removable screws, bolts, or nuts to mount the switch and
actuator. Do not over torque the mounting hardware. 

Position the switch and actuator so they are aligned with each other.

Mount the switch and actuator to removable guard, door or gate.
Keep the switch and actuator within the sensing range below.

Nut Torque Specification

Plastic Barrel Switch: 2.26 N

•

M (20 in

•

lbs)

Plastic Actuators: 2.26 N

•

M (20 in

•

lbs)

PA-75056-180-01(A), September 2006

4

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions

30 mm Actuator

48.92

[1.926]

19.81
[0.78]

22.22

[0.875]

48.92

[1.926]

19.81
[0.78]

22.22

[0.875]

30.40

[1.197]

16.84

[0.663]

3.17

[0.125]

4.57

[0.18]

DIA

2 PLACES

Sensor

18 mm Actuator

67.06

[2.640]

2.03

[.080]

M18X1

36.47

[1.436]

13.72
[0.54]

15.87

[0.625]

36.47

[1.436]

13.72
[0.54]

15.87

[0.625]

4.57

[0.180]

DIA

19.81
[0.78]

3.17

[0.125]

15.42

[0.607]

2 PLACES

 

Minimum Distance Between Sensors

Misalignment Curve

18 mm Unit with 18 mm Target

18 mm Unit with 30 mm Target

Note:

There must be a minimum spacing of 4 mm

(0.157 in) if actuator and sensor face approaches
laterally. This will prevent false triggering due to the
side lobe areas.

Wiring Diagram

Pin #

Wire Color

Signal

1

White

Aux Outputs

2

Brown

+24V

3

Green

NA

4

Yellow

OSSD 2, +24V Input

5

Grey

OSSD 1

6

Pink

OSSD 2

7

Blue

0V

8

Red

OSSD 1, +24V Input

Recommended mating cable, 2 m (6.5 ft). 889D-F8AC-2.  

Lengths are available up to 30 m (98.4 ft)

Diagnostic

Unit Indicators (per IEC 60073)

State

Status

Troubleshooting

Off

Not Powered

NA

Device Output

Red

Not Safe, OSSD not active

NA

LED

Green

Safe, OSSD active

NA

Green flash

Power up test or OSSD

Check 24V DC or OSSD inputs

inputs not valid  

(yellow and red wire)

Red Flash

1 Hz Flash Recoverable Fault

Recoverable fault —check OSSD

4 Hz Flash Non-recoverable Fault

outputs are not shorted to GND,

24V DC or each other. Cycle power.

PA-75056-180-01(A), September 2006

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions     

5

18 mm Actuator

75 mm

Sensor

1

Sensor

2

30 mm Actuator

100 mm

Sensor

1

Sensor

2

Lateral Misalignment Tolerance—mm (in)

Face to Face Distance—mm

-15 

(-0.59)

-10 

(-0.39)

-5 

(-0.19)

0

5 

(0.19)

10 

(0.39)

15 

(0.59)

0

5

10

15

20

25

-25 

(-0.98)

-20 

(-0.787)

20 

(0.787)

25 

(0.98)

Side Lobe

Side Lobe

Assured Sensing

Distance

OFF

OFF

ON

0

5

10

15

20

25

30

35

-30

(-1.18)

-20

(-0.787)

-10

(-0.39)

010

(0.39)

20

(0.787)

30

(1.18)

Face to Face Distance—mm

Side Lobe

Side Lobe

Assured Sensing

Distance

OFF

OFF

ON

Lateral Misalignment Tolerance—mm (in)

Note:

There must be a minimum spacing of 7

mm (0.275 in) if actuator and sensor face
approaches laterally. This will prevent false 
triggering due to the side lobe areas.

4

7

6

8

1

5

2

3

Brown

White

Blue

Pink

Grey

Green

Red

Yellow

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Troubleshooting

Series Circuit

PA-75056-180-01(A), September 2006

6

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions

Yel

Red

Brown

Gray

Pink

Blue

24VDC

Power

Supply

1606

-XL120D

Switch 1

+24

RT

N

Switch 2

White

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 1

Actuator 2

Switch 3

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 3

Switch 4

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 4

Switch 5

White

Yel

Red

Brown

Gray

Pink

Blue

Actuator 5

 

 

+24 V

+24 V

+24 V

+24 V

+0 V

+0 V

+0 V

+0 V

+0 V

+0 V

Actuator 2 is in sensing range.

Switch 

2 is functioning pr

operly

OSSDs ar

e ener

gize to 24 V

Gr

een LED is ON.

Actuator 3 is in sensing range.

Switch 

3 has fault.

See

 T

able

 Above—Red LED is flashing

Actuator 1 is in sensing range.

Switch 

1 is functioning pr

operly

OSSDs ar

e ener

gize to 24 V

Gr

een LED is ON.

Actuator 4 is in sensing range.

Switch 

4 is functioning pr

operl

y
.

Series inputs ar

e 0

V

.

OSSDs ar

e de-ener

gized to 0V

.

Gr

een LED is Flashing to indicate

Series inputs ar

e not 24

V

.

Actuator 5 is in sensing range.

Switch 

5 is functioning pr

operl

y

.

Series inputs ar

e 0

V

.

OSSDs ar

e de-ener

gized to 0

V

.

Gr

een LED is Flashing to indicate

Series inputs ar

e not 24

V

.

OSSD

’s

 ar

e OF

F

Recoverable fault

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Unit Response Time (does not include safety relay response time)

PA-75056-180-01(A), September 2006

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions     

7

Yel

Red

White

Gray

Pink

Blue

24V DC

Power

Supply

1606

Sensor 1

+24

RT

Sensor 2

Brown

Brown

Gray

Pink

White

Yel

Red

Blue

Sensor 3

Brown

Yel

Red

White

Gray

Pink

Blue

A1

S21

S11

41

33

23

13

S12

S52

42

34

24

14

A2

S34

S22

440R-N23126

Actuator 1

Actuator 2

Actuator 3

Initial Conditions:

All actuators are in sensing 

distance.

Actuator 1 is moved out of

sensing range.

Sensor 2 drops the 24 volts 

(red and yellow) from Sensor 1 

OSSD outputs.

Green LED flashes.

Sensor 3 drops the 24 volts 

(red and yellow) from Sensor 2 

OSSD outputs.

Green LED flashes.

0 mS

54 mS

72 mS

90 mS

Actuator 1 is out of sensing 

range.

Actuator 2 and 3 are in 

sensing range.

Actuator 1 is moved into sensing 

range.

Sensor 1 OSSD outputs are 

energized.

Sensor 2 OSSD inputs (red and yellow) 

transition to 24V DC from Sensor 1 

OSSD outputs.

Sensor 2 OSSD outputs are energized

Sensor 3 OSSD inputs (red and 

yellow) transition to 24V DC from 

Sensor 2 OSSD outputs.

Sensor 3 OSSD outputs are 

energized.

0 mS

360 mS

378 mS

396 mS

OFF

ON

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Application Wiring Examples

PA-75056-180-01(A), September 2006

8

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions

K1

+24V DC

MSR127RP with 1 sensor

, monitor

ed manual r

eset, drivin

g

 100S or 700S safet

y contr

o

llers.

A1

S11

S52

S12

13

23

33

41

S21

S22

S34

A2

14

24

34

42

MSR127RP

Reset

GND

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuar

d

Unit 1

K2

+24V DC

GND

MSR127RP with 3 sensors in series, monitor

ed manual r

eset, drivin

g

 100S or 700S safet

y contr

o

llers

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuar

d

Unit 1

SensaGuar

d

Unit 2

SensaGuar

d

Unit 3

K1

A1

S11

S25

S

12

13

23

33

41

S21

S

22

S34

A

2

14

24

34

42

MSR127RP

Reset

K2

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

MSR127RP with 3 sensors and 1 440L light curtain in series, monitor

ed manual r

eset, driving 100S or 700S safety r

elays.

Note:

 Light curtain must be last (farthest fr

om MSR127).

GND

A1

S11

S52

S12

13

23

33

41

S21

S22

S34

A2

14

24

34

42

MSR127RP

Reset

K1

K2

+24V DC

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuar

d

Unit 1

SensaGuar

d

Unit 2

SensaGuar

d

Unit 3

Guar

dShield

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

A1

S11

S52

S12

13

23

33

41

S21

S22

S34

A2

14

24

34

42

MSR127TP

GND

MSR127RP with 1 sensor

, automatic r

eset, drivin

g

 100S or 700S safet

y contr

o

llers

+24V DC

SensaGuar

d

Unit 1

K1

K2

Blue

Gray

Pink

Yellow

Red

Brown

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Application Wiring Examples

PA-75056-180-01(A), September 2006

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions     

9

MSR127TP with 3 sensors in series, automatic r

eset, drivin

g

 100S or 700S r

ela

ys.

MSR127TP

+24V DC

GND

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuar

d

Unit 1

K1

A1

S11

S52

S12

13

23

33

41

S21

S22

S34

A2

14

24

34

42

K2

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

SensaGuar

d

Unit 3

SensaGuar

d

Unit 2

MSR127TP with 3 sensors and 1 440L light curtain in series, automatic r

eset, driving 100S or 700S safety contactors.

Note:

 Light curtain must be last (farthest fr

om MSR127)

MSR127TP

GND

A1

S11

S52

S12

13

23

33

41

S21

S22

S34

A2

14

24

34

42

K1

K2

+24V DC

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Blue

Gray

Pink

Yellow

Red

Brown

Guar

dShield

SensaGuar

d

Unit 1

SensaGuar

d

Unit 3

SensaGuar

d

Unit 2

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Application Wiring Examples

PA-75056-180-01(A), September 2006

10

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions

MSR200 series with 3 sensors and 1 440L light curtain, automatic r

eset, driving 100S or 700S safety contactors.

Note:

 Li

g

ht curtain can be attached to an

y in

p

ut

Guar

dShield

+24V DC

GND

440R-H23177

Y40

Y

41

S51

S12

S20

S

32

S11

S

21

S31

S

41

13

23

31

Y42

A

1

S32

S20

S12

S42

S50

S

62

S34

Y

1

Y

2

Y

3

14

24

32

Y

32

Y33

Y

30

A2

S62

S50

S42

440R-H23179

K1

S32

S20

S12

S62

S50

S42

S32

S32

440R-H23180

MSR221P

MSR211P

MSR230P

K2

K1

K2

K3

K4

SensaGuar

d

Blue

Brown

Gray

Pink

Blue

Brown

Yellow

Red

Gray

Pink

SensaGuar

d

SensaGuar

d

Gray

Pink

Gray

Pink

Blue

Brown

Yellow

Red

Blue

Brown

Yellow

Red

MSR200 series with 4 sensors and 1 440L light curtain, manual r

eset, driving 100S or 700S safety contactors.

Note:

 Li

g

ht curtain can be attached to an

y in

p

ut.

Reset

Guar

dShield

+24V DC

GND

440R-H23177

Y40

Y41

S51

S12

S

20

S32

S

11

S21

S31

S41

13

23

31

Y42

A

1

S32

S20

S12

S42

S

50

S62

S34

Y1

Y2

Y3

14

24

32

Y32

Y33

Y30

A

2

S62

S50

S42

440R-H23179

K1

S32

S20

S12

S62

S50

S42

S32

S32

440R-H23180

MSR221P

MSR211P

MSR230P

K2

K1

K2

K3

K4

SensaGuar

d

Blue

Brown

Gray

Pink

Blue

Brown

Yellow

Red

Gray

Pink

SensaGuar

d

SensaGuar

d

Gray

Pink

Gray

Pink

Blue

Brown

Yellow

Red

Blue

Brown

Yellow

Red

Note:

Refer to Technical Specifications for Certification information and ratings.

 

Application Wiring Examples

PA-75056-180-01(A), September 2006

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions    

11

MSR200 series with 4 sensors, automatic r

eset, driving 100S or 700S safety contactors.

Yellow

Red

+24V DC

GND

440R-H23177

Y40

Y41

S51

S12

S20

S32

S11

S21

S31

S41

13

23

31

Y42

A1

S32

S20

S12

S42

S50

S62

S34

Y1

Y2

Y3

14

24

32

Y32

Y33

Y30

A2

S62

S50

S42

440R-H23179

K1

S32

S20

S12

S62

S50

S42

S32

S32

440R-H23180

MSR221P

MSR211P

MSR230P

K2

K1

K2

K3

K4

SensaGuar

d

SensaGuar

d

Blue

Brown

Gray

Pink

Blue

Brown

Yellow

Red

Gray

Pink

SensaGuar

d

SensaGuar

d

Gray

Pink

Gray

Pink

Blue

Brown

Yellow

Red

Blue

Brown

Yellow

Red

MSR200 series with 4 sensors, manual r

eset, drivin

g

 100S or 700S safet

y contactors.

Reset

+24V DC

GND

440R-H23177

Y40

Y41

S51

S12

S20

S32

S11

S21

S31

S41

13

23

31

Y42

A1

S32

S20

S12

S42

S50

S62

S34

Y1

Y2

Y3

14

24

32

Y32

Y33

Y30

A2

S62

S50

S42

440R-H23179

K1

S32

S20

S12

S62

S50

S42

S32

S32

440R-H23180

MSR221P

MSR211P

MSR230P

K2

K1

K2

K3

K4

SensaGuar

d

SensaGuar

d

Blue

Brown

Gray

Pink

Blue

Brown

Yellow

Red

Yellow

Red

Gray

Pink

SensaGuar

d

SensaGuar

d

Gray

Pink

Gray

Pink

Blue

Brown

Yellow

Red

Blue

Brown

Yellow

Red

Note:

Refer to Technical Specifications for Certification information and ratings.

 

List of recommended relays

MSR126, MSR127, MSR123, MSR124, MSR131, MSR138, MSR211, MSR121, MSR320, MSR200
Family (Except MSR210), MSR300 Family, SmartGuard, 1791 DS DeviceNet™ Safety I/O

Maintenance

Every week.

Check the correct operation of the switching circuit. Also check for signs of abuse or tampering.
Inspect the switch casing for damage

Repair

If there is any malfunction or damage, no attempts at repair should be made. The unit should be
replaced before machine operation is allowed.

Declaration of Conformity

This is to declare that the products shown on this document conforms with the Essential Health and
Safety Requirements (EHSR’s) of the European Machinery Directive (73/23/EEC as amended by
93/68/EEC). These products also conform to EN 60947-5-3, EN 1088, EN292, EN 60204-1 and have
Third Party Approval.

For a comprehensive certificate please visit: 

www.ab.com/safety

.

Publication 75056-180-01(A), September 2006

12

SensaGuard

TM

18 mm Plastic Barrel Installation Instructions

Check the machine is 
isolated and stopped 
whenever the interlocked 
guard door is open.

IMPORTANT:

 After

installation and 
commissioning, the 
actuator, switch and switch 
lid fixing screws should be 
coated with tamper evident 
varnish or similar compound.

o