PSEN op4B-T, PSEN op4B-L, PSEN op4B-S Safety light curtains with infrared beams OPERATING MANUAL
A Pilz Ges.m.b.H., Automation LP., 01 7986263-0, Fax: 01 7986264, E-Mail: pilz@pilz.at AUS Pilz Australia Industrial B L Pilz Belgium, 09 03 95446300, Fax: 0395446311, E-Mail: safety@pilz.com.au 3217570, Fax: 09 3217571, E-Mail: info@pilz.be BR Pilz do Brasil Sistemas Eletr¶nicosIndustriais Ltda., 11 CH Pilz lndustrieelektronik GmbH, 062 88979-30, 4337-1241, Fax: 11 4337-1242, E-Mail: pilz@pilzbr.com.br Fax: 062 88979-40,E-Mail: pilz@pilz.ch pilz@pilz.dk E DK Pilz lndustrieelektronik S.L.
PSEN op4B Series Operating Manual OVERVIEW OF CONTENTS 1 GENERAL INFORMATION .......................................................................................... 1 1.1 General description of the safety light curtain ..................................................... 1 1.2 How to select a safety light curtain...................................................................... 3 1.3 Typical application areas.....................................................................................
Operating Manual PSEN op4B Series 1 GENERAL INFORMATION 1.1 General description of the safety light curtain Safety light curtains from the PSENopt series are multibeam optoelectronic protection devices. They secure work areas in which operating personnel can come into contact with moving parts of machinery, robots and automated systems in general, which present a risk of physical injury.
PSEN op4B Series NB: Operating Manual This manual uses the following abbreviations as defined in the applicable standards: AOPD Active opto-electronic protective device ESPE Electrosensitive protective equipment MPCE Machine primary control element OSSD Output signal switching device (switching output) TX Transmitting device RX Receiving device Some sections or paragraphs in this manual contain information of particular importance to those using or setting up the device.
Operating Manual PSEN op4B Series 1.2 How to select a safety light curtain • Muting function The safety light curtains are suitable for applications that require a muting function. Safety light curtains PSEN op4B-T and PSEN op4B-L are equipped with pre-assembled, pre-wired and prealigned muting sensors. The muting sensors are designed for one or two-way muting applications in an "L" or "T" shaped configuration. Safety light curtains PSEN op4B-S are linear models without integrated muting sensors.
PSEN op4B Series Operating Manual Fig. 1 The resolution can be calculated using the following formula: R=I+d The table below specifies the values for the light curtains with regard to the optical axis (I), the resolution (R) and the diameter of the optics (d). Model PSEN op4B-T-2-050 PSEN op4B-T-3-080 PSEN op4B-L-2-050 PSEN op4B-L-3-080 PSEN op4B-S-2-050 PSEN op4B-S-3-080 Optical axis mm (I) 500 400 500 400 500 400 No.
Operating Manual • PSEN op4B Series Height of protected field: Here it is important to distinguish between the “Height of the sensing area” and the “Height of the protected area” (Fig. 2). - The height of the sensing area is the distance between the upper limit of the first lens and the lower limit of the last lens.
PSEN op4B Series Operating Manual 1.3 Typical application areas Safety light curtains can be used in all areas of automation where it is necessary to control and guard access to danger zones.
Operating Manual PSEN op4B Series 1.4 Safety information For the proper, safe use of the safety light curtains, the following guidelines must be followed: 7 • It must be possible to control the machine stop electrically. • The control system must be able to stop the hazardous machine movement immediately at any stage of the operating cycle.
PSEN op4B Series Operating Manual 2 INSTALLATION 2.1 Precautionary measures when selecting and installing the device • Make sure that the category guaranteed by the safety light curtain (Type 4) matches the risk assessment for the machinery that is to be monitored, as defined in the standard EN 954-1. • The OSSD outputs on the safety light curtain must be used as machine stop devices and not as command devices (the machine must have its own START command).
Operating Manual • PSEN op4B Series Make sure that the muting sensors are used appropriately and in accordance with the following specifications. Avoid connections that are inappropriate and unmonitorable, so that any accidental, potentially hazardous activation can be prevented. 2.
PSEN op4B Series Operating Manual Also, under normal operating conditions, it must not be possible to start the machine until the operator is outside the danger zone. If it is impossible to install the safety light curtain in immediate proximity to the danger zone, a second safety light curtain must be installed and aligned horizontally, to exclude access from the side, as shown in Fig. 4b. Fig. 4a Fig.
Operating Manual 2.2.1 PSEN op4B Series Minimum safety distance The safety distance of the safety light curtain should be such that the operator cannot reach the danger zone until the movement of the hazardous machine part has come to a standstill (see Fig. 5).
PSEN op4B Series Operating Manual Please note: The value of K is: 2000 mm/s, if the value calculated for S is ≤ 500 mm, 1600 mm/s, if the value calculated for S is > 500 mm. If it is possible to access the danger zone from above and below (Fig. 5) and the devices used have a resolution of >40 mm, the upper beam must be positioned at a height of 900 mm (H2), starting from the reference plane (e.g. base of the machine), and the lower beam must be positioned at a height of 300 mm (H1).
Operating Manual 2.2.2 PSEN op4B Series Minimum distance from reflective surfaces Reflective surfaces close to the light beams emitted from the safety device (whether above, below or to the side), may cause passive reflections and adversely affect detection of the object within the protected field (Fig. 7). Fig. 7 Improper installation could mean that a protected field is interrupted without detection, resulting in serious injury.
PSEN op4B Series Operating Manual So, when installing the device close to reflective surfaces (metal walls, floors, ceilings or workpieces), it is vital that the minimum distance in relation to reflective surfaces is maintained, as shown in the diagram in Fig. 8. This minimum distance depends on: • • The range between the emitter (TX) and receiver (RX) The maximum open angle of the light beams transmitted by the emitter (TX): 5° for Type 4 ESPE (± 2.
Operating Manual 2.2.3 PSEN op4B Series Installing several adjacent safety light curtains If it is necessary to install several safety light curtains in adjacent areas, you will need to ensure that the emitter (TX) on one device cannot interfere with the receiver (RX) on another. To prevent this, the devices will need to be installed conversely or must be separated via screening (opaque surface). Fig. 9 gives an example of an installation that could lead to interference, plus two correct installations.
PSEN op4B Series 2.2.4 Operating Manual Use of deviating mirrors Deviating mirrors can be used to monitor danger zones where access is possible from various sides. Fig. 10 illustrates a potential solution for monitoring three different access sides using two deviating mirrors positioned at an angle of 45° to the safety light curtain. Fig.
Operating Manual PSEN op4B Series 3 MECHANICAL ASSEMBLY The emitter (TX) and receiver (RX) must be assembled so that the respective optical surfaces are aligned in parallel and the connectors are positioned on the same side. The distance between the emitter (TX) and receiver (RX) must be within the operating range of the model you are Fig.11 using (see type label or Chapter 9, “Technical details”). Align the devices precisely, following the guidelines given in Chapter 5, “Alignment”.
PSEN op4B Series Operating Manual Rigid mounting brackets are suitable for installations that require no large mechanical adjustments during alignment. Adjustable brackets enable the units to be inclined by ± 5° and are available on request. Where applications are subject to particularly strong vibration we recommend the use of angle brackets with vibration dampers. The drawing and table below indicate the recommended fixing points in relation to the length of the safety light curtain.
Operating Manual PSEN op4B Series 3.1 Installing the integral muting sensor profiles with "L" and "T" shaped configuration 19 • Install the unit with the active muting sensors on the receiver (RX) and the unit with the reflectors on the emitter (TX) of the safety light curtain. • Use the fastening clip to attach the muting sensor profile to the emitter (TX) and receiver (RX) of the safety light curtain.
PSEN op4B Series Operating Manual 4 WIRING 4.1 Electrical connections The electrical connections of the emitter (TX) and receiver (RX) are made via M12 connectors, which are located on the bottom of both units. RECEIVER (RX): 8-pin M12 connector OSSD1 PNP Feedback loop OSSD2 PNP 6 5 4 7 0V 3 2 1 +24 Vdc MUTING2 +24 Vdc 1 2 +24 Vdc External N.C. contact OVR1 not connected +24 Vdc Externer N.O. contact OVR2 4 3 0V +24 Vdc 8 MUTING1 0V External N.O.
Operating Manual PSEN op4B Series 4.2 Notes on wiring To ensure the correct operation of the safety light curtain, please note the following: • Safe electrical isolation must be ensured for the external 24 V supply. Failure to do so could result in electric shock. The supply voltage must conform to EN 60950, 03/97, section 2.3, EN 60742, 9/95 or EN 50178, 10/97. • Emitter and receiver must be connected using shielded cables (accessories). FIg. 14 shows how to connect the emitter and receiver properly.
PSEN op4B Series Operating Manual • The TEST/RESET input must be connected to the supply voltage on the ESPE via a button with a N/C contact. The test should be performed manually (by pressing the button) at least once a day in order to check the proper operation of the safety device. • If the safety light curtain is started and there is no TEST/RESET input connected to 24Vcc, it will switch to a monitoring condition, in which the OSSD is not activated.
Operating Manual • PSEN op4B Series Earthing: If evaluation devices are connected without safe separation, the safety light curtain must be operated in protection class 1. In this case, the emitter and receiver must be labelled with the protective earth symbol and must be earthed via the fastening kit. Both are supplied with the unit. Assembling the fastening kit: - Insert the slot nut (M4 x 0.7 mm tapped holes) into a groove on the safety light curtain.
PSEN op4B Series Operating Manual • Under no circumstances should safety contacts OSSD1 and OSSD2 be wired in series or parallel; however, both may be used separately. If one of these two configurations should be used by mistake, the safety light curtain will indicate an output malfunction (see Ch. 7 “Diagnostic functions”). • Connect both OSSD outputs to the control element.
Operating Manual PSEN op4B Series 5 ALIGNMENT The emitter (TX) and receiver (RX) must be aligned to ensure the proper function of the device. Perfect alignment is achieved when the optical axes of the first and last beam from the emitter (TX) meet the optical axes of the corresponding elements on the receiver (RX). Two yellow LEDs on the receiver (RX), “HIGH ALIGN” and “LOW ALIGN”, simplify the alignment process. 5.
PSEN op4B Series Operating Manual Follow the steps below to align the units: • Hold the receiver (RX) steady and align the emitter (TX) so that the yellow “LOW ALIGN” LED lights up, confirming that the first lower beam has been aligned correctly. • Rotate the emitter (TX) until the yellow “HIGH ALIGN” LED is also lit. The “SAFE/BREAK” LED switches from red (BREAK) to green (SAFE). NOTE: Make sure that the “SAFE/BREAK” LED is constantly green.
Operating Manual PSEN op4B Series 5.2 Aligning the muting sensors • Once the safety light curtain has been aligned and the muting sensor profiles have been installed and wired, you will need to check that the sensors on the profiles are aligned correctly. Slight adjustments may be made by moving the fastening clip. Fig.
PSEN op4B Series Operating Manual 6 FUNCTIONS 6.1 Selecting the operating mode via DIP switches On the front of the receiver (RX) there is a cover flap (Fig. 22), which is easy to open using a screwdriver and enables access to a row of DIP switches for the following configurations: - Muting function/muting timeout DIP SWITCHES - Feedback loop monitoring function - Manual/automatic reset The device will not accept configuration changes during normal operation.
Operating Manual PSEN op4B Series 6.3 Restart If the beams between the emitter (TX) and receiver (RX) are interrupted by an opaque object, the OSSD outputs will switch and the safety contacts will open (“BREAK” operating status). There are two different ways to restart normal mode (“SAFE” operating status): • Automatic reset: After the protected field has been interrupted, the safety light curtain returns to its normal mode as soon as the detected object has been removed from the protected field.
PSEN op4B Series Operating Manual Fig. 23 shows the two operating modes: SAFE BREAK Automatic reset Normal mode Beams clear RX TX SAFE OSSD ON OSSD OFF Beams interrupted OSSD ON RX Beams clear TX RX TX BREAK BREAK Manual reset OSSD OFF OSSD OFF TEST/RESET button SAFE OSSD ON Fig. 23 Automatic or manual reset can be selected via the DIP switches on the receiver (RX).
Operating Manual PSEN op4B Series 6.4 Test function The test function can be used to carry out a function test on the safety light curtain. The test function is activated via the input (TEST/RESET) on the receiver (RX). The function is activated when the TEST/RESET button has been operated for at least 0.5 s.
PSEN op4B Series Operating Manual 6.5 Reset function The safety light curtain has a reset function which is used in the case of internal errors. To cancel the reset lock and restore the normal operating status, press the TEST/RESET button for at least 5 s.
Operating Manual PSEN op4B Series 6.6 Feedback loop monitoring function The safety light curtain has a feedback loop for monitoring the externally connected contactors. The opening/closing of the electrical contacts is monitored by a N/C contact. Activate the feedback loop monitoring function: - Select the relevant DIP switch - Connect the feedback loop input to a 24 Vcc N/C contact on the device to be monitored.
PSEN op4B Series Operating Manual This function monitors the switching of the N/C contacts when the OSSD output status changes. TC ≤ 350 ms Time after which the feedback loop contacts open once the OSSD outputs switch from OFF-ON T0 ≤ 100 ms Time after which the feedback loop contacts close once the OSSD outputs switch from ON-OFF Use control elements whose dynamics are compatible with the time constraints stated above.
Operating Manual PSEN op4B Series 6.7 Muting function The muting function enables the safety light curtain to be suspended temporarily while material is transported through the protected field (Fig. 24). • "L" shape configuration: is suitable for applications in which an object leaves the danger zone in one direction. • "T" shape configuration: is suitable for applications in which an object moves in two directions.
PSEN op4B Series Operating Manual To comply with current regulations the safety device has two inputs (muting 1 and muting 2) for activating the muting function. For example, the muting function can be used when objects need to pass through the protected field, but operating personnel still require protection. Muting duration: • Muting timeout 10 min.
Operating Manual 37 PSEN op4B Series • The vehicle should be designed to make it impossible for people to ride on it. • Limit the size of the entry area by applying appropriate safety measures. People must not be permitted to enter the danger area during the muting phase. • Make sure that you select the correct muting configuration (DIP switch position 2). The "OFF" position is provided exclusively for safety light curtains with an L-shape configuration.
PSEN op4B Series Operating Manual Fig. 26 shows an example of a muting function application. Lamp flashes when muting is active MUTING OFF SAFE OSSD ON MUTING ON SAFE OSSD ON MUTING OFF SAFE OSSD ON Fig.
Operating Manual PSEN op4B Series Timing diagram of the muting function for configurations with 2 sensors (L-shaped version or linear version with 2 intersecting beams) Timing diagram of the muting function for configurations with 4 sensors (T-shaped version or linear version with 4 sensors) 39
PSEN op4B Series 6.7.1 Operating Manual Installing the muting sensors on PSEN op4B-S models As the package passes through, the safety function is temporarily suspended via the muting sensors. The outputs on these sensors are connected to the muting inputs MUTING 1 and MUTING 2 on the safety light curtain receiver (RX). The contacts for these sensors are monitored via the receiver (RX). Optoelectronic, mechanical, proximity sensors etc.
Operating Manual 41 PSEN op4B Series • The maximum possible distance of d1 between B2 and A2 or B1 and A1, depends on the object’s approach speed: d1max. [cm]= v [m/s] * tGl [s] * 100 d1min. [cm] ≥ 0.1 cm • Muting sensors A1 and B1 or A2 and B2 must be operated within 4 s.
PSEN op4B Series Operating Manual - Application with two optoelectronic sensors: configured with parallel intersecting beams This solution is suitable for applications in which the object can only be moved in one direction. For correct operation set position 2 on the DIP switch to ON. Connecting the muting sensors: 24 Vcc A PSEN Contact from A 4-pin M12 connector PSEN receiver L V=const.
Operating Manual 6.7.2 PSEN op4B Series Installing the muting sensors on PSEN opB-L models The integrated muting function in an L-shaped configuration enables the muting sensors to be easily installed and is suitable for applications in which the object is to travel out of the danger zone. For correct operation set position 2 on the DIP switch to OFF. Connecting the muting sensors: 24 Vcc Contact from A 4-pin M12 connector PSEN receiver L V=const.
PSEN op4B Series 6.7.3 Operating Manual Installing the muting sensors on PSEN opB-T models The integrated muting function in a T-shaped configuration enables the muting sensors to be easily installed and is suitable for applications in which the object is moved in two directions. For correct operation set position 2 on the DIP switch to ON.
Operating Manual PSEN op4B Series 6.8 Override function This function can be used to activate the muting function when the plant needs to be started even though there is an object within the protected field. The aim is to clear the danger zone of any material that may have accumulated due to a fault in the operating cycle.
PSEN op4B Series Operating Manual The override function is ended automatically when: • There are no muting sensors active • Muting timeout is exceeded • At least one override input is deactivated Timing diagram: Override function 24 Vcc OVR1 0V 24 Vcc OVR2 0V ON Override function OFF 0 ≤ ΔT < 400ms 46
Operating Manual PSEN op4B Series 7 DIAGNOSTICS 7.1 Function indicators 4 LEDs on the receiver (RX) and 2 LEDs on the emitter (TX) provide the user with information about the operating status of the safety light curtain. Fig. 27 The key to the LEDs on the receiver (RX) depends on the operating mode.
PSEN op4B Series Operating Manual 7.2 Error messages and diagnostics The LEDs that display the function can also be used by operators to evaluate the main causes of an error. RECEIVER: Defect Flashing red Flashing yellow Cause - Check the output connections. - Check that the load is compatible with the specifications given in the TECHNICAL DETAILS table (Ch. 9).
Operating Manual Defect Flashing green Flashing yellow PSEN op4B Series Cause Checks and remedy Irregular function of the integral muting display - Switch the device off and then on again; if the fault persists, contact PILZ. Supply voltage error - Check the supply voltage - If the fault persists, contact Pilz. The supply voltage is outside the permitted range Malfunction of the main microprocessor - Check the supply voltage - If the fault persists, contact Pilz.
PSEN op4B Series Operating Manual 8 REGULAR CHECKS AND MAINTENANCE Qualified personnel must carry out the following checks regularly. Ensure that: • The “SAFE/BREAK” LED is constantly red when you pass the test rod from top to bottom along the length of the whole sensing area, at any distance from either unit. • The safety light curtain switches to an OFF state when the test/reset button is operated (“SAFE/BREAK” LED lights up red OSSD outputs open - monitored machine switches to a safe condition).
Operating Manual PSEN op4B Series 8.1 Maintenance Safety light curtains require no particular maintenance, except for cleaning the optical covers. Moist cotton cloths should be used for cleaning. We recommend that you do not use: • Alcohol or solvents, • Cloths made of wool or synthetic material 8.2 General information and useful data Safety devices are only beneficial if they are installed correctly, in accordance with the regulations.
PSEN op4B Series Operating Manual 9 TECHNICAL DETAILS Supply voltage Internal capacity Current consumption, emitter (TX) Current consumption, receiver (RX) Current consumption, muting sensor profiles Outputs: Output current: Output voltage ON - min.: Output voltage OFF - max.
Operating Manual PSEN op4B Series 10 LIST OF AVAILABLE MODELS Length of sensing area Distance No. of beams Resolution mm Reaction time (ms) Operating range (m) PSEN op4B-T-2-050 515 500 2 515 14 0.5…3 m PSEN op4B-T-3-080 415 400 3 415 14 0.5…3 m PSEN op4B-L-2-050 515 500 2 515 14 0.5…3 m PSEN op4B-L-3-080 415 400 3 415 14 0.5…3 m PSEN op4B-S-2-050 515 500 2 515 14 0.5…25 m PSEN op4B-S-3-080 415 400 3 415 14 0.
PSEN op4B Series Operating Manual 12 ACCESSORIES 12.1 Mounting bracket MODEL DESCRIPTION Bracket kit PSEN 4 (1) Bracket (4-part kit) Bracket kit PSEN 4 anti vibr. (2) Anti-vibration brackets (4-part kit) Bracket kit PSEN 4 adjust. (3) Adjustable brackets (4-part kit) Mounting type A Mounting type B 5 6 .2 max. 54.3 min. 41.2 72.8 Standard mounting bracket (1) ±5° max. 57.4 max. 57 ±5° max. 50.2 max. 79 Standard mounting bracket + adjustable bracket (1 + 3) 72.8 56.2 20.
Operating Manual PSEN op4B Series 12.
PSEN op4B Series Operating Manual 12.
Operating Manual PSEN op4B Series 12.4 Laser pointer The laser pointer in the PSEN op2/4 series is a valuable guide when aligning and installing the safety light curtains. The pointer can be moved along the light curtain profile to check the overall alignment of the safety light curtain. MODEL LaserPointer for PSEN 4/2 DESCRIPTION Laser pointer for alignment Fig.
PSEN op4B Series Operating Manual 12.5 Connection box The connection box PSEN iop1 makes it easier to connect and operate the safety light curtains. Features: • Key switch for the override function • TEST/RESET button for activating the test, restart and reset function • - Connections for: Receiver (RX) Emitter (TX) Supply voltage Relay outputs - External control unit MODEL PSEN iop1 DESCRIPTION Connection box Fig.
