GAMMA SYSTEM GP02/E Bedienungsanleitung

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 1/35

USE AND MAINTENANCE MANUAL

PRESSURE-SENSITIVE BUMPERS

TYPE GSBPS

IN COMBINATION WITH CONTROL UNITS

TYPE GP02/E –GP02R.T

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 2/35

Revisions

REVISION

DATE

DESCRIPTION

20-1-2010

First draft

20-05-2016

Legislative reference update

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 3/35

Sommario

1Introduction.............................................................................................................................4

2Important warnings about safety ..........................................................................................4

2.1 Improper use ..........................................................................................................................5

2.2 Environmental limits..............................................................................................................5

3Legislative Reference..............................................................................................................6

3.1 Approvals.................................................................................................................................6

3.2 Identification plate..................................................................................................................7

4Description and working principle........................................................................................8

5Description of the product......................................................................................................9

5.1 Force-travel relation.............................................................................................................10

5.2 Technical Specifications of sensors.....................................................................................15

5.3 Chemical resistance .............................................................................................................16

6Applications...........................................................................................................................17

7SELECTING THE BUMPER WHICH BEST SUITS YOUR REQUIREMENTS .......18

7.1 How to select the correct pressure-sensitive bumper...........................................................19

8Transport and Package ........................................................................................................21

8.1 Storage .................................................................................................................................21

9Installation.............................................................................................................................22

9.1 Sensor location.....................................................................................................................22

9.2 Fastening..............................................................................................................................22

9.3 Wire connection...................................................................................................................24

Wire connection to the connector 4 pole.......................................................................................24

Wires connection without connector.............................................................................................24

10 Commissioning......................................................................................................................25

10.1 Functional test......................................................................................................................25

10.2 Verification of the system integrity.....................................................................................25

10.3 Testing Procedure ................................................................................................................27

11 Control unit or control device for bumpers........................................................................28

12 Maintenance ..........................................................................................................................29

12.1 Periodical Maintenance........................................................................................................29

13 FAILURES AND POSSIBLE CAUSES .............................................................................31

14 Warranty................................................................................................................................33

15 EC Declaration of conformity..............................................................................................34

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 4/35

1 Introduction

This Manual should always be kept by the user in a safe and accessible place for further consultation by the

personnel.

Installation and maintenance procedures are to be carried out only by qualified, well trained personnel in all

safety procedures. The pressure-sensitive bumper is used as protection against the risk of accidents/injuries

which can be eliminated by switching off the electrical energy.

Global safety of either the machine and pressure-sensitive bumpers depends on the compatibility and

reciprocal integrity of these components.

Carefully take into consideration the risk assessment of the machine to protect in order to choose the correct

safety category in compliance with the requirements of the EN ISO 13849-1

2 Important warnings about safety

This Manual is intended for use in conjunction with the Manual of the control units. Please read this Manual

carefully and completely before doing any work on the bumper or on the control unit.

The pressure-sensitive bumper used together with the control unit is a safety component used to protect

persons from shearing movements which may become a source of danger or injuries.

The bumper can be used as a “tripping device”, which means it is capable of stopping the movement of the

hazardous element or as a device to detect the presence of a person or part of a person.

In order to ensure that a special application of the safety bumper with the control unit used to protect a

machine/installation meets the existing rules it is necessary to assess: the risk level of the

machine/installation and the compatibility with the safety level declared by GAMMA SYSTEM; furthermore, it

should also be borne in mind that the “performance level” in conformity with EN ISO 13849-1 Standard for

pressure-sensitive bumpers (safety bumpers) used on machines/devices is defined by Type C

Standards

Other fundamental elements are the installation, maintenance and verification of proper operation of the

pressure-sensitive bumper together with the control unit.

These assessments and elements are the sole responsibility of the purchaser, installer and employer.

The additional requirements indicated below are to be met with before using the pressure-sensitive bumper

together with the control unit:

The machine onto which the pressure-sensitive bumper and the control unit are installed must be

able to come to a safe stop at any point along its working cycle. If the pressure-sensitive bumper

(used to detect the presence of persons) and the relevant control unit are used as a safety device ,

the employer is responsible for ensuring that all requirements, rules, codes and regulations

applicable under current rules are fully satisfied.

All braking and locking mechanisms are to be checked regularly so to ensure their correct operation.

If the locking mechanisms do not work correctly, there is a risk that the machine stops in an unsafe

manner even if the pressure-sensitive device (bumper) and the control unit are working correctly.

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 5/35

The testing procedure is to be carried out while installing the device and after each maintenance or

adjustment operation carried out on the machine. The correct testing procedure is described in this

Manual.

All electrical wirings are to be carried out and installed in compliance with the existing regulations

and electrical local Standards.

The user must follow all procedures described in this manual so to ensure the correct use of the

pressure-sensitive bumpers type GSBPS01, GSBPS02 and GSBPS03, in conjunction with the

control units type GP02/E or GP02R.T.

The employer is responsible for the selection and training of the personnel charged with the

installation, use and maintenance of the machine and its relevant safety system. It is mandatory for

the user of the machine to report all and any malfunctioning of the machine, tools and safety

devices. DO NOT put the machine into operation if the safety device is not working correctly.

2.1 Improper use

THE BUMPER AND THE CONTROL UNIT SHALL NOT BE USED:

In control circuits and equipment featuring inadequate stop time or inadequate control

instruments/mechanisms.

In environments which can adversely affect the correct working of the bumper and/or of the control unit

(i.e.: environments with the presence of chemical, corrosive agents).

To start the machine movement.

In environments where there is a risk of explosion or a risk of flood (where devices risk to be covered

with water).

In places where there is the passage of heavy means (forklift trucks, motor vehicles and similar ones).

Beyond the use and storage temperature limits.

In applications where finger detection is required.

2.2 Environmental limits

The material of the sensor can resist the deteriorative effects of ozone, sun rays, water, acids, bases, oily

liquids, fats. Hydraulic oils and cutting oils do not cause any damage.

Very aggressive liquids such as phosphoric acid, nitric acid, Freon, etc… can cause the deformation and the

loss of the material characteristics. The exposure to very high temperatures damages the product (the

product should be stocked at a temperature in the range -10 and +50°C).

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 6/35

3 Legislative Reference

The safety device called

PRESSURE-SENSITIVE BUMPER

consisting of the sensor type: GSBPS01, GSBPS02, GSBPS03

In combination with the control unit type: GP02/E, GP02R.T

has been designed and manufactured in compliance with the essential safety and health requirements for

people’s safeguarding. In particular, the design and manufacture provisions prescribed by the Machine

Directive 2006/42/UE, and the Electromagnetic Compatibility Directive 2014/30/UE, as well as the

European harmonized Standards for risk prevention (EN ISO 12100:2010) have been complied with. Also

taken into account have been the domestic technical specifications, in consideration of the technological

level in force at the moment of construction as well as of the technical and economical requirements.

GAMMA SYSTEM PRESSURE-SENSITIVE BUMPERS also comply with the applicable requirements of the

following Standards:

EN ISO 13856-3:2013

Safety of machinery - Pressure-sensitive protective devices - Part 3:

General principles for design and testing of pressure-sensitive

bumpers, plates, wires and similar devices (ISO 13856-3:2013)

EN ISO 13849-1

Safety of machinery - Safety-related parts of control systems - Part 1:

General principles for design (ISO 13849-1:2015)

EN 60204-1

Safety of machinery - Electrical equipment of machines - Part 1:

General requirements

CEI EN 60529: 1997 + A1: 2000

Degrees of protection of casings ( degree of protection IP)

EN ISO 12100:2010

Safety of machinery - General principles for design - Risk assessment

and risk reduction (ISO 12100:2010)

Other European Directives

2012/19/UE

(RAEE)

2011/65/UE

(ROHS)

(EC) Standard (CE) n°1907/2006

(REACH)

3.1 Approvals

Pressure-sensitive bumpers formed by the sensor type GSBPS0x (x=1,2,3) and used in combination with the

control units type GP02/E or GP02R.T conform to the requirements of EN ISO 13856-3 Standard.

The sensor GSBPS0x (x=1,2,3) in combination with the control units type GP02/E or GP02R.T is a safety

component of class 3 PL “d” which meets the prescriptions of EN ISO 13849-1 Standard. According to the

destination of use and the limits of use defined by the manufacturer, it is excluded that a mechanical failure

of the sensor can lead to the loss of safety function of the devices, meaning that, even if triggered, the

internal contact of the sensor cannot make. Also excluded is the risk for cuts with the ingress of foreign

bodies inside the sensor chamber capable of impairing the sensor operation or modifying its sensitivity (force

of activation).

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 7/35

3.2 Identification plate

Sensors are identified by the identification plate shown below:

GAMMA SYSTEM S.r.l

10044 PIANEZZA (TO) Italy

Via Torino 24/I

Tel: +39 011 968 24 66; Fax: +39 011 967 42 11; E-mail: info@gammasystem.com

PARAURTI SENSIBILI DI SICUREZZA

PRESSURE SENSITIVE BUMPER

Tipo/ Type

NUMERO DI

SERIE

SERIAL

NUMBER

DATA DI PRODUZIONE/ PRODUCTION

DATE

Mese / Month

Anno/year

2010

2011

As for the control units, please refer to the relevant Use and Maintenance Manual.

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 8/35

4 Description and working principle

Definition:

GAMMA SYSTEM PRESSURE-SENSITIVE BUMPER is a “safety device" used as an "electro-sensitive

protective device designed to detect persons or parts of person. It is described in Annex IV of the Machinery

Directive 2006/42/CE. In particular, it is classified as a "safety device equipped with a sensor, capable of

detecting a pressure, and a control circuit having a verification function according to the specified category

and an output interface”. The sensitive surface undergoes a local deformation which actuates the sensor”.

It consists of two essential parts:

A PRESSURE-SENSITIVE SENSOR

A CONTROL UNIT

Working principle:

When the pressure-sensitive bumper is actuated by an external force, after a defined deformation called

“pre-travel”, the two parts of the plastic material come into contact and the circuit makes. The change in state

of the internal sensor (from NO to NC) is processed by the control unit (sensor control device) which sends a

stop signal to the machine thereby eliminating the danger situation. After the pre-travel, the bumper still

allows for an extra depression called “over-travel” during which the hazardous movement is stopped.

Legend

1 Pressure-sensitive bumper

2 Sensor/s

3 Control unit (can be located inside the enclosure of the machine control system or be an integral part of the control

system itself).

4 Switching device(s) for the output signal (can be installed inside the enclosure of the machine control system or it can

be an integral part of the control system itself

5 Part of the machine control system for processing the output signal of the pressure-sensitive bumper

6 Actuation force

7 Sensor output signal

8 Signal for active state (ON)/inactive state (OFF)

9 Signal for manual reset (if appropriate, alternative to A)

10 Reset signal from the machine control system (if appropriate)

11 Monitoring signals (optional)

A Signal for manual reset of the machine control system (if appropriate, alternative to 9))

B Machine control system(s)

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 9/35

5 Description of the product

Bumpers are made of a polyurethane material (foam) exhibiting appropriate elasticity and are coated with

protective fabric. Inserted inside the bumpers is a sensitive element (“sensor”) properly secured inside the

foam. The whole is closed by a frame that is glued to the foams and the aluminum plates. Inserted inside the

bumpers is a sensitive element (“sensor”) properly secured inside the foam. The whole is closed by a frame

that is glued to the foams and the aluminum plate.

The power supply cable is a 4-pole cable - 4*0,35mm2FROR 300/500 –standard length 3 m. (CS). Different

lengths can be supplied upon request (max. 10 m); indicate the length you require when ordering.

In the standard version, the pressure-sensitive bumper comes with a black fabric coating, front side with

yellow and black oblique stripes.

Standard shapes available:

500

200

250

150

300

100

200

100

200

100

Type GSBPS03

Type GSBPS02

Type GSBPS01

Sensitive zone

Sensitive element

(“sensor”)

Frame

Plate

Polyurethane material

coated with protective fabric

Use and Maintenance Manual –Pressure-sensitive bumpers type GSBPS 10/35

Actual detection zone

The effective sensitive zone is the surface which can potentially come in contact with a person. This surface is shown in

figures above. Versions in any length can be supplied up to a maximum length of 3 mt and with shapes with

135° minimum angle

5.1 Force-travel relation

Key:

b travel, mm

a force N

1 reference forces

2 lowest actuating force

3 hazard speed

4 sensor

c sensor before contact

d point of contact

e point of actuation

f deformation at point B2

g deformation at point C

h reaction force

i established stopping travel of machine

j actuating travel

k overtravel

l working travel

m total travel

Note: Forces are related to test pieces 1

and are example only.

135°

Actuation direction

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