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EOS4 A

Reer EOS4, EOS4 Series, EOS4 A, EOS4 X, EOS4 XM Installation, Use And Maintenance Manual

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PHOTOELECTRIC
SAFETY BARRIER
EOS4
www.reer.it
EOS4 SAFETY LIGHT CURTAIN
8540733 • 23/03/2016 • Rev.17
1
English
Positioning ...................................................................................................... 6
Master/Slave Positioning .................................................................................. 7
Calculation of safety distance .......................................................................... 8
Multiple systems ............................................................................................. 9
Use of deflecting mirrors ............................................................................... 10
Distance from reflective surfaces ................................................................... 11
Mechanical assembly and optical alignment ................................................... 12
Vertical positioning of the light curtain .......................................................... 13
Models with 14, 20mm resolution ............................................................... 13
Models with 30, 40mm resolution ............................................................... 13
Models with 50, 90mm resolution ............................................................... 13
Multibeam Models ...................................................................................... 14
Horizontal positioning of the light curtain ...................................................... 14
Electrical connections .................................................................................... 15
Layout of the connectors on MASTER/SLAVE light curtain ............................ 15
Emitter connections .................................................................................... 16
Receiver connections .................................................................................. 17
Warnings regarding connection cables ........................................................ 18
Configuration and operating modes (Master Models / With integrated control
functions) ...................................................................................................... 19
Automatic operation ................................................................................... 19
Manual operation ....................................................................................... 19
Connection of external contactors K1 and K2 .............................................. 20
Examples of connection with REER safety modules ...................................... 21
Light signals .................................................................................................. 24
Emitter light signals ................................................................................... 24
Receiver light signals .................................................................................. 24
TEST function ................................................................................................ 25
Status of the outputs ..................................................................................... 25
Technical specifications ................................................................................. 26
Dimensions ................................................................................................... 31
Checking of light curtain efficiency ................................................................ 33
Troubleshooting ............................................................................................ 34
Accessories/Spares ........................................................................................ 36
EOS4 SAFETY LIGHT CURTAIN
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Functional earth (earth connection)
Master/Slave System
Output Signal Switching Device = Light curtain’s solid state safety outputs = Safety light curtain emitter. = Safety light curtain receiver.
Hand protection light curtains
Arm and leg protection light curtains.
Full body protection light grids.
This symbol indicates an important warning for Failure to comply
with this warning may result in high level risk for exposed personnel.
This symbol indicates an important warning.
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INTRODUCTION
The EOS4 light curtain is an optoelectronic safety device belonging to the category of Type 4 electro-sensitive protective equipment for the protection of personnel exposed to risks inherent in the use of hazardous machines or plants, complying with the EN 61496-1 and IEC 61496-2 standards. The EOS4 is available in three different versions:
Type 4 light curtain consisting of Emitter plus Receiver with automatic reset.
Type 4 light curtain consisting of Emitter plus Receiver with integration of additional functions such as control of feedback from any external contactors and management of manual/automatic operation.
Type 4 light curtain (with integrated control functions) comprising two (or three) TX/RX pairs (connected in series), one of which comprising the MASTER light curtain (with integrated functions) and one (or two) the SLAVE light curtain.
A set of indicator leds on the Emitter and Receiver provide the information needed for a correct use of the device and for the assessment of any malfunction. The automatic fault sensing system permits independent detection by the EOS4 light curtain of any dangerous fault in a time equal to the light curtain response time.
For any safety problem, if necessary, consult the safety authorities of the country of
use or the competent industrial association.
For applications in the food industry, consult the manufacturer to verify compatibility
of light curtain materials with the chemical agents used.
The protection capability of optoelectronic safety devices is not effective in cases in
which:
- The machine stopping device cannot be actuated electrically and it is not possible to stop all dangerous machine movements immediately and at any time during the operating cycle.
- The hazardous condition is associated with the falling of objects from above or ejection of these from the machine.
- Anomalous forms of light radiation are present (for example, use of cablelless control devices on cranes, radiation from weld spatter, etc). In this case additional measures may be necessary to ensure that the ESPE does not fail to danger.
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PRINCIPLE OF OPERATION
If the protected area is clear, the two outputs on the Receiver are active and enable the machine to which they are connected to operate normally.
Each time that an object bigger than or equal in size to the resolution of the system intercepts the optical path of one or more beams, the Receiver deactivates its own outputs. This condition enables hazardous machine movements to be stopped (by means of an adequate machine emergency stop circuit).
Resolution is the smallest sized object that, passing through the protected area, interrupts at least one of the beams generated by the light curtain (Figure 1), causing certain intervention of the device and consequent stopping of the hazardous movement of the machine.
Figure 1 - Resolution
Resolution remains constant regardless of working conditions as it depends only on the geometric characteristics of the mirrors and on the centre distance between two adjacent lenses.
is the effective height protected by the safety light curtain. If the curtain is positioned horizontally, this value indicates the depth of the protected area.
indicates how far the emitter and receiver can be separated and
function properly.
EOS4 is available with the following resolutions:
14mm (protected heights from 160mm to 1810mm): PROTECTION OF THE FINGERS. 20mm (protected heights from 160mm to 1810mm): PROTECTION OF THE FINGERS. 30mm (protected heights from 160mm to 1810mm): PROTECTION OF THE HANDS. 40mm (protected heights from 310mm to 1810mm): PROTECTION OF THE HANDS. 50mm and 90mm (protected heights from 310mm to 1810mm):
PROTECTION OF THE LIMBS.
The EOS4 is also available in a Multibeam version with a distance between the mirrors of:
500mm (2 beams), 400mm (3 beams), 300mm (4 beams).
PROTECTION OF THE BODY.
P = Pitch between two lenses D = Diameter of a lens R = Resolution = P+D
P
R
D
Receiver
Emitter
Beam
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INSTALLATION
Before installing the EOS4 safety system, check all the conditions listed below:
The level of protection of EOS4 (Type 4, SIL3, SILCL3 PLe) must be compatible with
the level of danger of the system to be protected.
The safety system is used only as a stopping device and not to control the machine. The machine movement is actuated electrically. All dangerous movements of the machine can be interrupted immediately. In
particular, the machine stopping times must be known and, if necessary, measured.
The machine must not generate hazards due to projection or falling of materials from
above; otherwise, additional mechanical guarding must be provided.
The smallest size object to be detected must be greater than or equal to the
resolution of the selected model.
Knowing the shape and dimensions of the dangerous area, it is possible to calculate the width and height of the related access area :
Compare these dimensions with the maximum working range and the height of the
protected area of the model used.
Before positioning the safety device, comply with the following general indications:
Check that the temperature of the environment in which the system is installed is
compatible with the operating temperature parameters indicated on the product label and in the technical data.
Do not position the Emitter and the Receiver close to very bright or flashing sources
of light.
Particular operating conditions may affect the sensing level of photo-electric devices.
In environments characterised by fog, rain, fumes or dust, to always guarantee correct operation of the appliance, it is advisable to apply suitable correction factors Cf so as to maximum working range values. In these cases:
where Pu and Pm are, respectively, the working and maximum range expressed in metres.
The recommended correction factors CF are indicated in the table below.
Fog
0.25
Vapours
0.50
Dust
0.50
Dense fumes
0.25
Table 1 – CF correction factors
If the device is installed in environments characterised by sudden changes in
temperature, suitable precautions must be taken to prevent the formation of condensation on the mirrors, which could impair detection capability.
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Positioning
The Emitter EOS4E and the Receiver EOS4R must be positioned so that it is impossible to access the dangerous area from above, from below and from the sides without intercepting one of the beams. Useful indications for correct positioning of the light curtain are provided in the figure below.
Incorrect positioning of the light curtain
Correct positioning of the light curtain
Figure 2 - Positioning
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Master/Slave Positioning
In addition to standard models (that can be positioned either horizontally or vertically), EOS4 can be purchased in a MASTER/SLAVE configuration. This configuration comprises two (or three) pairs of light curtains in which the two (or three) Emitters and the two (or three) Receivers are connected in series.
Figure 3 – Examples of Master/Slave configurations
The connection cable between the master and slave may be up to 50 metres in length. This characteristic permits configuration of an application with two light curtains positioned one at the front and one at the rear of the dangerous machine, with a single connection towards the machine power and control circuits (Figure 4).
Figure 4 - Example of Master/Slave application with mechanical guards
MASTER
MASTER
SLAVE
SLAVE2
SLAVE
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Calculation of safety distance
The light curtain must be positioned at a distance equal to or greater than the minimum safety distance so that the dangerous point can be reached only after stopping the dangerous movement of the machine (Figure 5).
According to the EN13855:2010 European standards, the minimum safety distance must be calculated using the following formula :
where:
Minimum safety distance
mm
Operator approach speed to the dangerous area
mm/sec
Total response time of the light curtain, in seconds
sec
Response time of the machine in seconds, i.e. the time taken by
the machine to stop the dangerous movement from the moment
in which the stop signal is transmitted
sec
Additional distance that varies according to the application
1
mm
Resolution
mm
Table 2 – Safety distance
Failure to comply with the safety distance reduces or impairs the protection function
of the light curtain.
If positioning of the light curtain does not prevent the operator from accessing the
dangerous zone without being detected, additional mechanical guards must be installed.
Figure 5 – Safety distance S
For further information on additional safety distance, refer to EN13855:2010.
DANGEROUS ZONE
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Multiple systems
When several EOS4 are used, precautions must be taken to prevent optical interference between these: position the elements so that the beam of the Emitter of one system is received only by its respective Receiver.
Figure 6 provides examples of correct positioning of two photo-electric systems. Incorrect positioning may cause interference, with possible malfunction of the system.
Figure 6 – Multiple systems
This precaution is not necessary in the case of MASTER/SLAVE systems.
Adjacent positioning of the two emitters
Crossed positioning between emitters and receivers
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Use of deflecting mirrors
For protection or control of areas accessible from several sides, one or more deflecting mirrors can be used in addition to the Emitter and Receiver.
Deflecting mirrors make it possible to redirect the beams generated by the Emitter on several sides.
Wishing to deflect the beams generated by the Emitter by 90°, the perpendicular to the surface of the mirrors must form an angle of 45° with the direction of the beams.
An application in which two deflecting mirrors have been used for "U" shaped protection is illustrated in the figure below.
Figure 7 – Deflecting mirrors
When using deflecting mirrors, comply with the following rules:
Position the mirrors so as to comply with the minimum safety distance
(Figure 7) on each side of access to the dangerous area.
The working distance (working range) is given by the sum of the lengths of all the
access sides to the protected area. (Note that the maximum working range between the Emitter and Receiver is reduced by 15% for each mirror used).
In the installation phase, take care to avoid twisting along the longitudinal axis of
the mirror.
Standing close to and in axis the Receiver, check that the of the
Emitter is visible on the first mirror.
It is advisable not to use more than three deflecting mirrors.
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Distance from reflective surfaces
The presence of reflective surfaces close to the light curtain may cause occasional
reflections that prevent sensing. Referring to Figure 8, object is not detected due to surface that, reflecting the beam, closes the optical path between the Emitter and Receiver. Therefore, a minimum distance d must be maintained between any reflecting surfaces and the guarded area. The minimum distance must be calculated according to the distance between the Emitter and Receiver and taking into account that the angle of projection and reception is 4°.
Figure 8 - Reflective surfaces
The distance to be kept as the distance between Emitter and Receiver varies is shown in Picture 9.
Figure 9 - Minimum distance d
After installing the system, check for any reflective surface that intercept the beams, first of all at the centre and then close to the Emitter and Receiver. During this procedure, the red led on the Receiver must never switch off.
d
l
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