Omron OS32C User Manual

Safety Laser Scanner OS32C Series

User's Manual

P/N 99863-0010 Rev.N

Manual No. Z296-E1-13

Original Detailed Instructions

Introduction

Thank you for purchasing the OS32C Safety Laser Scanner (herein after referred to as the "OS32C" ). This is the instruction Manual describing the use of the OS32C. Always take into account the following points when using the OS32C:

Make sure OS32C is handled by a "Responsible Person" who is well aware of and familiar with the machine to be installed. The term "Responsible Person" used in this Instruction Manual means the person qualified, authorized and responsible to secure "safety" in each process of the design, installation, operation, maintenance services and disposition of the machine. It is assumed that the OS32C will be used properly according to the installation environment, performance and function of the machine. A responsible Person should conduct a risk assessment of the machine and determine the suitability of this product before installation. Read this Manual thoroughly and understand its contents.

Trademarks

• Windows, Windows XP, Windows 7, Windows 8.1 and Windows 10 are either registered trademarks or trademarks of Microsoft Corporation in the USA and other countries.

• ODVA and EtherNet/IP

•

Other company names and product names in this document are the trademarks or registered trademarks of their respective companies.

• Microsoft product screen shot(s) reprinted with permission from Microsoft Corporation.

are trademarks of ODVA, Inc.

Legislation and Standards

1. Application of an OS32C sensor by itself cannot receive the type approval provided by Article 44-2 of the Labor Safety and Health Law of Japan. It is necessary to apply it as a system. Therefore, when using this product in Japan as a "safety system for presses and shearing machines" as prescribed in Article 42 of the Labor Safety and Health Law, the complete system must receive the type approval.

2. (1) This product is electro-sensitive protective equipment (ESPE) in accordance with European Union (EU)

Machinery Directive Index Annex V, Item 2.

(2) This product complies with the following legislation and standards:

1) EU legislation Machinery Directive 2006/42/EC EMC Directive 2014/30/EU RoHS Directive (2011/65/EC) and EU 2015/863

2) European & International EN 61496-1 (Type 3 ESPE)

Standards EN 62061

EN 50178 EN ISO 13849-1 IEC 61496-3 (Type 3 AOPDDR) IEC 61508, Parts 1-7 (SIL-2) EN 60204-1

3) North American Standards: per UL File E241445, US and C-UL approvals (CNN: NIPM/NIPM7).

• ANSI/UL 508 (Industrial Control Equipment)

• ANSI B11.19

• ANSI/RIA R15.06

• NFPA 79

• Code of Federal Regulations CFR29

• IEC 61496-1 (Type 3 ESPE)

• IEC 61496-3 (Type 3 AOPDDR)

• UL 1998 (Software in Programmable Components)

• IEC 61508 (Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems)

• IEC 61508-3 (Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems - Part 3: Software Requirements)

• CAN/CSA-C22.2 No. 14 (Industrial Control Equipment)

• CAN/CSA-C22.2 No. 0.8 (Safety Functions Incorporating Electronic Technology)

4) JIS standards JIS B 9704-1, JIS B 9704-3 (Type3 ESPE)

(3) This product received the following approvals from TÜV Rheinland of the EU.

-EC Type-Examination in accordance with the EU Machinery Directive, Type 3 ESPE (IEC61496-1), Type 3 AOPDDR (IEC61496-3)

Introduction

OS32C

User’s Manual

Introduction

Warranties.

(a) Exclusive Warranty. Omron's exclusive warranty is that the Products will be free from defects in materials and

(b) Limitations. OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NON-

Omron further disclaims all warranties and responsibility of any type for claims or expenses based on infringement by the Products or otherwise of any intellectual property right. (c) Buyer Remedy. Omron's sole obligation hereunder shall be, at Omron's election, to (i) replace (in the form originally shipped with Buyer responsible for labor charges for removal or replacement thereof) the non-complying Product, (ii) repair the non-complying Product, or (iii) repay or credit Buyer an amount equal to the purchase price of the non-complying Product; provided that in no event shall Omron be responsible for warranty, repair, indemnity or any other claims or expenses regarding the Products unless Omron's analysis confirms that the Products were properly handled, stored, installed and maintained and not subject to contamination, abuse, misuse or inappropriate modification. Return of any Products by Buyer must be approved in writing by Omron before shipment. Omron Companies shall not be liable for the suitability or unsuitability or the results from the use of Products in combination with any electrical or electronic components, circuits, system assemblies or any other materials or substances or environments. Any advice, recommendations or information given orally or in writing, are not to be construed as an amendment or addition to the above warranty. See

Terms and Conditions Agreement

workmanship for a period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron). Omron disclaims all other warranties, express or implied.

INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE.

http://www.omron.com/global/ or contact your Omron representative for published information.

Limitation on Liability; Etc.

OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY. Further, in no event shall liability of Omron Companies exceed the individual price of the Product on which liability is asserted.

Suitability of Use.

Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply to the combination of the Product in the Buyer's application or use of the Product. At Buyer's request, Omron will provide applicable third party certification documents identifying ratings and limitations of use which apply to the Product. This information by itself is not sufficient for a complete determination of the suitability of the Product in combination with the end product, machine, system, or other application or use. Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyer's application, product or system. Buyer shall take application responsibility in all cases. NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY OR IN LARGE QUANTITIES WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

Programmable Products.

Omron Companies shall not be responsible for the user's programming of a programmable Product, or any consequence thereof.

Performance Data.

Data presented in Omron Company websites, catalogs and other materials is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of Omron's test conditions, and the

OS32C

User’s Manual

user must correlate it to actual application requirements. Actual performance is subject to the Omron's Warranty and Limitations of Liability.

Change in Specifications.

Product specifications and accessories may be changed at any time based on improvements and other reasons. It is our practice to change part numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the Product may be changed without any notice. When in doubt, special part numbers may be assigned to fix or establish key specifications for your application. Please consult with your Omron's representative at any time to confirm actual specifications of purchased Product.

PATENTS

Elements of the electronics and optics essential to meet the specifications and performance standards of Omron controls are covered by one or more of the following U.S. Patents Numbers: 6,665,621; 6,753,776; 6,493,653; 6,587,811; 7,965,384. Additional patents pending.

Errors and Omissions.

Information presented by Omron Companies has been checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical or proofreading errors or omissions.

Introduction

OS32C

User’s Manual

iii

Introduction

The Alert symbols and their meanings ensure safe use of the products

In order to use the OS32C safely, the precautions listed in this manual are indicated by alert symbols. The descriptions must be followed, failure to follow all precautions and alerts may result in an unsafe installation or operation. The following indictions and symbols are used.

Meanings of Alert Symbols

Safety Precautions

Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.

Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or there may be property damage.

Indicates prohibited actions.

Indicates mandatory actions.

Alert Statements in this Manual

An OS32C is an electro-sensitive protective equipment designed to guard personnel working around hazardous machinery.

Whether a specific machine application and the OS32C system installation complies with safety regulations depends on the proper application, installation, maintenance and operation of the OS32C system. These items are the responsibility of the purchaser, installer and user.

User

The administrator is responsible for the selection and training of personnel to properly install, operate, and maintain the machine and its safeguarding systems.

An OS32C system should only be installed, verified and maintained by a qualified person. A qualified person is defined as ”an individual who understands, is trained on, and demonstrates competence with the construction, operation or maintenance of the machinery and the hazards involved.” (ANSI/PMMI B155.1-2006)

OS32C

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The machine requirements

The guarded machine must be able to stop anywhere in its cycle. Do not use an OS32C on a press with a full-revolution clutch.

The guarded machine must have a consistent stopping time and adequate control mechanisms.

All safety-related machine control elements must be designed so that an alarm in the control logic or failure of the control circuit does not lead to a failure to danger.

Do not use the auxiliary output or warning output for safety applications. A human body may not be detected even if a failure of OS32C occurs, resulting in serious injuries.

Installation

Introduction

The main unit must be securely mounted and its cable connectors must be tightly attached.

The OS32C must not be mounted behind glass or within a secondary enclosure. Failure to do so will cause a reduction in detection capability, which can cause serious injury or death.

A start switch to release interlock must be installed where an operator can observe the monitored/ guarded zone as a whole and cannot operate the switch within the hazardous zone.

Per the International standard IEC 61496-3, area scanners used in applications where the angle of approach exceeds +/- 30 degrees with respect to the detection plane, must use reference boundary monitoring (RBM) of the detection zone.

Make sure to remove any retro-reflector from the field of view of the OS32C when in RBM mode.

A protective mechanism must be installed to prevent a hazardous condition in the event of a subsequent machine component failure. The OS32C does not protect against ejected flying material.

Severe smoke and particulate matter may degrade the efficiency of an OS32C, causing it to unexpectedly enter a Machine Stop state.

Use of mirrors or mirror-like objects in the protection plane must be avoided, as they can hide part of the area to be monitored/guarded.

Additional guarding may be required to prohibit access to dangerous areas not covered by the OS32C system.

OS32C

User’s Manual

Introduction

Perform the test procedure in this document at installation, after maintenance, adjustment, repair or modification to the machine controls, tooling or the OS32C system. See page 162.

Perform only the test and repair procedures outlined in this manual.

Additional measurement error resulting from reflective backgrounds may need to be added to the measurement error of the OS32C.

To use the protective function of the OS32C, a safety zone must be properly defined and configured.

If the response time is changed, re-calculation of the safety distance is required. This may require re-configuration of the safety zones or re-installation of the OS32C. If the safety distance is not appropriate for the application, the machine may not stop before contact with the hazardous part, resulting in serious injuries or death.

The activation of RBM Only mode will increase the response time. This additional time must be taken into consideration when calculating the safety guarding distance.

When using more than one OS32C, mutual interference should be prevented. This may require different scanner positions or physical shields to be installed.

To ensure a protection degree of IP65, DO NOT use this product without proper sealing of the cable connector, I/O block, and scan window.

If the external zone switching device momentarily exceeds the configured number of active zone set select inputs during the zone switch, an additional Zone Delay may be incurred in the event that wiring of a zone set select input fails. The external zone switching device must properly sequence so the configured number of active inputs is not exceeded in order to guarantee that failed zone set select input wiring will be detected within the normal Zone Switching Time described below.

If an insufficient Zone Delay is used for the actual worst case switching time of the installation, the scanner might start monitoring the wrong zone during the switching period. Also, if an insufficient Zone Delay is used for the actual worst case switching time of the installation, there might be a fault condition during the zone switching period.

If tstart (switching start time) is configured without consideration of TmaxReaction (total maximum reaction time), object detection within the new safety zone after switching and turning OFF of the safety outputs may be delayed.

Monitoring zone parameters are subject to a number of constraints that include projective consistency, maximum radius, and angle limits. As a result, an imported zone may not correspond exactly to the zone defined in the file. The user must visually verify the imported zone when the zone coordinate import process is complete. Refer to Checkout and Test Procedure Log on page

162.

The installer is responsible for assessing the risk and to ensure that the zone of limited detection does not create a safety hazard. If a hazard exists additional countermeasure must be taken, this may require additional guarding measures.

OS32C

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Wiring Connections

Do not connect the OS32C to a power supply with more than 24VDC + 25% / -30%. Do not supply AC power to the OS32C, this may result in electrical shock.

For the OS32C to meet IEC 61496-1 and UL 508, its DC power supply unit must satisfy all of the following conditions:

• Within rated line voltage (24 VDC +25% / -30%)

• Complying with EMC directives (industrial environments)

• Double-insulation or reinforced insulation between primary and secondary circuits

• Automatic return for overcurrent protection

• Output retention time of 20 ms or longer

• Satisfying output characteristics requirements of Class 2 circuit or limited voltage/current circuit defined in UL508.

• Power supply complying with regulations and standards of EMC and safety of electrical equipment in a country or a region where OS32C is used. (Example: In EU, a power supply must comply with the EMC and Low Voltage Directives.)

Introduction

To prevent electrical shock, use double-insulation or reinforced insulation from hazardous voltage (such as 230 VAC).

Cable extensions must be within the specified lengths, otherwise it may result in a failure of the safety functions.

To use this product for a category 3 safety system, both safety outputs must be connected to the safety system. Configuring a safety system with only one safety output may result in serious injuries due to output circuit fault and a failure of the machine to stop.

Protection of Cable at Installation: Care should be taken when installing the OS32C cable. The cable must be properly routed and secured to ensure that damage does not occur.

Functional Earth: The OS32C system requires a functional earth connection. Do not connect Functional Earth to a positive ground system. If it is connected to positive ground, the guarded machine to be controlled may NOT stop, resulting in severe operator injury.

Signal Connector Isolation: The connectors used during installation must provide sufficient signal separation in order to prevent a short circuit condition of the input power and system signals.

When wiring the OS32C to external devices, make sure to follow the color and coding schemes per EN 60204-1.

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Introduction

Others

Do not modify the main unit of the OS32C. Do not replace or fix any component of the OS32C other than the ones specified in this manual. Doing so may result in a failure of this device to function correctly.

If there is any damage to the window, replace it as soon as possible. Otherwise it may result in a failure of the OS32C. Take preventive measures when performing replacement work so that dust does not enter the OS32C.

Always detach all cables from the OS32C before replacing the scan window. Otherwise the motor may start rotating, resulting in injuries.

The window replacement procedure must only be performed by qualified personnel in a clean environment at ambient temperature (5 to 35°C) to prevent the internal optical surface from contamination. Make sure the inside and the outside of the replacement window is clean and free from scratch, dust, and finger print.

The calibration procedure must only be performed by qualified personnel. Before performing window calibration of the new scan window, make sure the window is clean and free from scratch, dust, and finger print. The window calibration procedure must be performed at ambient temperature 5 to 35°C. Failure to inspect the window or set the proper environmental condition during window calibration procedure may cause a reduction in the detection capability of the scanner.

The tests outlined in the Test Procedure (See "Checkout and Test Procedure Log" in p.162) must be performed at time of installation, according to the employer's regular inspection program and after any maintenance, tooling change, set up, adjustment, or modification to the OS32C system or the guarded machine. Where a guarded machine is used by multiple operators or shifts, it is suggested that the test procedure be performed at each shift or operation change and also if there is a change in the OS32C operating mode or defined zone sets. Testing ensures that the safety laser scanner and the machine control system are working properly to stop the machine. Failure to test properly could result in serious injury to personnel.

If the OS32C is operated under automatic start, make sure that the machine stops and does not restart as long as an object is detected in a safety zone. Check the operation by placing a test piece into the safety zone. It is recommended to perform the test at least after a shift change or 24 hours of operation.

If the safety system or the machine fails any of these tests, do not run the machine. Immediately tag or lock out the machine to prevent its use and notify the appropriate supervisor.

System and zone status parameters monitored over EtherNet/IP are to be used for diagnostic purposes only, and must not be used in safety-critical functions.

Measurement data monitored over EtherNet/IP are to be used for diagnostic purposes only, and must not be used in safety-critical functions.

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When transferring data from the PC to the OS32C and more than one OS32C is connected to the network, it is necessary to visually check the diagnostic code on the status/diagnostic display. It is recommended that the OS32C be installed in a position where the status/diagnostic display will be visible.

Before sending the changes to the sensor, verify that the safety parameters are configured as intended for the application.

Take precautions to prevent dirt, dust or debris from entering the sensor and I/O block connectors. It is recommended that this be done on a clean workstation as contaminants may degrade the performance of the OS32C.

Adhesion of dust to the scan window may cause a false operation. The OS32C will require periodic cleaning of the scan window and dust detection surface.

Operation of the OS32C may be affected by light in the environment, such as incandescent light, strobe light and light from a photosensor using infrared light.

Introduction

Operation of the OS32C may be affected by substances in the environment, such as fog, smoke, steam and other small particles.

Ensure the measurement report configuration of the OS32C-xxx-DM matches the expected measurement data format.

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Introduction

Make sure to follow all the safety precautions that are necessary to ensure safe use of the product.

• Thoroughly read this installation manual and understand the installation, operation checks, and maintenance procedures before using the product.

• Loads must satisfy both of the following conditions:

• The main unit must be properly mounted with the proper mounting hardware.

• Do not drop the product, serious damage will occur.

• Comply with all the laws, regulations, and standards of the country/region where the product is used.

• Dispose of the product in accordance with the relevant rules and regulations of the country/region where the product is used.

Observe the precautions described below to prevent operation failure, malfunctions, or undesirable effects on product performance.

Precautions for Safe Use

- Not short-circuited

- Not used with a current that is higher than the OSSD rating (250 mA sourcing)

Precautions for Correct Use

 Installation environment

Do not install the OS32C in the following types of environments:

• Areas where OS32C may be exposed to intense interference light, such as direct sunlight

• Areas with high humidity where condensation is likely to occur

• Areas subject to condensation resulting from severe changes in temperature

• Areas where corrosive gases are present

• Areas exposed to vibration or shock levels higher than in the specification provisions

• Areas where the product may come into contact with water

• Areas where the product may get wet with oil

• Areas where smoke and/or water vapor exists on the laser scanning plane

• Keep the OS32C far enough from devices that generate high frequency noise or eliminate the noise.

• Be sure to route the OS32C cable separate from high-potential power lines or route through an exclusive conduit.

This is a class A product. In residential areas it may cause radio interference, in which case the Responsible Person may be required to take adequate measures to reduce interference.

 Wiring and installation

• Make sure to perform wiring while the power supply is OFF. Otherwise, the OS32C may fail to operate due to the diagnostics function.

• Properly perform the wiring after confirming the signal names of all the terminals.

• Do not operate the control system until 14 seconds or more after turning ON the power of the OS32C.

• Be sure to route the OS32C cable separate from high-potential power lines or through an exclusive conduit.

• When using a commercially available switching regulator power supply, make sure to ground the FG terminal (frame ground terminal).

• Sharing the power supply with other devices may cause the OS32C to be affected by noise or voltage drop. It is recommended that the safety-related devices use a dedicated power supply, not shared with other devices.

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 Cleaning

Do not use thinner, benzene, or acetone for cleaning. They will adversely affect the product's resin parts and paint on the case.

 Object detection

The OS32C has a configurable minimum object resolution of 30mm, 40mm, 50mm, or 70mm. It cannot detect transparent or translucent objects, or objects with reflective surfaces, of less than 1.8% reflectivity.

Introduction

OS32C

User’s Manual

Introduction

How to Read This Manual (Explanation of Symbols)

Indicates the description of an essential function, such as operation or advice on how to properly use this product .

Indicates the page number for related content.

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Configuration Tool Features and Compatibility

Please refer to the table below for supported features and compatibility with OS32C versions. Refer to the product labels to determine the OS32C version. For information on the OS32C-DM model, please refer to the OS32C-DM Addendum available on the Omron's website at http://www.omron.com/global/

NOTE:

• Only the version of the sensor block and the configuration tool were updated to support the new features. No changes were made to the I/O block.

• The part numbers have changed: OS32C-SN: 40591-0010 (old), 40591-0020 (current) OS32C-SN-DM: 40591-0040 (current) OS32C-SN-4M: 40603-0020 (current) OS32C-SN-DM-4M: 40603-0040 (current)

OS32C Versions OS32C-DM OS32C-4M OS32C-DM-4M

Introduction

: Supported 40591-0010 40591-0020 40591-0040 40603-0020 40603-0040

Configurable minimum object resolution

Standby mode with laser shutoff

Copy & paste zones and zone sets

Record system monitoring

Playback system monitoring

Support for inverting 7-segment display

Display configuration filename in config tool header

Additional zone shapes (180° semi-circle, 180° rectangle, 180° polygon)

Config tool support for switching between default OS32C configuration and the user's current working configuration

Troubleshooting tips displayed in fault log

Configuration checksum, safety checksum

 

 *1  *1  *1  *1  *1

Windows 7 support

Non-safety checksum  *2  *2  *2  *2  *2

Single Import & Export Zone Coordinate Data

Maintenance access level --

Rotation of monitor screen view  *4  *4  *4  *4  *4

French, German, Italian & Spanish Languages

Multiple Import & Export Zone Coordinate Data

 

 *2  *2  *2  *2  *2

 *3  *2  *2  *2

 *4  *4  *4  *4  *4

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OS32C

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Introduction

OS32C Versions OS32C-DM OS32C-4M OS32C-DM-4M

: Supported 40591-0010 40591-0020 40591-0040 40603-0020 40603-0040

EtherNet/IP and Measurement Data

Pollution Tolerance Mode --  *6  *6  *5  *5

Variable response time settings --  *6  *6  *5  *5

4 meter safety/ 15 meter warning zone -- -- --  *5  *5

Status information during monitor mode --  *6  *6  *5  *5

Confirmation of Safety parameters --  *6  *6  *5  *5

Warning Zone changed via Ethernet/IP capability

Windows 10 support --

*1. Requires Configuration Tool Version 1.4.0 and up *2. Requires Configuration Tool Version 1.6.0 and up *3. If serial number of the sensor block is higher than AS08300 and Configuration Tool is version 1.6.0 and up *4. Requires Configuration Tool is Version 1.8.0 and up *5 Requires Configuration Tool is Version 2.0.0 and up *6 If serial number of the sensor block is higher than AS17500 and Configuration Tool is Version 2.0.0 and up *7. Requires Configuration Tool Version 2.2.8 and up

: Supported

-- --



 *6 --  *5



 *7  *7  *7  *7

Configuration Tool Version

before 1.4.0 1.4.0 and up 1.6.0 and up 1.8.0 and up 2.0.0 and up 2.2.8 and up

Configurable minimum object resolution

Standby mode with laser shutoff

Copy & paste zones and zone sets

Record system monitoring

Playback system monitoring

Support for inverting 7-segment display

Display configuration filename in config tool header

Additional zone shapes (180° semi-circle, 180° rectangle, 180° polygon)

Config tool support for switching between default OS32C configuration and the user's current working configuration

Troubleshooting tips displayed in fault log

Configuration checksum, safety checksum

Windows 7 support



xiv

Non-safety checksum

Single Import & Export Zone Coordinate Data

Maintenance access level

OS32C

User’s Manual

-- --



Configuration Tool Version

Introduction

: Supported

Rotation of monitor screen view

French, German, Italian & Spanish Languages

Multiple Import & Export Zones Coordinate Data

Pollution Tolerance Modes

Variable response time settings

4 meter safety/ 15 meter warning zone

Status information during monitor mode

Confirmation of Safety parameters

Warning Zone changed via Ethernet/IP capability

Windows 10 support

Note: The configuration data file extension is *.cf2 until Configuration Tool Version 1.8.0 and *.cf3 from Version 2.0.0.

before 1.4.0 1.4.0 and up 1.6.0 and up 1.8.0 and up 2.0.0 and up 2.2.8 and up

-- -- --

-- -- -- --

-- -- -- -- --







: Supported

Model Sensor Head P/N

OS32C-SN 40591-0010

OS32C-SN 40591-0020

OS32C-SN-DM 40591-0040

OS32C-SN-4M 40603-0020

OS32C-SN-DM-4M 40603-0040

Configuration Tool Version

before 1.4.0 1.4.0 and up 1.6.0 and up 1.8.0 and up 2.0.0 and up



-- --

-- -- -- --







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Introduction

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Contents

Legislation and Standards i Terms and Conditions Agreement ii Safety Precautions iv Precautions for Safe Use x Precautions for Correct Use x

Chapter1 Description of Use and Features 1

Theory of Operation 2 Features 3

System Components 4

Application Examples 5

Applying the OS32C to fixed stationary applications 5

Introduction

Applying the OS32C on Automated Guided Vehicles (AGV) 7

Rating/Performance 10

Chapter2 Operating States & Output Modes 13

Operating States 14 Operating Mode 17

Automatic Start 17 Start Interlock 17 Start/Restart Interlock 17 Power Reserve Mode 18

Parameter Configuration 19

Safety Critical Parameters 19

Non-Safety Critical Parameters 20 Safety Outputs 21 Auxiliary & Warning Outputs 21 Reference Boundary Monitoring (RBM) 23 Pollution Tolerance Mode (PTM) 24 Zone Set Selection 26

Zone Set Input Selection 26

Zone Set Switching 28

Chapter3 Basic Operation of Configuration Tool 33

Getting Started 35 Installing Configuration Tool 35 How to Start 36 Description of Screen 37

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Introduction

Menu 37

Tool Bars 39

Information Bar 40

Offline Mode 40 Connection to the OS32C 41

Connecting the PC and the OS32C 41

Forced DHCP mode 42

Changing the IP address of the PC (Windows XP) 42

Changing the IP address of the PC (Windows 7) 44

Changing the IP address of the PC (Windows 8.1 and Windows 10) 44 Logging on to the OS32C 45

Detecting the OS32C on the network 45

Logging On 46

Logging OFF 46

Changing Password 46

Forgot the Password? 47 Changing Ethernet Configuration of OS32C 48 Receiving OS32C Configuration Information 49 Configuring New OS32C Property and Monitoring Zone 49

Default Configuration Settings 49

Creating a New Configuration 50

Saving OS32C Configuration to PC 55 Import & Export Zone Coordinate Data 57

File Format 57

Importing Zone Coordinate Data 60

Exporting Zone Coordinate Data 62 Zone Set Selection and Configuration 64

Add a Zone 64

Copy and Paste Zones 65

Delete a Zone 67 Zone Set Input Selection 68 Editing Properties 69

xviii

Editing Monitor Zones 73 Sculpting & Reference Boundary Monitoring 76 Monitor Mode 81 Record System Monitoring 82 Playback System Monitoring 84 Read Fault Log 85 Window Calibration 86 Changing Options of Configuration Tool 88 Caution on Safety Zone Configuration 89 Reset to Default Configuration 90

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Chapter4 Installation 93

Mounting Considerations 94 Configuring Multiple OS32C Scanners 94 Distance from Wall 96 Stationary Installation and Configuration 97

Installation for Stationary Area Scanning 97

Configuration 98

Configuration Example: Installation on a Machine (1) 99

Configuration Example: Installation on a Machine (2) 101

Configuration Example: Entry Access Protection 101

Configuration Example: Hand Detection Protection 103 Mobile Installation and Configuration 105

Applying OS32C on Automated Guided Vehicles (AGV) 105

Configuration for Automated Guided Vehicles (AGV) 107

Configuration Example: Use of an AGV 108

Introduction

AGV Standards 109 External Dimensional Drawings 110

Ethernet Cable 119

XS5 OMRON SmartclickTM Connection 120

Chapter5 Wiring 121

Power Supply Unit 122 Additional Wiring Information 123 Input/Output Signal 124 Example of Safety Circuit 125

Chapter6 Checkout 129

Checkout and Test Procedures 130

Checkout and Test Procedures 130 Testing Safety Zone 131 Detection Capability 133

Chapter7 Appendix 135

Troubleshooting 136

OS32C Status Check 139 Additional Error due to Reflective Background 142

Conditions of Background Influence 142

Using Other Safety Device in Combination 144 Sensor Replacement 145

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Introduction

Checking the Firmware Version 145

Sensor and I/O Block Replacement 147

How to Recover from a Fault Code 60 148 Scan Window Replacement Procedure 151

Window Replacement Procedure 151

OS32C Maintenance 153 Warning Zone Object Resolution 154 Additional Zone Set Switching Strategies 155 Glossary 159 Accessories 161 Checkout and Test Procedure Log 162 Declaration of Conformity 163 Revision History 165

OS32C

User’s Manual

Chapter1 Description of Use and Features

Theory of Operation 2

Features 3

System Components 4

Application Examples 5

Applying the OS32C to fixed stationary applications 5 Applying the OS32C on Automated Guided Vehicles (AGV) 7

Rating/Performance 10

Chapter1

OS32C

User’s Manual

Description of Use and Features

Chapter1

Theory of Operation

The OS32C safety laser scanner is an optical safety sensor that uses diffuse reflection of a pulsed laser light to determine the location of objects entering a predefined monitoring zone. Internally, a spinning mirror assembly scans a monitoring zone by sending a pulse of light which reflects off the first object in its path. The distance from the sensor to the object is determined by measuring the time that the light requires to return from the sensed object.

This method of sensing allows for standard, simple or irregular shapes to be used as the predetermined sensed monitoring zones. It also allows for the monitoring zone to be changed if the hazardous area changes. Using diffused reflection of light back to the OS32C precludes the need for a traditional transmitter/receiver pair.

Within the sensing range of the OS32C, three fields can be monitored simultaneously: One safety zone and two warning zones.

• One Safety Zone is used to detect personnel or other objects entering an area that has been determined to be a hazard. Upon sensing that the object is within the Safety Zone, the OS32C will send a stop signal to the control circuitry of the machine being guarded.

• Two Warning Zones can be defined with a longer distance than a safety zone, allowing a configuration to detect objects that are closely approaching the hazardous area of the Safety Zone before the actual Safety Zone is encroached.

Applications for the OS32C include mobile applications on automatic guided vehicles (AGV) or transfer carts as well as stationary use, such as within a robotic work cell, in front of a press or around other hazardous machinery.

OS32C

User’s Manual

Description of Use and Features

Features

• Can detect intrusions within the safety zone with a radius of up to 4 m (min. obj. resolution of 70mm) and two warning zones with a radius of 15 m, covering a maximum scan angle of 270°.

• When an object is detected within the safety zone, individual sector indicators immediately turn on (8 red indicators), indicating the object’s position of intrusion.

• Seventy sets of safety zone and warning zone combinations are available, supporting complicated changes of working environments.

• The configuration tool allows easy to use monitoring zone configuration.

• A safety relay can be directly monitored by the external device monitoring function.

• The physical mounting position of the safety laser scanner can be monitored by the reference boundary monitoring function.

• Compact design allows for low-clearance installations.

Chapter1

OS32C

User’s Manual

Description of Use and Features

Chapter1

 System Components

(1)

(2)

(3)

Fig. 1-1 System Components

(5)

(4)

(7)

(6)

(8)

(9)

(10)

(11)

(12)

(13)

Number Component Function

(1) RUN indicator (green) Will turn ON when safety zone is clear and OSSDs are ON.

Interlock Indicator (yellow) Will turn ON when in interlock state, blink under lockout (@ 1Hz), and blink under

(2)

(3) Status/Diagnostic Display The scanner's status ,configuration/operation, or failure is displayed.

Warning Output Indicator

(4)

(orange)

(5) STOP indicator (red) Will turn ON when safety zone is blocked, OSSD are OFF or under interlock state.

(6) Dust Ring Dust detection cover with reflective surface, for dust accumulation detection

Individual Sector Indicators

(7)

(ISI)

(8) Scan Window The window where the laser light is emitted and received.

(9) Communication Connector Provides for Ethernet interface.*1

(10) Power Connector For power connections, 18-pin connector (pigtail).*1

(11) I/O Block Connector module

(12) Center of rotation Indicates the location of the axis around which the laser irradiates from.

(13) Sensor Sensor head; field replaceable.

*1: The communication and power connections can also be mounted on the left side of the I/O block.

Table 1-1 System Components and Indicators

configuration (@ 4Hz).

Will turn ON when the warning output is ON and will flash when dust or contamination is detected on the scan window (@ 1 Hz).

Will turn ON when an intrusion is detected in the safety zone (default), 8 sectors total. Each sector = 33.75°. Will flash when dust or contamination is detected on the scan window.

For details on indicators, refer to "Indication Patterns" on page 14.

For details on Status/Diagnostic Display, refer to "OS32C Status Check" on page 139.

OS32C

User’s Manual

Description of Use and Features

Application Examples

The OS32C may be used for personnel safeguarding. Typical applications include work cell area guarding and collision prevention of AGV (Automated Guided Vehicles). The OS32C is a versatile Safety Laser Scanner capable of guarding many types of applications. The application examples in this chapter are for informational and instructional purposes only and not intended to represent complete guarding solutions. Care must be taken to ensure that all aspects of a machine or work cell are reviewed and appropriate guarding techniques are employed.

 Applying the OS32C to fixed stationary applications

Chapter1

Zone A

Zone B

Fig. 1-2 Dual Zone Area Guarding

In this application the OS32C is the primary guarding device, using a horizontal protective field for area protection. The OS32C will guard one side of the area based on the robot’s position. This application takes advantage of the multi-zone functions of the OS32C. This function allows an operator to enter and set-up on one side “the safe side” shown as Zone A, while the robot performs its tasks on the “hazardous side” shown as Zone B. The warning zones are represented by the lighter colors. The robot’s position is determined via external devices that provide discrete inputs to the OS32C.

Zone A

Zone B

Fig. 1-3 270 deg. Area Guarding

In this application the OS32C is the primary guarding device, using a 270 degree horizontal protective field for area protection guarding. The production process in this example does not allow for any frontal hard guarding obstructions in front of the work cell. The warning fields (shown as Zone A & Zone B) of the OS32C provides manufacturing personnel with a preliminary warning to prevent them from accidentally stopping the manufacturing process. In some cases an unintentional interruption can result in very high waste costs.

OS32C

User’s Manual

Chapter1

Description of Use and Features

Fig. 1-4 Internal Robot Cell Guarding

In this application the OS32C is the secondary guarding device in conjunction with a safety light curtain. The OS32C is responsible for detecting that the work area is clear before start-up of the robot occurs.

Fig. 1-5 Vertical Guarding Installation

In this application the OS32C is the primary guarding device, using a vertical protective field for point of operation guarding. In some cases the machine’s architecture or production flow may not permit the installation of a safety light curtain. The OS32C meets all the requirements of IEC 61496-3 for vertical guarding installations and employs a reference boundary monitoring function.

OS32C

User’s Manual

Description of Use and Features

Chapter1

Zone-1

Zone-2

Fig. 1-6 Dual Zone Vertical Guarding

Zone-1

Zone-2

In this application the OS32C is the primary guarding device, using a vertical protective field for entry presence detection. The OS32C can guard the hazardous area based on the robot’s position. When the robot is in the left side, the OS32C guards the left side and changes to the right side along with the robot. This application takes advantage of the multi-zone functions of the OS32C. This function allows an operator to enter and set-up on one side, “the safe side”, while the robot performs its tasks on the hazardous side. The robot’s position is determined via external devices that provide discrete inputs to the OS32C. The OS32C meets all the requirements of IEC 61496-3 for vertical guarding installations and employs a reference boundary monitoring function.

 Applying the OS32C on Automated Guided Vehicles (AGV)

Unmanned automated vehicles require guarding devices to prevent accidental collisions. The OS32C will scan the path of the AGV and will send a stop signal to the vehicle if it detects an object or person. The OS32C is more adjustable and reliable than conventional pressure-sensitive bumpers.The OS32C's flexibility allows three types of monitoring.

See Fig. 1-7

 Warning Zone 1 Detection

When the Warning Output is assigned to follow Warning Zone 1, it will send a signal to the AGV when Warning Zone 1 is infringed. This will trigger the vehicle to sound an alarm, allowing a person to move away from the vehicle’s path.

 Warning Zone 2 Detection

When the Auxiliary Output is assigned to follow warning zone 2, it will send a signal to the AGV when Warning Zone 2 is infringed. This will trigger the vehicle to slow down, allowing a person to move away from the vehicle’s path.

 Safety Zone Detection

The two safety outputs will send an E-stop to the AGV when the Safety Zone is infringed. This will signal the vehicle to come to a complete stop.

Safety Zone Detection

Warning Zone 2 Detection

Warning Zone 1 Detection

Fig. 1-7 AGV Navigation

OS32C

User’s Manual

Chapter1

Description of Use and Features

Fig. 1-8 Automated Guided Vehicles, Bi-directional (AGV)

In this application two OS32Cs are the primary guarding devices. The two warning fields of the OS32C are used to give personnel extra warning, allowing them to move out of the AGV path. This is essential in achieving maximum travel efficiency.

Left Turn Zone

Right Turn Zone

Slow Zone

Fast Zone

Fig. 1-9 Automated Guided Vehicles, Multiple Zones (AGV)

In this application the OS32C is the primary guarding device. The drawing illustrates a common AGV guarding configuration where 4 zone sets are used to safely navigate the vehicle around a factory floor. The four zone sets consist of two for forward motion (high speed, low speed), one for left turn and one for right turn. The active safety zone set is selected by the AGV’s controls, which are configured for maximum efficiency.

OS32C

User’s Manual

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