Omron F3SP-U1P-TGR User manual

F3SP-U1P-TGR User's manual
page 1 of 30
Cat. No. E507-E2-01
F3SP-U1P-TGR
Safety control unit,
for use with 1 to 4 safety photoelectric switches
USER'S MANUAL

F3SP-U1P-TGR User's manual
page 2 of 30
The equipment conforms with the EC requirements in compliance with the
following standards:
-Low Voltage Directive 73/23/EEC
-EMC Directive 89/336/EEC
-Machinery Directive 98/37/EC
-IEC 61496-1: 1997
-DIN V VDE 0801: 1990 and
-amendment A1: 1994
-EN 50081-2: 1993
-EN 55022: 1994
-DIN EN 60204-1: 1993
-EN 50178: 1997
Manufacturer: TECHNO-GR s.r.l.
via Torino, 13/15
10046 Poirino (TO) - ITALY
Tel. [phone]
FAX [phone]
USER’S MANUAL: Version 1.0 issued on 01/05/2001

F3SP-U1P-TGR User's manual
page 3 of 30
INDEX
1 BEFORE USING THE DEVICE.......................................................4
1-1 GENERAL INSTRUCTIONS..........................................................................4
1-2 ROUTINE MAINTENANCE............................................................................4
1-3 PRECAUTION OF SAFETY. .........................................................................4
2 GENERAL INFORMATION. ............................................................5
3 OPERATION....................................................................................7
4 PRECAUTIONS AND INSTALLATION CRITERIA.........................8
4-1 CALCULATION OF THE MINIMUM SAFETY DISTANCE. ............................8
4.2 REFLECTIVE SURFACES............................................................................9
5 CONNECTIONS.............................................................................10
5.1 TERMINAL BLOCK ASSIGNMENT.............................................................10
5.2 WIRING EXAMPLE. ....................................................................................11
6 ALIGNMENT PROCEDURE..........................................................14
7 OPERATING PROCEDURES. ......................................................15
7.1 DIP-SWITCHES CONFIGURATION............................................................15
7.2 CONFIGURATION FOR UNUSED PES. .....................................................15
7.3 MUTING FUNCTION. ..................................................................................16
7.3.1 DESCRIPTION. ............................................................................................16
7.3.2 INSTALLATION CRITERIA.........................................................................16
7.4 OVERRIDE..................................................................................................22
7.5 STARTING THE OVERRIDE FUNCTION....................................................22
7.6 MUTING RESTRICTIONS (MUTING FUNCTION).............................................22
7.7 LED INDICATOR.........................................................................................23
8 FINAL CHECKS.............................................................................24
9 ROUTINE MAINTENANCE OPERATIONS...................................24
10 GENERAL INFORMATION AND USEFUL DATA. .......................25
11 TECHNICAL DATA........................................................................26
12 DISPLAY OF STATE CODES.......................................................27
12.1 STATE IN NORMAL OPERATION...............................................................27
12.2 STATE IN FAILURE (FOR TROUBLE SHOOTING).............................................27
13 OVERALL DIMENSIONS..............................................................29

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1 BEFORE USING THE DEVICE.
1-1 GENERAL INSTRUCTIONS.
Read this manual and the manual of safety PES (safety photoelectric
switch) completely. Be sure the information provided is understood before
attempting to operate the safety PES .
Keep the manual in a secure and convenient location and refer to it as
necessary.
To guarantee correct installation, carefully follow the instructions of this
manual.
z Do not touch non-insulated cables, if they have been energised.
z Make sure that the cables connected to the control unit are not taut
and that they do not hinder the movement of persons or objects.
z Before carrying out any outer operation, turn off the power.
Failure to do so may result in loss of life or serious injury.
1-2 ROUTINE MAINTENANCE.
Be sure to conduct inspection regularly.
Please refer to sec. 9 and the safety PES instruction manual.
OMRON Europe and Techno GR refuse to accept any responsibility for
damage to persons or objects due to the incorrect use / installation of the
control unit and safety PES.
1-3 PRECAUTION OF SAFETY.
The following symbols are used for highlighting items in order to ensure
safe and proper use of the F3SP-U1P-TGR. Items highlighted are critical
for safe operation and must be heeded at all times.
WARNING
NOTICE

F3SP-U1P-TGR User's manual
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2 GENERAL INFORMATION.
WARNING
• The safety control unit of the F3SP-U1P-TGR has been designed to
be used with the dedicated safety PES (Please refer to sec.11).
It must not be connected to other safety PESs.
The control unit complies with the requirements for type 4 safety equipment
in accordance with the latest international standards, IEC 61496-1.
However, the safety system category depends on the safety PES’s type as
follows.
Type 4 safety PES : Safety system category 4
Type 2 safety PES : Safety system category 2
Only type 2 safety PES is available as of 01.04.2001.
• A qualified person, as determined by local regulations, must confirm that
installation, inspection, and maintenance are implemented correctly.
• Do not disassemble, repair, and modify the control unit and safety PES.
The control unit does not contain parts subject to maintenance.
• The presence of a limb or an object interrupting one of the safety PESs
will open the safety outputs and consequently stop the connected
machine. It is necessary to install the safety PESs in such a way that
bypassing of any person is not possible.
• Do not use the control unit and safety PES on machines that cannot be
stopped by electrical control in case of an emergency.
• Do not use the control unit and safety PES in environments exposed to
flammable or explosive gases.
• Do not use the control unit and safety PES in a retro-reflective
configuration. Otherwise detection may fail.
NOTICE
• Do not install the control unit and safety PES in the following environments;
- Areas exposed to intense interference light such as direct sunlight.
- Areas with high-humidity where condensation is likely to occur.
- Areas exposed to corrosive gases.
- Areas exposed to vibration or shock levels higher than specification
provisions.
• Do not use the cellular phones or transceivers near the control unit and
safety PES.
• The control unit and safety PES must not be used in water.

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The DIN/OMEGA mounted control unit is protected to IP20 by a plastic
housing. It has 32 screw terminals to which it is possible to connect from 1 to
4 pairs of safety PESs.
This control unit has the double ‘muting’ function. This function makes it
possible to inactivate one or more safety PESs in order to allow, for instance,
the objects passage without stopping the machine.
The ‘override’ function represents the possibility to force the system. The
‘override’ function allows closing the output contacts manually so that stuck
material can be cleared from the muting area after the cause of an error is
removed.
Both the muting and the override functions force the system to work.
Therefore, activating these functions needs some precautions to avoid the
reduction in safety (see sec. 7.2).
The control unit has been designed to the following standards:
IEC 61496-1: 1997. Safety of machinery: electro-sensitive
protective equipment
- General requirements and test.
FDIS IEC 61496-2: 1997. Safety of machinery: electro-sensitive
protective equipment
- Particular requirements for system using
active opto-electronic devices.

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3 OPERATION.
The control unit has two independent microprocessors forming a system
with “two independent channels” as required in the standards.
When one or more safety PESs are interrupted, the control unit opens both
safety output contacts and indicates which safety PES has been
interrupted by four green LEDs locating on the front panel.
A 7-segment display supplies information on normal states and on
probable failures.
The control-unit can work in two different modes (see sec. 7) as follows:
1. Automatic mode:
The control unit automatically starts after power-ON and automatically
restarts after the object in the detection zone is removed.
2. Interlock mode:
Returns to the normal operating mode only after the object has been
removed and the RESET button has been pressed.
The control unit needs following two buttons.
• TEST : This is used to check if the whole system works effectively. By
pressing the TEST button (opening of the contact), this simulates the
interruption of one or more safety PESs. This operation makes the
machine stop, so the system checks can be made according to the
established time and modes.
• RESET : It is used to reset the interlock (see above “2. Interlock mode).
It is also used to restart after the cause of an error is removed (see sec.
12).
In addition, the control unit can be set for the muting function. This function
can be selected by setting of dip-switches inside the control unit.
NOTICE
While the control unit is connected to power, do not change any dip switch to
avoid influence on the system safety.

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4 PRECAUTIONS AND INSTALLATION CRITERIA.
The safety products used must be suitable for the required application, and
other influences must be also taken into account such as room
temperature, electromagnetic interference, intense light sources etc.
4-1 CALCULATION OF THE MINIMUM SAFETY DISTANCE.
The safety distance ‘S’ must be sufficient to guarantee that an operator
cannot reach the hazardous area by the moment when the dangerous
movement stops. Regarding the calculation of safety distance, please
read the related standards, e.g. EN 999 (European Standard. Safety of
machinery – The positioning of protective equipment in respect of
approach speeds of parts of the human body)
Using EN 999 Formula
Safety distance is calculated based on the following equation;
S = ( K * T ) + C
S = safety distance.
T = T1 + T2 + T3
whereas T1 = machine response time in seconds.
T2 = safety PES response time in seconds.
T3 = control unit response time in seconds.
K = speed of the body approaching the dangerous area
C = additional distance based on intrusion towards the hazardous area prior to
actuation of the protective equipment.
1) Multiple separate beams
K = 1600 mm/s
C = 850 mm
The following heights are recommended in EN999;
4 Beams 3 Beams 2 Beams
Height of 1st ray 300 mm 300 mm 400 mm
Height of 2nd ray 600 mm 700 mm 900 mm
Height of 3rd ray 900 mm 1100 mm --
Height of 4th ray 1200 mm -- --

F3SP-U1P-TGR User's manual
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2) Single height beam
Where the risk assessment allows the use of a single beam, the following values
can be used
K = 1600 mm/s
C = 1200 mm
The height of the beam from the ground or reference plane: 750mm
(Recommended in EN 999)
WARNING
Always maintain the safety distance between the safety PES and a
hazardous part of a machine.
4.2 REFLECTIVE SURFACES.
In case that reflective surface exists, the distance must be sufficient to avoid
the possibility of passive reflections.
Distance between emitter and
receiver (detection distance L) Minimum installation distance D
0.3 to 3 m 0.27 m
3 m or more L x tan 5° = L x 0.087 (m)
WARNING
Do not install the safety PES in a location affected by shiny surface
reflections.
Emitter Receiver
L
D
5°
<Top View>
Reflecting surface
5°

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5 CONNECTIONS.
5.1 TERMINAL BLOCK ASSIGNMENT.
TERMINAL OUTER CONNECTION
1 - 2 Connect to the 24 Vdc power supply, note the polarity indicated on the label.
3 - 4 RESET button; Connect to a normally opened contact. (N.O.).
4 - 5 TEST button; Connect to a normally closed contact. (N.C.).
6 - 7 Connect to the muting lamp.
8 Input of the muting B sensor;
Connect to the N.O. contact of the muting sensor (PES, proximity switch, etc.).
9 Input of the muting A sensor;
Connect to the N.O. contact of the muting sensor (PES, proximity switch, etc.).
10 Input of the muting D sensor;
Connect to the N.O. contact of the muting sensor (PES, proximity switch, etc.).
11 Input of the muting C sensor;
Connect to the N.O. contact of the muting sensor (PES, proximity switch, etc.).
12 This terminal not used.
13 - 14 (OUT1) safety output 1 with N.O. contact.
15 - 16 (OUT2) safety output 2 with N.O. contact.
17 - 18 Power supply to emitters (TX) of safety PES 1 and 2; Connect Vs wires (pin 1 of
connector) to terminal 17, and 0V wires (pin 3 of connector) to terminal 18.
19 - 20 Sending test signal to emitters (TX) of the safety PES 1 and 2; Connect Test wire (pin 4 of
connector) of PES 1 to terminal 19, and that of PES 2 to terminal 20.
21 - 22 Power supply to emitters (TX), of safety PES 3 and 4; Connect Vs wires (pin 1 of
connector) to terminal 21, and 0V wires (pin 3 of connector) to terminal 22.
23 - 24 Sending test signal to emitters (TX) of the safety PES 3 and 4; Connect Test wire (pin 4 of
connector) of PES 3 to terminal 23, and that of PES 4 to terminal 24.
25 - 26 Power supplyto receivers (RX), of safety PES 1 and 2; Connect Vs wires (pin 1 of
connector) to terminal 25, and 0V wires (pin 3 of connector) to terminal 26.
27 - 28 Receiving PNP output from the receivers (RX) of safety PES 1 and 2: Connect PNP out
wire (pin 4 of connector) of PES 1 to terminal 27, and that of PES 2 to terminal 28.
29 - 30 Power supplyto receivers (RX), of safety PES 3 and 4; Connect Vs wires (pin 1 of
connector) to terminal 29, and 0V wires (pin 3 of connector) to terminal 30.
31 - 32 Receiving PNP output from the receivers (RX) of safety PES 3 and 4: Connect PNP out
wire (pin 4 of connector) of PES 3 to terminal 31, and that of PES 4 to terminal 32.

F3SP-U1P-TGR User's manual
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5.2 WIRING EXAMPLE.
Connection of four E3FS-10, safety PESs, to the control unit F3SP-U1P-TGR.
+
+
-
-
GND
N.C.
MUTING
SENSOR MUTING SENSOR
REST
LAMP
MUTING
+24 Vdc GND
TEST MUTING
LAMP
BADC
OUT2OUT1
+24 VDC
MUTING SENSORS
-
+
-
+
GND
+24 VDC
OUT
GND
Vcc OUT
GND
Vcc
OUT
GND
Vcc
OUT
GND
Vcc
TEST SWITCH
RESET SWITCH
OUTPUT 1
SAFETY
OUTPUT 2
SAFETY
E3FS(1)
Emitter(1)
Brown
Pink/Black
Blue
Brown
Pink/Black
Blue
Brown
Pink/Black
Blue
Brown
Pink/Black
Blue
E3FS(2)
Emitter(2)
E3FS(3)
Emitter(3)
E3FS(4)
Emitter(4)
Receiver(1)
Receiver(2)
Receiver(3)
Receiver(4)
Blue
Pink/White
Black
Brown
Blue
Pink/White
Black
Brown
Blue
Pink/White
Black
Brown
Blue
Pink/White
Black
Brown
TX1 TX2 TX3 TX4
TX1/TX2 TEST TEST TEST PNP PNP
OUT RX3 OUT RX4
TX3/TX4 RX1/RX2
TEST
OUT RX1 OUT RX2
PNP RX3/RX4 PNP
RESET TEST

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WARNING
• It is necessary to protect the control unit with an outer fuse having a
nominal interruption current equal to 1 A.
• DC power supply units must satisfy all the conditions below so that the
control unit can comply with the applicable standards.
- The power supply voltage must be within rating (24 VDC ± 10 %).
- The power supply uses double or reinforced insulation between the primary
and secondary circuits to fulfil EN60742 or equivalent standard requirements.
- The power supply has automatic reset characteristics (voltage drop) to protect
against over current.
- The power supply maintains an output holding time of at least 20ms.
- FG (frame ground terminal) must be connected to PE when using a
commercially available switching regulator.
- The power supply must have output characteristics required for the power
source for Class 2 Circuit of limited Voltage/Current Circuit as defined in
UL508.
- The power supply must conform to regulatory requirement and standards,
regarding EMC and electrical equipment safety, of the country where the
control unit is installed and where machinery will be operated, for
example: The EMC Directive(industrial environment) and the Low Voltage
Directive in EU.
• Do not short the output lines to the Vs line. Doing so will cause the
output to be always ON, creating a dangerous situation.
• Do not connect the control unit to an AC or DC power supply with
higher voltage than nominal 24 VDC.
• The TEST and RESET buttons must be positioned in such a way
- that the operator can see the protected area when he carries out
reset, test, or override operations.
- that it can not be activated from inside the hazardous area.

F3SP-U1P-TGR User's manual
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NOTICE
• The control unit can be combined with up to four pairs of safety PES,
but at least one pair of Safety PES must be connected.
If less than four pairs of safety PES are used, the unused “TEST TXn”
terminal for an emitter must be connected to the “PNP OUT RXn”
terminal of the corresponding receiver (see sec. 12.2).
• Make sure to connect the muting lamp, otherwise the control unit is
locked.
• Read the paragraph relating to the
muting function and its use for the
positioning of the activation sensors of this function.
• Both safety contacts OUT1 and OUT2 must be connected. If the
machine has a single locking circuit, the two normally opened contacts
must be connected in series.
• The connection cables of the safety PESs must be at least AWG24.
The connection cables of
muting request, test button and reset button
must be at least AWG22. When shielding cable is used, all shield
braids must be earthed on the control unit side.
• Be sure to isolate the power prior to wiring.
• Be sure to route the control unit and safety PESs cable separately
from high-potential power lines or through an exclusive conduit.
• Make sure the conductor path in the connector is rated IP54 or higher.
• A load must be basic insulated to prevent the load from being applied
to hazardous voltage (e.g. 230 VAC) when the load is a relay.

F3SP-U1P-TGR User's manual
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6 ALIGNMENT PROCEDURE.
After having carried out the correct mechanical assembly and the correct
connections as described in the previous paragraphs, it is necessary to
align the safety PESs. Follow the operating guide as follows:
• Turn off the power supplying the control unit.
• Open the test button contact.
• Power the control unit.
• Align the safety PESs by observing the LEDs on the control unit: If
the alignment of the relevant pair of safety PES is correct, the LED
is turned on.
• After the alignment, turn off the power supplying the control unit,
close the test contact and power the control unit again.
• Wait for the control unit to carry out the initial tests, showing on the
display a count-down which indicates the control unit activity.
• At the end of this operation, the display will show letter ‘A’ indicating
the active state of the control unit.
• Carry out all the checks described in the final checks and in the
routine maintenance operations.
NOTICE
The control unit can detect the mutual interference between safety PESs. The
control unit forces the output contacts to open, when it detects external
disturbance light including mutual interference light.
The safety PESs should be installed the following way to avoid mutual
interference.
- The safety PESs are installed with sufficient interval.
- Emitters and receivers of safety PESs are installed alternately
(see below drawing).
During aligning operations or normal working, check that the safety PESs
connected to the same or other control units do not interfere with each other.
Emitter Receiver
Emitter
Emitter
Emitter
Receiver
Receiver
Receiver

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7 OPERATING PROCEDURES.
7.1 DIP-SWITCHES CONFIGURATION.
The configuration shown in the below table must be selected from the both
dip-switches on the internal board. To configure dip-switch, remove the round
plastic cover on the lateral surface of F3SP-U1P–TGR with a screwdriver.
Pole 1 function
X not used
Pole 2 function
Off muting A-B act on the safety PES 1 and 2.
muting C-D act on the safety PES 3 and 4.
On muting A-B act on the safety PES 1.
muting C-D act on the safety PES 2.
The safety PES couples 3 and 4 continue to
function normally.
Pole 3 function Pole 4 function
Off muting 60 s Off interlock mode
On muting ∞s On automatic mode
Factory default set
Pole 2 : Off (All of four PESs in
muting )
Pole 3 : Off (the maximum duration of the
muting is of 60 seconds)
Pole 4 : On (Automatic mode)
7.2 CONFIGURATION FOR UNUSED PES.
If you use safety PESs less than four sets, terminals which are not connected
to safety PESs must be connected directly as follows;
unused safety
PES connection
1 19 and 27
2 20 and 28
3 23 and 31
4 24 and 32
At least one pair of safety PES must be used, otherwise the control unit is
locked.
NOTE: Configure the two dip-
switch in the same way,otherwise
code '8' is displayed, which
means a failure.
1
2
3
4
ON
1
2
3
4
ON
SW2SW1

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7.3 MUTING FUNCTION.
7.3.1 DESCRIPTION.
The muting function makes it possible to inactivate one or more safety PESs in
order to allow, for instance, the objects passage without stopping the machine.
As required by the standard, the control unit has two inputs for the activation of
this function. Two separate muting functions are present.
It is necessary to position and connect the muting sensors in order to avoid
undesired muting inputs. It is important to remember that the muting function
forces the system to work and for this reason, it must be used with much care.
7.3.2 INSTALLATION CRITERIA.
1 The muting sensors must recognise the material (namely pallets,
vehicles, etc.) over its full length.
2 The muting sensors must be arranged in such a way that the
material is recognised even when it is not on a pallet but on other
transporting medium like a lift.
3 In case of different transport speeds through the muting area,
consideration must be given on the muting duration.
4 All the safety PESs and the muting sensors must be arranged in
such a way that the previous material has already passed the last
muting sensor before the new material has reached the first muting
sensors.
S1
S2
S3
B2 A2 B1 A1
Parcel 1 Parcel 2 Parcel 3

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On the previous page, an installation example of a protection arranged on
a conveyor is shown. It must allow the passage of package 1, preventing
other packages from passing (refer to Wiring example 1) or it must allow
the passage of packages 1 and 2, preventing package 3 from passing
(refer to wiring example 2). Safety PESs S# are connected to the control
unit and are temporarily muted, as the object passes, by means of the
muting sensors A1, A2, B1 and B2.
Sensors A# and B# may be optical, mechanical, proximity, etc. sensors
with closed contact in the presence of the object to be detected.
In the case of Wiring example 1, the pole 2 of
dip-switches must be set in
the On position. And in the case of wiring example 2, the pole 2 of
dip-
switches
must be set in the Off position.
Wiring example 1)
Application with four
muting
sensors, passage permitted only for package 1:
Pole 2 of dip-switches : On
N.C.
A1B1
S
A2B2
d1
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
24 VDC
F3SP-U1P-TGR
terminals
D
L
v
9MUTE A
8MUTE B
11 MUTE C
10 MUTE D
N.C.

F3SP-U1P-TGR User's manual
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Wiring example 2)
Application with four muting sensors, passage permitted only for packages 1 and 2:
Pole 2 of dip-switches: Off
N.C.
A1B1
S
A2B2
d1
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
24 VDC
F3SP-U1P-TGR
terminals
D
L
v
9MUTE A
8MUTE B
11 MUTE C
10 MUTE D
N.C.
Wiring example 3)
Application with two muting sensors, passage permitted only for package 1:
Pole 2 of dip-switched: On
A
S
B
d1 = D
Muting sensor connection:
contact of A
contact of B
24 VDC
F3SP-U1P-TGR
terminals
9MUTE A
8MUTE B
11 MUTE C
10 MUTE D
N.C.
N.C.
L
v
D: minimum distance so that the
muting sensors keep active
the request; it depends on the parcel length: D < L.
d1: necessary maximum distance so that the muting request is
accepted; it depends on object speed:
d
1[cm]= v[m/s] * 3[s] * 100

F3SP-U1P-TGR User's manual
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Wiring example 4)
Application with four muting sensors and safety PES S1 to S4:
Pole 2 of dip-switches: Off
S4
S3
S2
S1
Power cable
Li
g
ht cable
Mutin
g
cable
RX cable
TX cable
Muting
lamp
Test and reset
buttons
F3SP-U1P-TGR
A1B1
S
A2B2
d1
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
24 VDC
F3SP-U1P-TGR
terminals
9MUTE A
8MUTE B
D
L
v
11 MUTE C
10 MUTE D
With the pole 2 of dip-switches in the Off position; sensors S1 and S2 are
controlled by the
muting A and B inputs, while sensors S3 and S4 are
controlled by the
muting C and D inputs. In the case of Wiring example 4, you
can control four sets of safety PESs simultaneously.

F3SP-U1P-TGR User's manual
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Wiring example 5)
Application with eight
muting
sensors and output and input control
Pole 2 of dip-switches: Off
S3
S4
D2 C2 D1 C1
S1
S2
A2 B1 A1
Trigger zone of
handler
B2
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
F3SP-U1P-TGR
terminals
9MUTE A
8MUTE B
11 MUTE C
10 MUTE D
24 VDC
Muting enable to S3 and S4
from robot system control
contact of C1
contact of C2
contact of D1
contact of D2
Muting enable S1 and S2 from
robot system control