Pilz PSEN-op2H-s-30-180-1 User Manual
PSEN op2H-s-30-XXX/1
Safety light curtains with infrared beams
OPERATION MANUAL
1001421-EN-02
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH &
Co. KG. Copies may be made for internal purposes.
Suggestions and comments for improving this documentation
will be gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®,
SafetyBUS p®, SafetyEYE®, SafetyNET p®, the spirit of
safety® are registered and protected trademarks of
Pilz GmbH & Co. KG in some countries.
Pilz GmbH & Co. KG
Felix-Wankel-Straße 2
73760 Ostfildern, Germany
Telephone: +49 711 3409-0
Telefax: +49 711 3409-133
E-Mail: pilz.gmbh@pilz.de
www.pilz.com
PSEN op2H-s Series Instruction Manual
INDEX
1. GENERAL INFORMATION ........................................................................................ 1
1.1. General description of the safety light curtains .................................................. 1
1.1.1. Package contents ................................................................................. 3
1.2. New features compared to the PSEN op2H Series ............................................ 3
1.3. How to choose the device ................................................................................. 4
1.3.1. Resolution ............................................................................................ 4
1.3.2. Controlled height................................................................................... 5
1.3.3. Minimum installation distance ............................................................... 6
1.4. Typical applications ........................................................................................... 9
1.5. Safety information ........................................................................................... 11
2. INSTALLATION MODE ............................................................................................ 12
2.1. Precautions to be observed for the choice and installation of the device......... 12
2.2. General information on device positioning ....................................................... 13
2.2.1. Minimum installation distance ............................................................. 14
2.2.2. Minimum distance from reflecting surfaces ......................................... 15
2.2.3. Emitter and receiver orientation .......................................................... 17
2.2.4. Installation of several adjacent safety light curtains ............................. 18
2.2.5. Use of deviating mirrors ...................................................................... 19
2.2.6. Controls after first installation .............................................................. 20
3. MECHANICAL MOUNTING ..................................................................................... 22
4. ELECTRICAL CONNECTIONS ................................................................................ 25
4.1. Notes on connections ...................................................................................... 26
4.2. Earth connection ............................................................................................. 29
5. ALIGNMENT PROCEDURE..................................................................................... 30
5.1. Correct alignment procedure ........................................................................... 32
6. FUNCTIONING MODE ............................................................................................. 33
6.1. Reset mode ..................................................................................................... 33
6.2. Test function ................................................................................................... 33
6.3. Reset function ................................................................................................. 34
7. DIAGNOSTIC FUNCTIONS ..................................................................................... 35
7.1. User interface .................................................................................................. 35
7.2. Diagnostic messages ...................................................................................... 36
8. PERIODICAL CHECKS ........................................................................................... 38
8.1. General information and useful data ................................................................ 39
9. DEVICE MAINTENANCE ......................................................................................... 40
9.1. Product disposal.............................................................................................. 40
10. TECHNICAL DATA .................................................................................................. 41
11. LIST OF AVAILABLE MODELS .............................................................................. 42
12. OVERALL DIMENSIONS ......................................................................................... 43
13. OUTFIT .................................................................................................................... 44
14. ACCESSORIES ....................................................................................................... 45
14.1 Angled fixing bracket mounting ....................................................................... 46
15. GLOSSA RY ............................................................................................................. 50
Instruction Manual PSEN op2H-s Series
1. GENERAL INFORMATION
1.1. General description of the safety light curtains
The safety light curtains of the PSEN op2H-s series are
optoelectronic multibeam devices that are used to protect working
areas that, in presence of machines, robots, and automatic systems
in general, can become dangerous for operators that can get in
touch, even accidentally, with moving parts.
The light curtains of the PSEN op2H-s series are Type 2 intrinsic
safety systems used as accident-prevention protection devices and
are manufactured in accordance with the international Standards in
force for safety, in particular:
CEI IEC 61496-1: 2004 Safety of machinery: electro-
sensitive protective equipment. Part
1: General prescriptions and tests.
CEI IEC 61496-2: 2006 Safety of machinery: electro-
sensitive protective equipment Particular requirements for
equipment using active
optoelectronic protective devices.
The device, consisting of one emitter and one receiver housed inside
strong aluminium profiles, generates infrared beams that detect any
opaque object positioned within the light curtain detection field. The
emitter and the receiver are equipped with the command and control
functions. The connections are made through a M12 connector
located in the lower side of the profile. The synchronisation between
the emitter and the receiver takes place optically, i.e. no electrical
connection between the two units is required. The microprocessor
guarantees the check and the management of the beams that are
sent and received through the units. The microprocessor – through
some LEDs – informs the operator about the general conditions of
the safety light curtain (see section 7 “Diagnostic functions”).
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PSEN op2H-s Series Instruction Manual
The device consists in 2 units that, according to the model, are
composed by one or several emitting and receiving modules.
The receiver checks the control operations and safety actions.
During installation, two yellow LEDs facilitate the alignment of both
units (see section 5 “Alignment procedure”).
As soon as an object, a limb or the operator’s body accidentally
interrupts one or some of the infrared beams sent by the emitter, the
receiver immediately opens the OSSD outputs and blocks the MPCE
machine (if correctly connected to the OSSD).
Some parts or sections of this manual containing important
information for the operator are preceded by a note:
Notes and detailed descriptions about particular characteristics of the
safety devices in order to better explain their functioning.
Special instructions regarding the installation process.
The information provided in the paragraphs following this symbol is
very important for safety and may prevent accidents.
Always read this information accurately and carefully follow the
advice to the letter.
This manual contains all the information necessary for the selection
and operation of the safety devices.
However, specialised knowledge not included in this technical
description is required for the planning and implementation of a
safety light curtain on a power-driven machine. As the required
knowledge may not be completely included in this manual, we
suggest the customer to contact Pilz Technical Service for any
necessary information relative to the functioning of the PSEN op2H-s
light curtains and the safety rules that regulate the correct installation
(see section 8 “Periodical checks ”).
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Instruction Manual PSEN op2H-s Series
1.1.1. Package contents
Package contains the following objects:
• Receiver (RX)
• Emitter (TX)
• Quick Guide for first installation
• CD with user manual and other documents
• Checklist and periodical maintenance schedule
• 4 angled fixing brackets and specific fasteners
• 2 angled fixing brackets for models with heights included between
1200 and 1800 mm
1.2. New features compared to the PSEN op2H Series
The PSEN op2H-s safety light curtains, compared to the
PSEN op2H-s series, present the following new features:
• Increased operating distance
• Range enlargement with 150 to 1800 mm controlled heights
• Reduced response times
• New fastening system with rotating brackets
• New mechanical profile compatible with PSEN op2H-s accessories
• Different positioning of synchronisation optics (the first one from the
reference line)
• Different mechanical mounting
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PSEN op2H-s Series Instruction Manual
1.3. How to choose the device
There are at least three different main characteristics that should be
considered when choosing a safety light curtain, after having
evaluated the risk assessment:
1.3.1. Resolution
The resolution of the device is the minimum dimension that an
opaque object must have in order to obscure at least one of the
beams that constitute the sensitive area.
The resolution strictly depends on the part of the body to be
protected.
R = 30 mm hand protection
Type 2
As shown in Fig.1, the resolution only depends on the geometrical
characteristics of the lenses, diameter and distance between centres,
and is independent from any environmental and operating conditions
of the safety light curtain.
Fig. 1
The resolution value is obtained applying the following formula:
R = I + d
where:
I = Distance between two adjacent optics
d = Lens diameter
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Instruction Manual PSEN op2H-s Series
1.3.2. Controlled height
The controlled height is the height protected by the safety light
curtain ( Hp )
Fig. 2
The PSEN op2H-s controlled height is delimited by the yellow line
pad-printed on the front glass and by the dimensions listed in the
table:
Model
PSEN op2H-s-30-015/1 150
PSEN op2H-s-30-030/1 300
PSEN op2H-s-30-045/1 450
Hp
Reference
PSEN op2H-s-30-060/1 600
PSEN op2H-s-30-075/1 750
PSEN op2H-s-30-090/1 900
PSEN op2H-s-30-105/1 1050
PSEN op2H-s-30-120/1 1200
PSEN op2H-s-30-135/1 1350
PSEN op2H-s-30-150/1 1500
PSEN op2H-s-30-165/1 1650
PSEN op2H-s-30-180/1 1800
Controlled
height Hp
(mm)
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PSEN op2H-s Series Instruction Manual
1.3.3. Minimum installation distance
The safety device must be positioned at a specific safety distance
(Fig. 3). This distance must ensure that the dangerous area cannot
be reached before the dangerous motion of the machine has been
stopped by the AOPD.
The safety distance depends on 4 factors, according to the EN-999
Standard:
• Response time of the AOPD (the time between the effective beam
interruption and the opening of the OSSD contacts).
• Machine stopping time (the time between the effective opening of
the contacts of the AOPD and the real stop of the dangerous
motion of the machine).
• AOPD resolution.
• Approaching speed of the object to be detected.
Fig. 3
The following formula is used for the calculation of the safety
distance:
S = K (t
+ t2) + C
1
where:
S = Minimum safety distance in mm.
K = Speed of the object, limb or body approaching the
dangerous area in mm/sec.
= Response time of the AOPD in seconds (see section 9
t
1
“Technical data”)
= Machine stopping time in seconds.
t
2
d = Resolution of the system.
C = Additional distance based on the possibility to insert the body or
one of body parts inside the dangerous area before the protective
device trips.
C = 8 (d -14) for devices with resolution ≤ 40mm
C = 850 mm for devices with resolution > 40mm.
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Instruction Manual PSEN op2H-s Series
: K value is:
NOTE
2000 mm/s if the calculated value of S is ≤ 500 mm
1600 mm/s if the calculated value of S is > 500 mm
When devices with >40 mm resolution are used, the height of the top
beam has to be ≥ 900 mm (H2) from machine supporting base while
the height of the bottom beam has to be ≤ 300 mm (H1).
If the safety light curtain must be mounted in a horizontal position
(Fig.4), the distance between the dangerous area and the most
distant optical beam must be equal to the value calculated using the
following formula:
S = 1600 mm/s (t
+ t2) + 1200 – 0.4 H
1
where:
S = Minimum safety distance in mm.
t
= Response time of the AOPD in seconds
1
(
t2 = Machine stopping time in seconds.
H = Beam height from ground; this height must always be less than
1,000 mm.
see section 9 “Technical data”)
Fig. 4
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PSEN op2H-s Series Instruction Manual
Practical examples:
Let's suppose to have a light curtain with height = 600 mm
1) To calculate the distance of the device from the AOPD, in a vertical
position, the following formula is used:
S = K*T + C
where:
T = t1 + t2
= AOPD response time + PNOZsigma relay release time (max 80 ms)
t
1
t2 = Machine total stopping time.
C = 8 * (d – 14) for devices with resolution <= 40 mm
C = 850 for devices with resolution > 40 mm
d = Resolution of the system.
In all cases, if K = 2000mm/sec then S will be > 500 mm.
Distance will have then to be recalculated using K = 1600 mm/sec.
PSEN op2H-s-30-060/1
T
C
S
0.398 sec
128 mm
764.8 mm
2) To calculate the distance of the device from the AOPD, in a
horizontal position
, the following formula is used:
S = 1600 * T + 1200 – 0.4 * H
where:
H = Beam min. height from ground 15 * (d – 50)
D = resolution
t
H
S
PSEN op2H-s-30-060/1
0.3 Sek.
0 mm
1828.8 mm
WARNING
: the reference standard is EN 999 “Machine safety - the
positioning of the protective device based on the approaching speed
of the human body”.
This information is just an indication and a kind of summary.
For safety distance correct calculation, it is compulsory to refer to the
whole EN 999 standard.
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Instruction Manual PSEN op2H-s Series
1.4. Typical applications
The safety light curtains of the PSEN op2H-s series are used in all
automation fields where the control and protection of the access to
dangerous areas are necessary.
In particular, they are used to stop the moving of mechanical parts in:
- Automatic machines;
- Machines for packaging, material handling, storing;
- Weaving machines, wood working machines, ceramic working
machines;
- Automatic and semiautomatic assembly lines;
- Automatic warehouses.
In food industry applications, Pilz Technical Service has to
verify the compatibility of the material of the safety light curtain
housing with any chemical agents used in the production
process.
Example 1: Cooling and conditioning systems
Cooling and conditioning
systems, as well as automotive
equipment and components are
checked inside a machine, to
detect possible leaks by a
helium mass spectrometer. The
point where these parts are
positioned inside the measuring
chamber requires a Type 2
protection ensuring a certain
space saving and an easy access to the protected area.
Solution: the PSEN op2H-s safety light curtain series represents the
ideal solution if the safety requirements and the application are
considered. When even just one of the light curtain beams is
interrupted, the test machine is immediately stopped.
Advantages: the PSEN op2H-s light curtain meets the customer's
needs when easy access is necessary in presence of machine stops.
Easy installation, configuration and use are other advantages.
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PSEN op2H-s Series Instruction Manual
Example 2: Automatic warehouses
Operator protection in automatic warehouses.
Solution:
the PSEN op2H-s safety light curtain series represents the
ideal solution if the safety requirements and the application are
considered. When even just one of the light curtain beams is
interrupted, the carousel is immediately stopped.
Advantages: the PSEN op2H-s light curtain meets the customer's
needs when easy access is necessary in presence of machine stops.
Easy installation, configuration and use are other advantages.
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Instruction Manual PSEN op2H-s Series
1.5. Safety information
For a correct and safe use of the safety light curtains of the PSEN
op2H-s series, the following points must be observed:
• The stopping system of the machine must be electrically controlled.
• This control system must be able to stop the dangerous movement
of the machine within the total machine stopping time T as per par.
1.1.3, and during all working cycle phases.
• Mounting and connection of the safety light curtain must be carried
out only by qualified personnel, according to the indications
included in the special sections (refer to sections 2; 3; 4; 5) and in
the applicable Standards.
• The safety light curtain must be securely installed in a particular
position so that access to the dangerous zone is not possible
without the interruption of the beams (see section 2 “Installation
mode”).
• The personnel operating in the dangerous area must be well trained
and must have adequate knowledge of all the operating procedures
of the safety light curtain.
• The TEST button must be located outside the protected area
because the operator must check the protected area during all Test
and Reset operations.
Please carefully read the instructions for the correct functioning
before powering the light curtain.
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PSEN op2H-s Series Instruction Manual
2. INSTALLATION MODE
2.1. Precautions to be observed for the choice and installation of the
device
Make sure that the protection level assured by the PSEN op2H-s
device (Type 2) is compatible with the real danger level of the
machine to be controlled, according to EN 954-1 and EN 13849.
• The outputs (OSSD) of the AOPD must be used as machine
stopping devices and not as command devices. The machine must
have its own START command.
• The dimension of the smallest object to be detected must be larger
than the resolution level of the device.
• The AOPD must be installed in a room complying with the technical
characteristics indicated in section 10 “Technical data”.
• Do not place the device near intense and/or flashing light sources
and, in particular, close to receiving unit front surface.
• The presence of intense electromagnetic disturbances could affect
device correct operation. This condition shall be carefully assessed
by seeking the advice of Pilz Technical service.
• The operating distance of the device can be reduced in presence of
smog, fog or airborne dust.
• A sudden change in environment temperature, with very low
minimum peaks, can generate a small condensation layer on the
lenses and so jeopardise functioning.
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Instruction Manual PSEN op2H-s Series
2.2. General information on device positioning
The safety light curtain should be carefully positioned, in order to
reach a very high protection standard. Access to the dangerous area
must only be possible by passing through the protecting safety light
beams.
Fig.5a shows some examples of possible access to the machine from
the top and the bottom sides. These situations may be very
dangerous and so the installation of the safety light curtain at
sufficient height in order to completely cover the access to the
dangerous area (Fig.5b) becomes necessary.
NO
Fig.5a
YES
Fig.5b
Under standard operating conditions, machine starting must not be
possible while operators are inside the dangerous area.
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