Omron F3SP-U3P-TGR User manual

Cat. No. E04E-EN-01 Note: Specifications subject to change without notice.
F3SP-U3P-TGR Single Beam Safety Control Unit/Safety Level 2 USER´S MANUAL
Cat. No. E04E-EN-01
USER´S MANUAL
Single Beam
Safety Control Unit
Safety Level 2
F3SP-U3P-TGR Series
Cat. No. E04E-EN-01
Authorised Distributor:
Printed in Europe

F3SP-U3P-TGR User's manual
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Cat. No. E04E-EN-01
F3SP-U3P-TGR series
Single beam safety control unit,
safety level 2,
from 1 to 2 pairs of photocells E3FS
USER'S MANUAL

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The device conforms with the EC requirements in compliance with the
following standards:
-Low Voltage Directive 73/23/EEC
-EMC Directive 89/336/EEC
-Machinery Directive 89/392/EEC
-IEC 61496-1: 1997
-IEC 61496-2 ed.2 IEC 2001 (CDV draft 8)
-DIN V VDE 0801: 1990 and
-amendment A1: 1994
-EN 61000-4-2,-3,-4,-5,-6
-EN 55022: 1994
-DIN EN 60204-1: 1993
-EN 50178: 1998
-IEC 664-1: 1997
MANUFACTURER: TECHNO-GR s.r.l.
via Torino, 13/15
10046 Poirino (TO) - ITALY
Tel. [phone]
FAX [phone]
USER MANUAL: Version 3.0 of 12/06/2003

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INDEX
1BEFORE USING THE DEVICE. ......................................................5
1-1 GENERAL INSTRUCTIONS. ............................................................................5
1-2 PRECAUTION OF SAFETY .............................................................................5
1-3 ROUTINE MAINTENANCE...............................................................................5
2GENERAL INFORMATION AND MAIN APPLICATIONS..............6
3OPERATION....................................................................................8
4PRECAUTIONS AND INSTALLATION CRITERIA. .......................9
4-1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE.....................9
4-2 REFLECTIVE SURFACES. ............................................................................10
5CONNECTIONS............................................................................ 11
5-1 REFERENCES ON THE TERMINAL BOARD.................................................11
5-2 PIN OVERVIEW..............................................................................................12
5-3 WIRING EXAMPLE.........................................................................................13
6ALIGNMENT PROCEDURE......................................................... 15
7OPERATING PROCEDURES. ..................................................... 16
7-1 DIP-SWITCHES CONFIGURATION...............................................................16
7-2 CONFIGURATION OF THE NUMBER OF PHOTOCELLS.............................16
7-3 MUTING FUNCTION. .....................................................................................17
7.3.1 DESCRIPTION......................................................................................17
7.3.2 INSTALLATION CRITERIA ..................................................................18
7-4 OVERRIDE. ....................................................................................................20
7-5 STARTING THE OVERRIDE FUNCTION.......................................................20
7-6 MUTING RESTRICTIONS (MUTING FUNCTION)................................................21
8LED DIAGNOSTIC. ...................................................................... 22
9FINAL CHECKS. .......................................................................... 23
10 ROUTINE MAINTENANCE OPERATIONS. ................................ 23
11 GENERAL INFORMATION AND USEFUL DATA. ..................... 24
12 TECHNICAL DATA. ..................................................................... 25
13 OVERALL DIMENSIONS. ............................................................ 26

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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) carefully and completely. Make sure the user information provided
is understood before attempting to operate the safety PES.
Keep the manual in a secure and convenient location and confirm
information if necessary.
To guarantee correct installation, carefully follow the instructions of this
manual.
•Do not touch non-insulated cables, unless they have been
disconnected from the power supply.
•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.
•Before carrying out any outer operation, turn off the power.
Failure to do so may result in lethal or serious injury.
1-2 PRECAUTION OF SAFETY
The following symbols are used for highlighted items in order to ensure
safe and proper use of the F3SP-U3P-TGR. Highlighted items are critical
for safe operation and must be heeded at all time.
NOTICE
WARNING
1-3 ROUTINE MAINTENANCE.
Be sure to conduct inspection regularly.
Please refer to sec.10 and the safety PES instruction manual.
Omron Europe and Techno-GR refuses to accept any responsibility for
damage to persons or object due to the incorrect use / installation of the
control unit and safety PES.

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2 GENERAL INFORMATION AND MAIN APPLICATIONS.
The single beam safety control unit F3SP-U3P-TGR has been designed and
produced to meet the need to protect persons in areas where it is necessary
to guarantee the safety of the operator using machinery, robots or in general
automation systems which are considered dangerous or subject to casual or
undesired access to unsafe parts.
The system conforms with the requirements for safety devices of type 2 in
compliance with international standards, e.g. IEC 61496 1-2.
This safety device is made up of a control unit protected by a plastic
container so that it can be installed on a DIN/OMEGA guide; it has 16
removable screw terminals to which it is possible to connect from 1 to 2 pairs
of photocells.
This version of the single beam safety control unit has the ‘muting’ function
integrated, by means of this function it is possible to connect or disconnect
one or more pairs of photocells in order to allow - for instance - the material
passage without stopping the machine.
The additional ‘override’ function enables system, to keep the output relays
closed even with intruded rays to enable material transport after a system
shutdown.
Both muting and override functions represent a system that require additional
precautions to limit the reduction of the safety level. This precautions have to
be considered carefully.
The muting and override function is available by simply connecting the F39-
A11 muting lamp (or similar yellow bulb type lamp for 24VDC / 3W to 7 W)
supplied separately.
The presence of a limb or an object interrupting a beam causes the opening
of the safety outputs and the consequent stopping of the connected machine.
It is necessary for the safety sensors to be connected in the right position in
such a way that there isn’t any possibility to climb over or defeat the system.
Here is a list of the commonly used applications:
◊Machines for the processing of wood, glass and ceramic products.
◊Automatic warehouses.
◊Conveying lines.
◊Palletizers

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The unit has been designed in accordance to the following standards:
IEC 61496-1: 1997. Safety of machinery: electro-sensitive
protective devices
- General requirements and test.
FDIS IEC 61496-2: 1997. Safety of machinery: electro-sensitive
protective devices
-Particular requirements for system using
active opto-electronic devices.

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3 OPERATION.
The electronic control system of the device is made up of a microprocessor.
By means of the suitable hardware, it continuously control and check the
connected photocells. No interference among the photocells is possible as
they are controlled sequentially; it will be thus possible to install one or two
adjacent photocells. When one or more beams are interrupted, the electronic
system opens the outputs .
The photocells have been triggered are displayed by LEDs on the housing.
The control-unit can work in two different modes (please refer to par. 7 page
14) which he can carry out the following operations:
The two external buttons that have to be connected are for:
•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. If pressed after a failure detection of the
unit (see the table error code), reset of the system is required.
•RESET button: It is used to start the system, also for manual reset
condition after relay triggering or after an error which can be reset (see
table related to the error codes).
Two different operating modes are available:
1. Automatic reset: The system will start automatically after the beam
intrusion have been removed.
2. Manual reset: The system will remain in safe off condition until the
RESET button have been pressed. This manual reset allows to start
the system only on a wanted action of the user.
During the unit working, no operation set by the user interface involves
functions which can influence 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 a room
temperature, electromagnetic interference, intense light sources etc.
Please refer to the manual for specification or contact the manufacturer for
details
4-1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE.
The safety distance ‘S’ must be sufficient to guarantee that the dangerous
area cannot be reached by the operator up to the moment in which the
machine with moving part stops. The safety distance must be calculated
according EN999 (European Standards. Safety of Machinery – The
positioning of protective equipment in respect of approach speeds of part
of the human body)
Using EN 999 formula:
S = ( K * T ) + C
S = safety distance.
T = T1 + T2
whereas T1 = machine response time in seconds.
T2 = unit response time in seconds including Safety sensor response time.
K = 1600 mm/s (speed of the body approaching the dangerous area).
C = additional distance depend on resolution of SLC and applicable standard
1) Multiple separate beams (EN999, clause 6.1.4)
K = 1600 mm/s
C = 850 mm
Heights recommended
in EN999
4 Beams 3 Beams 2 Beams
Heights of 1st ray 300 mm 300 mm 400 mm
Heights of 2nd ray 600 mm 700 mm 900 mm
2) Single height beam (EN999, clause 6.1.5)
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 beam from the ground or reference plan: 750mm (EN 999)

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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 exist, the distance must be sufficient to avoid
the possibility of passive reflections.
<Top View>
Distance between emitter and
receiver (detection distance L)
Minimum installation distance
D
0.3 to 3m 0.27 m
3m or more L x tan 2° = L x 0.034 (m)
WARNING.
Do not install the safety PES in a location affected by shiny surface
reflections.
Object
TX barRX bar
A
A
2°2°
2° 2°
reflective material
reflective material

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5 CONNECTIONS.
5-1 REFERENCES ON THE TERMINAL BOARD.
TERMINAL BLOCK ASSIGNMENT
TERMIN
AL
OUTER CONNECTION
1 - 2 Connect to the 24 Vdc power supply, 1 to 24Vcc and 2 to
0Vcc
3 Connect the muting signaller LMS.
4 Connect to the ground of plant.
5 TEST button; connect a normally closed button (N.C.).
6 RESET button; connect a normally open button (N.O.).
7 Input of the muting A sensor. Connect to the N.O. contact of
the muting sensor (photocell, proximity switch, other).
8 Input of the muting B sensor. Connect to the N.O. contact of
the muting sensor (photocell, proximity switch, other).
9 Connect the photocells test input of transmitters TX1.
Black wire (pin 4 of connector).
10 Connect to the PNP output of the receivers RX1.
Black wire (pin 4 of connector).
11 Connect the photocells test input of transmitters TX2.
Black wire (pin 4 of connector).
12 Connect to the PNP output of the receivers RX2.
Black wire (pin 4 of connector).
13 - 14 (OUT1) safety output 1 with N.O. contact.
15 - 16 (OUT2) safety output 2 with N.O. contact.

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5-2 PIN OVERVIEW

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5-3 WIRING EXAMPLE.
Connection of 2 safety PES to the control unit.
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
MAIN SUPPLY
24 VDC
EXTERNAL
FUSE
F39-
A
11
T
E
S
T
N.
C.
R
E
S
E
T
N.
A
.
GND
F3SP-U3P-TGR
control unit
Safety output 1
Safety output 2
E3FS
Receiver
E3FS
Transmitter
Muting
A
- B
T
E
S
T
T
E
S
T
P
N
P
O
U
T
P
N
P
O
U
T
E3FS
Receiver
E3FS
Transmitter
TOP VIEW

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Please, note:
•All models can be connected in all the possible combinations for a
maximum of two pairs of sensors with at least one pair connected.
In the following paragraph you can find the codes of the available
models which can be used in the configuration.
•The power supply which is necessary to power the system must
conform to standard EN 60742 (double insulation) or with equal
insulation, for instance VDE 0551.
•It is necessary to protect the control unit with an outer fuse having a
nominal interruption current equal to 1 A.
•The TEST and RESET pushbuttons must be positioned in such a way
that the operator can see the protected area when he restarts, or
carries out a test or override operation.
•The Muting lamp (F39-A11) must be positioned in a place where it
can be seen from any operative point.
•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.
•Photocells of the type E3FS, S5-5 and S10-5 are delivered with wired
cable or standard M12 connector and the wiring on the control unit is
indicated according to the cable colour, or to the male connector pin
number.
•Photocells of the type S30-5 are available also in the version with
terminal board.
•The connection cables of the photocells, of muting request, start and
test must be masked with minimum section 22AWG. The screen
braids must be all earthed towards the control unit side.

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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 pairs of photocells. Follow the operative modes as follows:
•Turn off the power supplying the control unit.
•Open the TEST pushbutton.
•Power the control unit.
•Align the photocells by observing the LEDs on the control unit: If the
alignment of the relevant pair of photocell is correct, the
corresponding LED will turn on.
•After the alignment, turn off the power supplying the control unit,
close the TEST pushbutton and re-power the control unit again.
•Wait for the control unit to carry out the initial tests.
•At the end of this operation, the unit indicates the right alignment
with the guard led green on.
•Carry out all the checks described in the final checks and in the
routine maintenance operations.
During aligning operations or normal working, check that the photocells
connected to the same or other units do not interfere which each other,
modifying their mutual position, for instance by positioning some pairs of
transmitters on the other receiver side.
NOTICE
The control unit can detect the mutual interference between safety PESs. The
control unit forces the output contact 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 distance.
- Emitters and receivers of safety PES are installed alternately as follows:
TX RX
RX TX

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7 OPERATING PROCEDURES.
7-1 DIP-SWITCHES CONFIGURATION.
The configuration indicated in the table must be selected on the dip-switch
available in the front.
4 Function
X not used
3 Function
Off muting A-B act on the sensor
couples 1 and 2.
On muting A-B act on the sensor
couple 1.
2 Function
Off muting 60 s
On muting ∞s *
1 Function
Off manual restoring
On automatic restoring
The control-unit is manufactured from the factory with the following configuration:
•Automatic reset, all 2 sensors in muting, the maximum duration of
the muting is of sixty seconds.
* infinite muting duration: this feature must be used carefully because it’s
against the norm. Using this, the user must know that it works under its sole
responsibility.
7-2 CONFIGURATION OF THE NUMBER OF PHOTOCELLS.
In case you use only a pair of photocells, operate as follows:
Turn off the power and short the terminal 11-12.
At least one pair of photocells must be connected, otherwise the control unit
is locked.
1
2
3
4
ON
SW1

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7-3 MUTING FUNCTION.
7.3.1 DESCRIPTION.
As mentioned in the introduction, the muting function can be enabled with
any unit by simply connecting the F39-A11 muting lamp when the unit is
switched off.
This presence of this indicator is recognised every time the unit is
powered on. If its presence is detected, the unit will enable the muting
function and if its presence is not detected the unit will ignore any request
for muting. It is important to note that if the muting indicator is connected
during the F3SP-U3P-TGR is powered on, it will not be recognised and
the muting function will not be enabled. Once enabled, if the indicator
develops a fault or is removed without first disconnecting the unit’s power
supply, it will signal an error as described in section 8.
To disable the muting function, the unit’s power supply must be turned on
without the F39-A11 muting lamp connected.
In brief: this function, present on all units, is enabled and disabled by
means of the following simple procedure:
-Disconnect the unit’s power supply.
-Connect the appropriate F39-A11 muting lamp and the muting
sensors.
-Restore the unit’s power supply.
Bypass the muting function as follows.
-Disconnect the unit’s power supply.
-Disconnect the F39-A11 muting lamp and the muting sensors.
-Restore the unit’s power supply.

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7.3.2 INSTALLATION CRITERIA
1. The muting sensors must recognise the material (pallets, vehicles, etc.)
in all its length.
2. The sensors must be arranged in such a way that the material is
recognised even when it must be lifted for the relevant processing.
3. In case of different transport speeds in the muting area, always bear in
mind their influence on the muting total duration.
4. All the safety photocells 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 sensors.
In the previous figures, an installation example of a protection arranged on
a conveyor is drawn. The protection photocells Sare connected to the
F3SP-U3P-TGR control unit and are temporarily interrupted at the
package passage by means of the muting A1, A2, B1 and B2 activated
sensors.
Sensors Aand Bare optical, mechanical, proximity, etc. sensors with
closed contact in the presence of the object to be detected.
S1
S2
B2 A2 B1 A1
GOODS 1 GOODS 2

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Typical application with four muting sensors:
Application with two muting sensors, passage permitted only for package 1:
A
S
B
d1 = D
Muting sensor connection:
contact of
A
contact of B
24 VDC
7 MUTE A
8 MUTE B
F3SP-U3P-TGR
terminals
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 the parcel speed:
d
max [cm]= v[m/s] * 3[s] * 100
This distance must not allow to activate both sensors and
the muting with the accidental passage of a person.
To allow the muting function only for the first photocells it’s necessary to
set the unit with the dip-switch number 3 in ON.
To allow the muting function for both the photocells the dip-switch number
3 must be setted OFF.
A
1B1
S
A
2B2
d1
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
24 VDC
F3SP-U3P-TGR
terminals
D
L
v
7 MUTE A
8 MUTE B