Pilz PSEN-op4H-s-30-150-1 User Manual

PSEN op4F/H-s-...../1

Safety light curtains with infrared beams

OPERATING MANUAL

1001422-EN-03

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 op4F/H-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 PSEN op4F-s series (with EDM function) .................... 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 ............................................................................................. 8

1.5. Safety information ............................................................................................. 11

2. INSTALLATION MODE .............................................................................................. 12

2.1. Precautions to be observed for the choice and installation ............................... 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. Distance between homologous devices ............................................... 17

2.2.4. Emitter and receiver orientation ........................................................... 20

2.2.5. Use of deviating mirrors ....................................................................... 20

2.2.6. Controls after first installation ............................................................... 21

3. MECHANICAL MOUNTING ....................................................................................... 23

4. ELECTRICAL CONNECTIONS ................................................................................. 26

4.1. Notes on connections ........................................................................................ 28

4.2. Ground connection ............................................................................................ 31

5. ALIGNMENT PROCEDURE ...................................................................................... 33

5.1. Correct alignment procedure ............................................................................. 34

6. FUNCTIONING MODE ............................................................................................... 36

6.1. Restart mode ..................................................................................................... 36

6.2. Test function ...................................................................................................... 37

6.3. Reset function ................................................................................................... 37

6.4. EDM function ..................................................................................................... 38

6.5. Alignment aid function ....................................................................................... 39

7. DIAGNOSTIC FUNCTIONS ....................................................................................... 40

7.1. User interface .................................................................................................... 40

7.2. Dagnostic messages ......................................................................................... 41

8. PERIODICAL CHECKS ............................................................................................. 44

8.1. General information and useful data ................................................................. 45

9. DEVICE MAINTENANCE ........................................................................................... 46

9.1. Product disposal ................................................................................................ 46

10. TECHNICAL DATA .................................................................................................... 47

11. LIST OF AVAILABLE MODELS ................................................................................ 48

12. OVERALL DIMENSIONS ........................................................................................... 49

13. OUTFIT ....................................................................................................................... 50

14. ACCESSORIES .......................................................................................................... 51

14.1 Angled fixing bracket mounting ......................................................................... 52

15. GLOSSARY ................................................................................................................ 57

Instruction Manual PSEN op4F/H-s Series

1. GENERAL INFORMATION

1.1. General Description of the safety light curtains

The safety light curtains of the PSEN op4F/H-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 op4F/H-s series are Type 4 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: electrosensitive

protective equipment. Part 1: General prescriptions and tests.

CEI IEC 61496-2: 2006 Safety of machinery: electrosensitive

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 LEDs inform the operator about the general conditions of the safety light curtain (see section 7 “Diagnostic functions”).

PSEN op4F/H-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, an user interface facilitates 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 user or installing 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 op4F/H-s light curtains and the safety rules that regulate the correct installation (see section 8 “Periodical checks”).

Instruction Manual PSEN op4F/H-s Series

1.1.1. Package contents

• Package contains the following objects:

• Receiver (RX)

• Emitter (TX)

• Installation Quick Guide of PSEN op4F/H-s curtain

• Biannual checklist and periodical maintenance schedule

• CD with instruction manual and other documents

• 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 PSEN op4F-s series (with EDM function)

With respect to PSEN op4F-s (EDM) series, the PSEN op4F/H-s.../1 Series safety light curtain series presents new important features:

• Higher operating distance

• Shorter response time (see sect.10 “Technical Data”)

• Range enlargement with 150 to 1800 mm controlled heights

• New fastening system with rotating brackets

• TEST line with reversed activation logics (active high)

• Advanced alignment for receiver and transmitter units

Furthermore, PSEN op4F-s has 2 selectable functions, i.e.:

• EDM function

• Manual/automatic Restart

PSEN op4F/H-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 = 14mm Finger protection

Type 4

R = 30 mm Hand protection

Type 4

As shown in Fig.1, the resolution only depends on the geometrical characteristics of the lenses, diameter and distance between centres, and is independent of 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

Instruction Manual PSEN op4F/H-s Series

Controlled

(mm)

Reference

1.3.2. Controlled height

The controlled height is the height protected by the safety light curtain (Hp)

Fig. 2

The PSEN op4F/H-s controlled height is delimited by the yellow line pad-printed on the front glass and by the dimensions listed in the table:

xx = Resolution (14 mm – 30 mm)

Model

PSEN op4F/H-s-XX-015/1 150

PSEN op4F/H-s-XX-030/1 300

PSEN op4F/H-s-XX-045/1 450

PSEN op4F/H-s-XX-060/1 600

PSEN op4F/H-s-XX-075/1 750

PSEN op4F/H-s-XX-090/1 900

PSEN op4F/H-s-XX-105/1 1050

PSEN op4F/H-s-XX-120/1 1200

PSEN op4F/H-s-XX-135/1 1350

PSEN op4F/H-s-XX-150/1 1500

PSEN op4F/H-s-XX-165/1 1650

PSEN op4F/H-s-XX-180/1 1800

height Hp

PSEN op4F/H-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

where:

S = Minimum safety distance in mm.

K = Speed of the object, limb or body approaching the dangerous area in mm/sec. t

= Response time of the AOPD in seconds

(see section 10 “Technical data”) t2 = Machine stopping time in seconds. 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 ≤ 40 mm.

Instruction Manual PSEN op4F/H-s Series

NOTE: K value is: 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

where:

S = Minimum safety distance in mm.

= Response time of the AOPD in seconds

(see section 10 “Technical data”) t2 = Machine stopping time in seconds. H = Beam height from ground. This height must always be less than 1,000 mm.

Fig. 4

PSEN op4F/H-s Series Instruction Manual

0.393 sec

0.394 sec

Practical examples

Let's suppose to have a light curtain with height = 600 mm 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)

= Machine total stopping time.

C = 8 * (d – 14) for devices with resolution <= 40 mm D = resolution

In all cases, if K = 2000mm/sec then S > 500 mm. Distance will have then to be recalculated using K = 1600 mm/sec.

PSEN op4F-s-14-060/1 PSEN op4H-s-30-060/1

0 mm 128 mm

641.6 mm 758.4 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”.

The following information is to be considered as indicative and concise. For correct safety distance please refer to complete standard EN-999.

1.4. Typical applications

The PSEN op4F/H-s FINGER safety light curtains provide solutions in all automation fields where the access to dangerous areas has to be controlled. In particular, the safety curtains can be used in stopping moving parts in:

- Automatic machines;

- Packaging and cutting machines;

- Textile, wood-working and ceramic machines;

- Automatic assembling lines;

- Milling, lathe and shearing machines;

- Bending and metal-working machines.”

Instruction Manual PSEN op4F/H-s Series

Example 1: Operating point protection on drilling machines

The operator positions the part and takes it back after machining. The operator must be protected against possible abrasions while working. Solution: PSEN op4F/H-s 14 mm safety light curtain is especially suitable for this kind of application, which requires the installation of the device directly on the machine.

Benefits: The extremely reduced profile guarantees installation flexibility adapting itself to the machine dimensions. The rotating fixing brackets, supplied as accessories, speed up and facilitate mounting.

Example 2 : Paper cutting machines

These machines typically cut paper to a specific size for newspapers or special applications. The operator must be protected against abrasion or cuts by cutter blades. Solution: PSEN op4F/H-s 30 mm safety light curtain is especially suitable for this kind of application, which require the installation of the device directly on the machine. Benefits: Highly reduced profile and the two side slots ensure installation flexibility for machine dimensions. Advantages: The extremely reduced profile guarantees installation flexibility adapting itself to the machine dimensions. The rotating fixing brackets, supplied as accessories, speed up and facilitate mounting.

PSEN op4F/H-s Series Instruction Manual

Example 3 : Milling machines

A milling machine is a machine tool used for the shaping of metals and other solid materials. Operator hands and body must be protected from being dragged, entangled or cut by the tool / spindle.

Solution:

solution considering the required safety levels and application type. When even just one of the light curtain beams is interrupted, the machine is immediately stopped. Benefits: The extremely reduced profile guarantees installation flexibility adapting itself to the machine dimensions. The rotating fixing brackets, supplied as accessories, speed up and facilitate mounting.

PSEN op4F/H-s 30 mm series safety light curtain is the best

Instruction Manual PSEN op4F/H-s Series

1.5. Safety information

For a correct and safe use of the safety light curtains of the PSEN op4F/H-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 paragraph 1.3.3, and during all working cycle phases.

• Mounting and connection of the safety light curtain must be carried out by qualified personnel only, 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 placed in a particular position so that access to the dangerous zone is not possible without the interruption of the beams (refer 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 (optional for the safety light curtains Type 4) button must be located outside the protected area because the operator must check the protected area during all Test operation.

• The RESET/RESTART button must be located outside the protected area because the operator must check the protected area during all Reset/Restart operations.

Please carefully read the instructions for the correct functioning before powering the light curtain.

PSEN op4F/H-s Series Instruction Manual

2. INSTALLATION MODE

2.1. Precautions to be observed for the choice and installation

Make sure that the protection level assured by the PSEN op4F/H-s device (Type 4) is compatible with the real danger level of the machine to be controlled, according to EN 954-1 and EN 13849-1.

• 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 install device near strong and/or flashing light sources or close to similar devices.

• The presence of intense electromagnetic disturbances could jeopardise device functioning. 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.

Instruction Manual PSEN op4F/H-s Series

YES

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.

Fig. 5a

Fig. 5b

Under standard operating conditions, machine starting must not be possible while operators are inside the dangerous area.

PSEN op4F/H-s Series Instruction Manual

YES

When the installation of the safety light curtain near to the dangerous area is not possible, a second light curtain must be mounted in a horizontal position in order to prevent any lateral access, as shown in Fig.6b.

If the operator is able to enter the dangerous area, an additional mechanical protection must be mounted to prevent the access.

Fig. 6a

Fig. 6b

2.2.1. Minimum installation distance

Refer to paragraph1.3.3. “Minimum installation distance”

Instruction Manual PSEN op4F/H-s Series

2.2.2. Minimum distance from reflecting surfaces

Reflecting surfaces placed near the light beams of the safety device (over, under or laterally) can cause passive reflections. These reflections can affect the recognition of an object inside the controlled area. However, if the RX receiver detects a secondary beam (reflected by the side-reflecting surface) the object might not be detected, even if the object interrupts the main beam.

Fig. 7

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