Omron F3SP-U5P-TGR Operation Manual

Cat. No. E06-EN-01

F3SP-U5P-TGR Series

Single Beam
Safety Control Unit
Safety Level 4

USER´S MANUAL

F3SP-U5P-TGR User's manual

Cat. No. E06-EN-01

F3SP-U5P-TGR series

Single beam safety control unit,

safety level 4,

from 1 to 4 pairs of photocells E3FS

USER'S MANUAL

F3SP-U5P-TGR User's manual

The device conforms with the EC requirements in compliance with the
following standards:

-Low Voltage Directive 73/23/EEC

-EMC Directive 89/336/EEC

-Machinery Directive 89/392/EEC

-IEC 61496-1: 1997

-IEC 61496-2: Ed.2 IEC :2001 (CDV draft8)

-DIN V VDE 0801: 1990 and

-amendment A1: 1994

-EN 61000-2,-3,-4,-5,-6

-EN 55022: 1994

-DIN EN 60204-1: 1993

-EN 50178: 1997

-IEC 664-1: 1997

MANUFACTURER: TECHNO-GR s.r.l.
via Torino, 13/15
10046 Poirino (TO) - ITALY
Tel. [phone]
FAX [phone]

USER MANUAL: Versione 3.0 del 12/06/2003

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F3SP-U5P-TGR User's manual

INDEX

1 BEFORE USING THE DEVICE. ......................................................5

1.1 GENERAL INSTRUCTIONS. ............................................................................5

1.2 PRECAUTION OF SAFETY .............................................................................5

1.3 ROUTINE MAINTENANCE...............................................................................5

2 GENERAL INFORMATION AND MAIN APPLICATIONS..............6

3 OPERATION....................................................................................8

4 PRECAUTIONS AND INSTALLATION CRITERIA. .......................9

4.1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE.....................9

4.2 REFLECTIVE SURFACES. ............................................................................10

5 CONNECTIONS............................................................................ 11

5.1 REFERENCES ON THE TERMINAL BOARD.................................................11

5.2 PINOUT TOP VIEW ........................................................................................12

5.3 WIRING EXAMPLE.........................................................................................13

6 ALIGNMENT PROCEDURE......................................................... 15

7 OPERATING PROCEDURES. ..................................................... 16

7.1 DIP-SWITCHES CONFIGURATION...............................................................16

7.2 CONFIGURATION OF THE NUMBER OF PHOTOCELLS.............................16

7.3 MUTING FUNCTION. .....................................................................................17

7.3.1 DESCRIPTION......................................................................................17

7.3.2 INSTALLATION CRITERIA ..................................................................18

7.4 OVERRIDE. ....................................................................................................23

7.5 STARTING THE OVERRIDE FUNCTION.......................................................23

7.6 MUTING RESTRICTIONS (MUTING FUNCTION)................................................24

8 LED DIAGNOSTIC ....................................................................... 25

9 FINAL CHECKS. .......................................................................... 25

10 ROUTINE MAINTENANCE OPERATIONS. ................................ 26

11 GENERAL INFORMATION AND USEFUL DATA. ..................... 27

12 TECHNICAL DATA. ..................................................................... 28

13 OVERALL DIMENSIONS. ............................................................ 29

14 NOTE ............................................................................................ 30

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F3SP-U5P-TGR User's manual

1 BEFORE USING THE DEVICE.

1.1 GENERAL INSTRUCTIONS.

To guarantee a correct installation, carefully follow the instructions of this
manual.
Do not touch non-insulated cables, unless they have been disconnected
from the power supply.
Make sure that the cables connected to the control unit are not too taut
and that they do not hinder the movement of persons or objects.
The control unit does not contain parts subject to maintenance; before
carrying out any outer operation, turn off the power.
Do not open the control unit for any reason (apart from the selection of the
configuration dip-switch which must be only carried out by skilled
workers) and in case of failure, send it to our laboratories indicating the
detected failure and the operation period.
Avoid touching the protective cover of the safety sensors with the hands in
order to prevent dust and/or grease build upon the device, thus reducing
the system performances.
The possible wear of the protective covers does not compromise the
system safety in any way but can cause a system tripping.

1.2 PRECAUTION OF SAFETY

The following symbols are used for highlighted items in order to ensure safe
and proper use of the F3SP-U5P-TGR. Highlighted items are critical for safe
operation and must be heeded at all time.

WARNING

NOTICE

1.3 ROUTINE MAINTENANCE.

Be sure to conduct inspection regularly.
Please refer to sec.10 and the safety PES instruction manual.

Omron Europe and Techno-GR refuses to accept any responsibility for
damage to persons or object due to the incorrect use / installation of the
control unit and safety PES.

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F3SP-U5P-TGR User's manual

2 GENERAL INFORMATION AND MAIN APPLICATIONS.

The single beam safety control unit F3SP-U5P-TGR has been designed and
produced to meet the need to protect persons in areas where it is necessary
to guarantee the safety of the operator using machinery, robots or in general
automation systems which are considered dangerous or subject to casual or
undesired access to unsafe parts.
The system conforms with the requirements for safety devices of type 4 in
compliance with international standards, e.g. IEC 61496 1-2.

WARNING

The safety system category depends on the safety PES’s used as follows.

Type 4 safety PES : Safety system category 4
Type 2 safety PES : Safety system category 2

• A qualified person, as determined by local regulations, must confirm that
installation, inspection, and maintenance are implemented correctly.

• Do not disassemble, repair, and modify the control unit and safety PES.
The control unit does not contain parts subject to maintenance.

• The presence of a limb or an object interrupting one of the safety PESs
will open the safety outputs and consequently stop the connected
machine. It is necessary to install the safety PESs in such a way that
bypassing and defeating of any person is not possible.

• Do not use the control unit and safety PES on machines that cannot be
stopped by electrical control in case of an emergency.

• Do not use the control unit and safety PES in environments exposed to
flammable or explosive gases.

• Do not use the control unit and safety PES in a retro-reflective
configuration. Otherwise detection may fail.

NOTICE

• Do not install the control unit and safety PES in the following environments;

- Areas exposed to intense interference light such as direct sunlight.

- Areas with high-humidity where condensation is likely to occur.

- Areas exposed to corrosive gases.

- Areas exposed to vibration or shock levels higher than specification

provisions.

• Do not use the cellular phones or transceivers near the control unit and
safety PES.

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F3SP-U5P-TGR User's manual

• The control unit and safety PES must not be used in water.

The F3SP-U5P-TGR safety controller is protected by a plastic housing so that
it can be installed on a DIN/OMEGA rail; it has 32 removable screw terminals
to which it is possible to connect from 1 to 4 pairs of photocells.

This version of the single beam safety control unit has the ‘muting’ function
integrated, by means of this function it is possible to connect or disconnect
one or more pairs of photocells in order to allow - for instance - the material
passage without stopping the machine.
The additional ‘override’ function enables system, to keep the output relays
closed even with intruded rays to enable material transport after a system
shutdown.
Both muting and override functions represent a system, that require
additional precautions to limit the reduction of the safety level. This
precautions have to be considered carefully.
The muting and override function is available by simply connecting the F39­A11 muting lamp (or similar yellow bulb type lamp for 24VDC / 3W to 5 W)
supplied separately.

The presence of a limb or an object interrupting a beam causes the opening
of the safety outputs and the consequent stopping of the connected machine.
It is necessary for the safety sensors to be connected in the right position in
such a way that there isn’t any possibility to climb over or defeat the system.
Here is a list of the commonly used applications:

◊ Machines for the processing of wood, glass and ceramic products.
◊ Automatic warehouses.
◊ Conveying lines.
◊ Palletizers

The unit has been designed in accordance to the following standards:

IEC 61496-1: 1997. Safety of machinery: electro-sensitive

protective devices

- General requirements and test.

FDIS IEC 61496-2: 1997. Safety of machinery: electro-sensitive

protective devices

- Particular requirements for system using
active opto-electronic devices.

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F3SP-U5P-TGR User's manual

3 OPERATION.

The electronic control system of the device is made up of a microprocessor.
By means of the suitable hardware, it continuously control and check the
connected photocells. No interference among the photocells is possible as
they are controlled sequentially; it will be thus possible to install one or two
adjacent photocells. When one or more beams are interrupted, the electronic
system opens the outputs.
The photocells have been triggered are displayed by LEDs on the housing.
The control-unit can work in two different modes (please refer to par. 7 page

16) which he can carry out the following operations:

The two external buttons that have to be connected are for:

• TEST : This is used to check if the whole system works effectively. By
pressing the TEST button (opening of the contact), this simulates the
interruption of one or more safety PESs. This operation makes the
machine stop, so the system checks can be made according to the
established time and modes. If pressed after a failure detection of the
unit (see the table error code), reset of the system is required.

• RESET button: It is used to start the system, also for manual reset
condition after relay triggering or after an error which can be reset (see
table related to the error codes).

Two different operating modes are available:

1. Automatic reset: The system will start automatically after the beam

intrusion have been removed.

2. Manual reset: The system will remain in safe off condition until the

RESET button have been pressed. This manual reset allows to start
the system only on a wanted action of the user.

During the unit working, no operation set by the user interface involves
functions which can influence the system safety.

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F3SP-U5P-TGR User's manual

4 PRECAUTIONS AND INSTALLATION CRITERIA.

The safety products used must be suitable for the required application,
and other influences must be also taken into account such as a room
temperature, electromagnetic interference, intense light sources etc.
Please refer to the manual for specification or contact the manufacturer for
details.

4.1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE.

The safety distance ‘S’ must be sufficient to guarantee that the dangerous
area cannot be reached by the operator up to the moment in which the
machine with moving part stops. The safety distance must be calculated
according EN999 (European Standards. Safety of Machinery – The
positioning of protective equipment in respect of approach speeds of part
of the human body).

Using EN 999 formula:

S = ( K * T ) + C

S = safety distance.
T = T1 + T2
whereas T1 = machine response time in seconds.
T2 = unit response time in seconds including Safety sensor response time.
K = 1600 mm/s (speed of the body approaching the dangerous area).
C = additional distance depend on resolution of SLC and applicable standard.

1) Multiple separate beams (EN999, clause 6.1.4)

K = 1600 mm/s
C = 850 mm

Heights recommended

in EN999

Heights of 1st ray 300 mm 300 mm 400 mm

Heights of 2nd ray 600 mm 700 mm 900 mm

Heights of 3rd ray 900 mm 1100 mm

Heights of 4th ray 1200 mm

2) Single height beam (EN999, clause 6.1.5)

Where the risk assessment allows the use of a single beam, the following values can be used

K = 1600 mm/s
C = 1200 mm

The height of beam from the ground or reference plan: 750mm (EN 999)

4 Beams 3 Beams 2 Beams

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