Pilz PSEN-op4B-S-3-080 User Manual

PSEN op4B-T, PSEN op4B-L,

PSEN op4B-S

Safety light curtains with infrared beams

OPERATING MANUAL

A Pilz Ges.m.b.H., 01 7986263-0, Fax: [phone], E-Mail: [e-mail] AUS Pilz Australia Industrial

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USA Pilz

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D Pilz GmbH & Co. KG, Sichere Automation, Felix-Wankel-Straβe 2, 73760 Ostfildern, Deutschland,

[phone], Fax: [phone], E-Mail: [e-mail]

826003081 rev.B

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..................................................................................... 6

1.4 Safety information ............................................................................................... 7

2 INSTALLATION............................................................................................................ 8

2.1 Precautionary measures when selecting and installing the device ..................... 8

2.2 General information on positioning the device .................................................... 9

2.2.1 Minimum safety distance ...................................................................... 11

2.2.2 Minimum distance from reflective surfaces .......................................... 13

2.2.3 Installing several adjacent safety light curtains .................................... 15

2.2.4 Use of deviating mirrors........................................................................ 16

3 MECHANICAL ASSEMBLY....................................................................................... 17

3.1 Installing the integral muting sensor profiles with "L" and "T"

shaped configuration......................................................................................... 19

4 WIRING....................................................................................................................... 20

4.1 Electrical connections ....................................................................................... 20

4.2 Notes on wiring.................................................................................................. 21

5 ALIGNMENT............................................................................................................... 25

5.1 Alignment instructions ....................................................................................... 25

5.2 Aligning the muting sensors .............................................................................. 27

6 FUNCTIONS............................................................................................................... 28

6.1 Selecting the operating mode via DIP switches ................................................ 28

6.2 Standard configuration ...................................................................................... 28

6.3 Restart............................................................................................................... 29

6.4 Test function...................................................................................................... 31

6.5 Reset function ................................................................................................... 32

6.6 Feedback loop monitoring function ................................................................... 33

6.7 Muting function.................................................................................................. 35

6.7.1 Installing the muting sensors on PSEN op4B-S models ...................... 40

6.7.2 Installing the muting sensors on PSEN opB-L models ......................... 43

6.7.3 Installing the muting sensors on PSEN opB-T models......................... 44

6.8 Override function............................................................................................... 45

7 DIAGNOSTICS........................................................................................................... 47

7.1 Function indicators ............................................................................................ 47

7.2 Error messages and diagnostics....................................................................... 48

8 REGULAR CHECKS AND MAINTENANCE ............................................................. 50

8.1 Maintenance...................................................................................................... 51

8.2 General information and useful data ................................................................. 51

9 TECHNICAL DETAILS............................................................................................... 52

10 LIST OF AVAILABLE MODELS ................................................................................ 53

11 OVERALL DIMENSIONS........................................................................................... 53

12 ACCESSORIES.......................................................................................................... 54

12.1 Mounting bracket............................................................................................... 54

12.2 Deviating mirror................................................................................................. 55

12.3 Floor brackets.................................................................................................... 56

12.4 Laser pointer ..................................................................................................... 57

12.5 Connection box ................................................................................................. 58

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.
The safety light curtains are designed as safe Type 4 systems for
accident prevention in accordance with applicable international
standards, in particular:

EN 61496-1: 2004

prEN 61496-2: 1997

The device consists of an emitter (TX) and a receiver (RX) housed in
robust aluminium profiles. It secures the protected area by generating
an infrared protected field, which will detect an opaque object as soon
as it enters the protected field.
Both the control and evaluation logic are located inside the two units;
the electrical connection is made via M12 connectors, which are
positioned underneath the profiles. The emitter (TX) and receiver (RX)
are synchronised optically. This means the two units do not have to be
connected directly to each other.
The infrared beams are controlled and monitored via a
microprocessor, which provides the user with information about the
operating status of the safety light curtain via LED indicators (see Ch.
7, “Diagnostics”).
Two yellow LEDs simplify the alignment of the two units during
installation (see Ch. 5 “Alignment”).
As soon as an object, a limb or the operator’s body interrupts the
beams sent by the emitter (TX), both outputs (OSSD) are immediately
opened and the machine connected to the OSSD is stopped.

Safety of machinery: Electrosensitive
protective equipment. Part 1: General
requirements and tests.

Safety of machinery - Electrosensitive
protective equipment. Part 2: Particular
requirements for equipment using active
optoelectronic protective devices.

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PSEN op4B Series Operating Manual

NB: 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. These
sections are highlighted using the following symbols:

Detailed notes and descriptions of specific features of the safety light
curtains, designed to explain their operation more clearly.

Specific installation guidelines.
This warning must be heeded! It warns of a hazardous situation that

could lead to serious injury and death and indicates preventive
measures that can be taken.

This manual contains all the information required for the selection and
operation of the safety light curtains.
Specialised knowledge of safety issues is required to integrate a safety
light curtain correctly on power-driven machinery.

As this manual is unable to provide such information in full, please
contact the technical service department at Pilz for any information
about the operation of the safety light curtains and the safety
regulations relating to correct installation (see Ch. 8, “Regular checks
and maintenance”).

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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.

- "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.

- Linear models: Are suitable for applications on which the
sensors are intended to be positioned individually. A plug
connector enables the muting sensors to be connected simply.

• Resolution, depending on the part of the body requiring protection.

R = 40 mm Body protection

The resolution (R) of a device is understood to be the minimum size
an opaque object must be in order to interrupt at least one of the
beams that form the sensing area.
As shown in Fig. 1, the resolution depends exclusively on the
geometrical properties of the lenses, the diameter and the centre
distance; it is independent of the ambient and operating conditions
of the safety light curtain.

3

Type 4

PSEN op4B Series Operating Manual

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).

Fig. 1

Model Optical

axis
mm

(I)

PSEN op4B-T-2-050 500 2 515 16 3
PSEN op4B-T-3-080 400 3 415 16 3
PSEN op4B-L-2-050 500 2 515 16 3
PSEN op4B-L-3-080 400 3 415 16 3
PSEN op4B-S-2-050 500 2 515 16 25
PSEN op4B-S-3-080 400 3 415 16 25

No. of
optics

(n)

Resolution

mm

(R)

Ø of optics

mm

(d)

Range

m

4

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.

- The height of the protected area is the effective protected area,
in which an opaque object whose size is greater than or equal to
the resolution of the safety light curtain will safely interrupt the
beam.

Fig. 2

• Safety distance: Great care must be taken when calculating the

distance at which the safety light curtain should be positioned in
relation to the hazardous machinery. (Please see Chapter 2,
“Installation”, for details of how to calculate the safety distance.)

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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.

In particular they are used to stop the hazardous movement of
mechanical parts on:

• Palletisers/depalletisers

• Packaging, handling and storage machinery

• Automatic or semi-automatic assembly lines

• Automated high-bay racking

With food industry applications, please contact customer services at
Pilz to check whether the safety light curtain’s housing material can
withstand the chemical substances that may be used in the production
process.

The following illustrations provide an overview of some of the main
application areas:

L-shape version with integral muting
sensors for muting in one direction
(leaving the danger zone)

T-shape version with integral muting
sensors for muting in two directions

Linear version with external muting sensors

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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:

• 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.

• The safety light curtain and its respective electrical connections

must be installed by qualified personnel, in line with the guidelines
stated in the relevant chapters.

• The safety light curtain must be positioned in such a way that the

danger zone cannot be accessed without interrupting the beams
(see Chapter 2 “Installation”).

• Personnel working in the danger zone must be appropriately

trained with regard to the operation of the safety light curtain.

• The test/reset button must be positioned outside the danger zone

in such a way that operating personnel have a complete view of
the danger zone during all reset, test or override operations.

• The feedback loop monitoring function used to monitor the external

contactors will only be active if the corresponding wire is connected
to the device.

• The muting lamp that displays the activated muting function must

be visible from all sides of the work area.

• To ensure the correct operation of the muting switching devices,

follow the instructions provided in the installation manual.

• Before switching on the safety light curtain, make sure you comply

with the instructions regarding correct operation.

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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).

• The dimensions of the smallest object to be detected must not be

less than the resolution level of the device.

• The environment in which the safety light curtain is installed must

comply with the technical details stated for the safety light curtain
in Chapter 10, “Technical details”.

• Avoid installing the device, particularly the receiver (RX), close to

intense and/or flashing light sources.

• Avoid strong electromagnetic interference as this can adversely

affect the proper operation of the device.

• Smoke, mist or dust within the operating environment can reduce

the range of the safety light curtain by up to 50%.

• Sudden temperature fluctuations beyond freezing point can cause

condensation to form on the surface of the lenses, adversely
affecting the proper operation of the safety light curtain.

• The activated muting function is displayed via an integral muting

lamp. Make sure that the intensity of the LED is appropriate and
that it is clearly visible, positioned close to the danger zone.

• Install and replace emitter and receiver only in pairs.

Emitter and receiver have the same serial number.

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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.

2.2 General information on positioning the device

For effective protection it is necessary to proceed very carefully when
positioning the device; in particular, the device must be installed in
such a way that the danger zone cannot be accessed without
interrupting the protected field.
To exclude the possibility of the machine being accessed from above
or below (Fig. 3a), it is necessary to install a safety light curtain that is
long enough to completely cover access to the danger zone (Fig. 3b).

NO

Fig. 3a

Fig. 3b

9

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. 4b

If the installation position of the safety light curtain still enables an
operator to access the danger zone without detection, an additional
mechanical barrier must be installed to prevent this.

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Operating Manual PSEN op4B Series

2.2.1 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).
According to the standards EN 999, 775 and 294, this distance
depends on four factors:

1 Reaction time of the safety light curtain (time it takes for the signal

at the OSSD output to switch from High to Low once the beams
have effectively been interrupted).

2 Machine's overrun time (time it takes for the machine to come to a

standstill once the reaction time of the safety light curtain has
elapsed).

3 Resolution of the safety light curtain.
4 Approach speed of the object requiring detection.

The formula for calculating the safety distance is as follows:

Fig. 5

S = K (t1 + t2) + C

where:
S = Minimum safety distance in mm between the protected field and

the danger zone

K = The speed at which the object requiring detection (body or parts

of the body) approaches the danger zone, in mm/s

t

= Reaction time of the safety light curtain in seconds (Ch. 10

1

“Technical details”).

t

= Machine’s overrun time in seconds

2

d = Resolution of the safety light curtain.
C = 850 mm for a safety light curtain with a resolution > 40mm

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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).

If the safety light curtain is to be installed horizontally
(Fig. 6), the distance between the danger zone and the furthest optical
beam must equal 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 between the protected field

and the danger zone

t

= Reaction time of the safety light curtain in seconds (Ch. 10

1

“Technical details”).

t

= Machine's overrun time in seconds

2

H = Height of the beams above the floor. This height must always

be less than 1000 mm.

Fig. 6

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Operating Manual PSEN op4B Series

2.2.2 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.

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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 (± 2.5° to light axis)

The values for the minimum distance in relation to the operating range
can be taken from the illustration in Fig. 8.

800
700
600
500
400
300
200
100

0

distanza superficie riflettente (mm)

reflecting surface distance (mm)

0 1 2 3 4 5 6 7 8 9 10111213141516171819202122232425

distanza operativa (m)

Operating distance (m)

Type 4

safety

light curtain

Fig. 8

14

Operating Manual PSEN op4B Series

2.2.3 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.

NO

YES

YES

Fig. 9

15