ipf electronic OY32 Series User guide

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Original Instruction Manual Safety Light Curtain OY32
Devices for finger- and handprotection
Safety Category Type 4
simple installation and configuration
Diagnostics inside
compact profile (32,3x36,9xlength)
Short response time
self testing
Connection with M12-Connector

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INDEX
1. GENERAL INFORMATION......................................................................................1
1.1. General Description of the safety light curtains ........................................................3
1.1.1. Package contents.....................................................................................................4
1.2. How to choose the device ........................................................................................5
1.2.1. Resolution................................................................................................................5
1.2.2. Controlled height......................................................................................................6
1.2.3. Minimum installation distance...................................................................................7
1.3. Typical applications..................................................................................................9
1.4. Serial Number ........................................................................................................11
1.5. Safety information ..................................................................................................11
2. INSTALLATION MODE............................................................................................9
2.1. Precautions to be observed for the choice and installation.......................................9
2.2. General information on device positioning..............................................................10
2.2.1. Minimum installation distance.................................................................................10
2.2.2. Minimum distance form reflecting surfaces ............................................................11
2.2.3. Distance between homologous devices..................................................................13
2.2.4. Emitter and receiver orientation..............................................................................19
2.2.5. Use of deviation mirrors .........................................................................................19
2.2.6. Controls after first installation.................................................................................21
3. MECHANICAL MOUNTING...................................................................................24
4. ELECTRICAL CONNECTIONS..............................................................................24
4.1. Notes on connections.............................................................................................25
4.2. Ground connection.................................................................................................27
5. ALIGNMENT PROCEDURE...................................................................................28
5.1. Correct alignment procedure..................................................................................29
6. FUNCTIONING MODE...........................................................................................31
6.1. Restart mode..........................................................................................................31
6.2. Test function...........................................................................................................32
6.3. Reset function........................................................................................................32
6.4. EDM-Function ........................................................................................................33
6.5. Alignment and function...........................................................................................34
7. DIAGNOSTIC FUNCTIONS ...................................................................................35
7.1. User interface.........................................................................................................35
7.2. Diagnostic messages.............................................................................................36
8. PERIODICAL CHECKS .........................................................................................39
8.1. General information and usefull data......................................................................39
8.2. Warranty ................................................................................................................40
9. DEVICE MAINTENANCE.......................................................................................41
9.1. Product disposal.....................................................................................................41
10. TECHNICAL DATA................................................................................................42
11. LIST OF AVAILABLE MODELS ............................................................................43
12. OVERALL DIMENSIONS.......................................................................................45
13. OUTFIT..................................................................................................................46
13.1. Angled fixing bracket mounting ..............................................................................47
13.2. Test pieces.............................................................................................................47
14. ACCESSOIRES .....................................................................................................48
15. GLOSSARY...........................................................................................................54
16. EC-DECLARATION OF CONFORMITY.................................................................57

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1. GENERAL INFORMATION
1.1. General Description of the safety light curtains
The safety light curtains of the OY32 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 OY32 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 prescrip-
tions and tests.
CEI IEC 61496-2: 2006 Safety of machinery: electrosensitive protective equipment -
Particular requirements for equipment using active optoelec-
tronic protective devices.
The device, consisting of one emitter and one receiver housed inside strong aluminium pro-
files, generates infrared beams that detect any opaque object positioned within the light cur-
tain 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 elec-
trical 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”).
During installation, two yellow LEDs facilitate the alignment of both units (see section 5
“Alignment procedures”).
As soon as an object, a limb or the operator’s body accidentally interrupts the beams sent by
the emitter, the receiver immediately opens the OSSD output and blocks the machine (if cor-
rectly connected to the OSSD).
Note: The following abbreviations, defined by the Standards in force, will be used in
this manual:
AOPD Active opto-electronic protective device
ESPE Electro-sensible protective equipment
OSSD Output signal switching device
TX Emitter
RX Receiver
EDM External Devices Monitoring

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Some parts or sections of this manual containing important information for the user or in-
stalling 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 regard 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 information necessary for the selection and operation of the safety
devices.
However, special knowledge not included in this technical description is required fort he
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 cus-
tomer to contact the technical service of ipf electronic for any necessary information rela-
tive to the functioning of the OY32 light curtains and the safety rules that regulate the cor-
rect installation.
1.1.1. Package contents
Package contains the following objects:
Receiver (RX)
Emitter (TX)
Installation Quick Guide of OY32 curtain
CD with instruction manual and other documents
4 angled fixing brackets and specific fasteners
6 angled fixing brackets for models with heights included between 1200 and 1800 mm

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1.2. 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:
1.2.1. 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 = 14 mm
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 betweentwo adjacent optics
d = Lense Diameter
Opaque
Object

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1.2.2. Controlled height
The controlled height is the height protected by the safety light curtain (Hp).
Fig.2
The OY32 controlled height is delimited by the yellow line padprinted on the front glass
and by the dimensions listed in the table:
MODEL
Controlled height
Hp (mm)
OY320100 / OY320130
150
OY320101 / OY320131
300
OY320102 / OY320132
450
OY320103 / OY320133
600
OY320104 / OY320134
750
OY320105 / OY320135
900
OY320106 / OY320136
1050
OY320107 / OY320137
1200
OY320108 / OY320138
1350
OY320109 / OY320139
1500
OY32010A / OY32013A
1650
OY32010C / OY32013C
1800
OY35010x = Resolution 30mm
OY35013x = Resolution 14mm
Hp
Reference

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1.2.3. 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 ESPE.
The safety distance depends on 4 factors, according to the EN-999 Standard:
Response time of the ESPE (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
ESPE and the real stop of the dangerous motion of the machine).
ESPE 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 (t1+ t2) + C
where:
S = Minimum safety distance in mm
K = Speed of the object, limb or body approaching the dangerous area in mm/s
t1= Response time of the ESPE in secondes (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 devise trips.
C = 8 (d -14) for devices with resolution 40 mm
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).

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If the safety light curtain must be mounted in a horizontal position (Fig.4), the distance be-
tween the dangerous area and the most distant optical beam must be equal to the value
calculated using the following formula:
S = 1600 mm/s (t1+ t2) + 1200 –0.4 H
where:
S = Minimum safety distance in mm
t1= Response time of the ESPE in secondes (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
Practical Examples
Let's suppose to have a light curtain with height = 600 mm.
To calculate the distance of the device from the ESPE, in a vertical position, the following
formula is used:
S = K*T + C
where:
T = t1+ t2
t1= ESPE response time + safety relay release time (max 80 ms)
t2= Machine total stopping time
d = Resolution
C = 8 * (d –14) for devices with resolution <= 40 mm
In all cases, if K = 2000mm/sec then S > 500 mm. Distance will have then to be recalculat-
ed using K = 1600 mm/sec.
OY320133
OY320103
t
0.393s
0.394s
C
0 mm
128 mm
S
641.6 mm
758.4 mm
WARNING: The reference standard is EN 999 „Machine safety - the positioning of the pro-
tective 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

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1.3. Typical applications
The safety light curtains of the OY32-series provide soulutions in all atomation 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.
Example 1: Operating point protection on drilling machines
The operator positions the part and takes it back after machin-
ing.
The operator must be protected against possible abrasions
while working
Solution: OY32013x safety light curtain is especially suitable for
this kind of application, which requires the installation of the de-
vice 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: Bending presses
The safety device must protect the operator from being squashed be-
tween the top and botttom parts or the machined part during the fast ap-
proach phase.
Solution: If only one beam of the OY32013x safety light curtain is in-
terupted while the press is moving down, the mobile tool bar will Stopp.
Benefits: The safety light curtain can be used in most bending operations
thanks to ist easy installation and compact dimensions. As well as offer-
ing excellent reliability, OY32013x ensures increased plant productivity as
it reduces the dead times necessary for machine accessing adjustment
and maintenance.

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Example 3: Paper cutting machines
These machines typically cut paper to a specific size for newspa-
pers or spezial applications. The operator must be protected
against abrasion or cuts by cutter blades.
Solution: OY32010x safety light curtain is especially suitable for
this kind of application, which requires the installation of the de-
vice directly on the machine.
Benefits: Highly reduced profile and the two side slots ensure in-
stallation flexibility for machine dimensions.
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 4: 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: OY32010x series safety light curtain is the best
solution considering the required safety levels and applica-
tion type. When even just one of the light curtain beams is
interrupted, the machine is immediately stopped.
Benefits: The extremely reduced profile guarantees instal-
lation flexibility adapting itself to the machine dimensions.
The rotating fixing brackets, supplied as accessories, speed up and facilitate mounting.

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1.4. Serial Number
The serial number is printed on the backside of the device.
Make sure that the assigned pair (transmitter –receiver) is provided with the same serial
number
The serial number consists of 9 positions:
S Y Y M# # # # #
1.5. Safety Information
The following points must be observed for a correct and safe use of the OY32 safety de-
vice:
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 sec-
tion 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 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
Manufacturing Pole:
B = Italy
H = Hungaria
- - -
Manufacturing Year:
10 = 2010
11 = 2011
12 = 2012
- - -
5 digit progressive
serial number for
manufaturing pole,
to be reset at every
month beginning
Manufacturing Month
A = January
B = February
C = March
D = April
E = May
F = June
G = July
H = August
I = September
L = October
M = November
N = December

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2. INSTALLATION MODE
2.1. Precautions to be observed for the choice and installation
Make sure that the protection level assured by the OY32 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 ESPE 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 ESPE must be installed in a room complying with the technical characteristics in-
dicated in section 10 “Technical Data”.
Do not install device near strong and/or flashing light sources or close to similar devic-
es.
The presence of intense electromagnetic disturbances could jeopardise device func-
tioning. This condition shall be carefully assessed by seeking the advice of ipf electron-
ic Technical service.
The operating distance of the device can be reduced in presence of smog, fog or air-
borne dust.
A sudden change in environment temperature, with very low minimum peaks, can gen-
erate a small condensation layer on the lenses and so jeopardise functioning.

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2.2. General information on device positioning
The safety light curtain should be carefully positioned, in order to reach a very high protec-
tion 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 bot-
tom 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 opera-
tors are inside the dangerous area.
NO
YES

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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.
Abb. 6a
Abb. 6b
2.2.1. Minimum installation distance
Refer to paragraph1.3.3. “Minimum installation distance”
NO
YES

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2.2.2. Minimum distance from reflecting surfaces
Reflecting surfaces placed near the light beams of the safety device (over, under or lateral-
ly) 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 sur-
face) the object might not be detected, even if the object interrupts the main beam.
Fig. 7
It is thus important to position the safety light curtain according to the minimum distance
from reflecting surfaces.
The minimum distance depends on:
operating distance between emitter (TX) and receiver (RX);
real aperture angle of ESPE (EAA); especially:
for ESPE type 4 EAA = 5° (α = ± 2,5°)
Diagram of Fig. 8 shows the minimum distance from the reflecting surface (Dsr), based on
the operating distance:

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Fig.8
The formula to get Dsr is the following
Dsr (m) = 0,15 for operating distances < 3m
Dsr (m) = 0,5 x operating distance (m) x tan 2αfor operating distances 3m

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2.2.3. Distance between homologous devices
If different safety devices have to be installed in adjacent areas, the emitter of one device
must not interfere dangerously with the receiver of the other device.
The TXBinterfering device must be positioned outside a minimum Ddo distance from the
TXA–RXAemitter-receiver couple axis.
Fig. 9
This minimum Ddo distance depends on:
the operating distance between emitter (TXA) and receiver (RXA)
the effective aperture angle of the ESPE (EAA)
The following graphic shows the distance from the interfering devices (Ddo) according to the
operating distance (Dop) of the couple ( TXA–RXA).
Abb. 10
The following table shows, for convenience, the values of the minimum installation distanc-
es relative to some operating distances:
Operating distance
(m)
Minimum installation
distance (m)
3
0,30
6
0,50
10
0,65
19
0,80

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WARNING: the interfering device (TXB) must be positioned at the same Ddo distance,
calculated as shown above, even if closer to TXArespect to RXA.
Installation precautions have to be taken to avoid interference between homologous devic-
es. A typical situation is represented by the installation areas of several adjacent safety de-
vices aligned one next to the other, for example in plants with different machines.
Fig. 11 provides two examples:
Fig. 11
TX
YES
NO
YES
RX
TX

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2.2.4. Emitter and receiver orientation
The two units shall be assembled parallel each other, with the beams arranged at right an-
gles with the emission and receiving surface, and with the connectors orientated towards
the same direction.
The configurations shown in Fig.12 must be avoided:
Fig. 12
2.2.5. Use of deviating mirrors
The control of any dangerous area, with several but adjacent access sides, is possible us-
ing only one safety device and well-positioned deviating mirrors.
Fig.13 shows a possible solution to control three different access sides, using two mirrors
placed at 45° respect to the beams.
Fig. 13
NO NO

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The operator must respect the following precautions when using the deviating mirrors:
The alignment of the emitter and the receiver can be a very critical operation when deviating
mirrors are used. Even very small displacement of the mirror is enough to lose alignment.
The use of laser pointer accessory is recommended under these conditions.
The minimum safety distance (S) must be respected for each single section of the beams.
The effective operating range decreases by about 15% by using only one deviating mirror,
the percentage further decreases by using 2 or more mirrors (for more details refer to the
technical specifications of the mirrors used).
The following table shows the operating distances relating to the number of mirrors used:
Number of
mirrors
Operating Distance
(14 mm)
Operating Distance
(30 mm)
1
5,1 m
16,5 m
2
4,3 m
13,7 m
3
3,7 m
11,6 m
Do not use more than three mirrors for each device.
The presence of dust or dirt on the reflecting surface of the mirror causes a drastic reduc-
tion in the range.