Omron F3SP-U5P-TGR User manual

Cat. No. E06-EN-01 Note: Specifications subject to change without notice.
F3SP-U5P-TGR Series Single Beam Safety Control Unit/Safety Level 4 USER´S MANUAL
Cat. No. E06-EN-01
USER´S MANUAL
Single Beam
Safety Control Unit
Safety Level 4
F3SP-U5P-TGR Series
Cat. No. E06-EN-01
Authorised Distributor:
Printed in Europe

F3SP-U5P-TGR User's manual
Cat. No. E06-EN-01
F3SP-U5P-TGR series
Single beam safety control unit,
safety level 4,
from 1 to 4 pairs of photocells E3FS
USER'S MANUAL

F3SP-U5P-TGR 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 draft8)
-DIN V VDE 0801: 1990 and
-amendment A1: 1994
-EN 61000-2,-3,-4,-5,-6
-EN 55022: 1994
-DIN EN 60204-1: 1993
-EN 50178: 1997
-IEC 664-1: 1997
MANUFACTURER: TECHNO-GR s.r.l.
via Torino, 13/15
10046 Poirino (TO) - ITALY
Tel. [phone]
FAX [phone]
USER MANUAL: Versione 3.0 del 12/06/2003

F3SP-U5P-TGR User's manual
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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 PINOUT TOP VIEW ........................................................................................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. ....................................................................................................23
7.5 STARTING THE OVERRIDE FUNCTION.......................................................23
7.6 MUTING RESTRICTIONS (MUTING FUNCTION)................................................24
8LED DIAGNOSTIC ....................................................................... 25
9FINAL CHECKS. .......................................................................... 25
10 ROUTINE MAINTENANCE OPERATIONS. ................................ 26
11 GENERAL INFORMATION AND USEFUL DATA. ..................... 27
12 TECHNICAL DATA. ..................................................................... 28
13 OVERALL DIMENSIONS. ............................................................ 29
14 NOTE ............................................................................................ 30

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1 BEFORE USING THE DEVICE.
1.1 GENERAL INSTRUCTIONS.
To guarantee a 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 too taut
and that they do not hinder the movement of persons or objects.
The control unit does not contain parts subject to maintenance; before
carrying out any outer operation, turn off the power.
Do not open the control unit for any reason (apart from the selection of the
configuration dip-switch which must be only carried out by skilled
workers) and in case of failure, send it to our laboratories indicating the
detected failure and the operation period.
Avoid touching the protective cover of the safety sensors with the hands in
order to prevent dust and/or grease build upon the device, thus reducing
the system performances.
The possible wear of the protective covers does not compromise the
system safety in any way but can cause a system tripping.
1.2 PRECAUTION OF SAFETY
The following symbols are used for highlighted items in order to ensure safe
and proper use of the F3SP-U5P-TGR. Highlighted items are critical for safe
operation and must be heeded at all time.
WARNING
NOTICE
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-U5P-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 4 in
compliance with international standards, e.g. IEC 61496 1-2.
WARNING
The safety system category depends on the safety PES’s used as follows.
Type 4 safety PES : Safety system category 4
Type 2 safety PES : Safety system category 2
•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 and defeating 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.

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•The control unit and safety PES must not be used in water.
The F3SP-U5P-TGR safety controller is protected by a plastic housing so that
it can be installed on a DIN/OMEGA rail; it has 32 removable screw terminals
to which it is possible to connect from 1 to 4 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 5 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
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
16) 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
Heights of 3rd ray 900 mm 1100 mm
Heights of 4th ray 1200 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>
Object
TX barRX bar
A
A
2°2°
2° 2°
reflective material
reflective material
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.

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Do not install the safety PES in a location affected by shiny surface
reflections.
5 CONNECTIONS.
5.1 REFERENCES ON THE TERMINAL BOARD.
TERMINAL BLOCK ASSIGNMENT
TERMINAL OUTER CONNECTION
1 – 2 Connect to the 24 Vdc power supply, terminal 1 Æ24Vdc / terminal 2 Æ0Vdc.
3 – 4 RESET button; connect a normally opened button (N.O.).
4 - 5 TEST button; connect a normally closed button (N.C.).
6 - 7 Connect the muting signaller.
8 Input of the muting B sensor.
Connect to the N.O. contact of the muting sensor (photocell, proximity switch, other).
9 Input of the muting A sensor.
Connect to the N.O. contact of the muting sensor (photocell, proximity switch, other).
10 Input of the muting D sensor.
Connect to the N.O. contact of the muting sensor (photocell, proximity switch, other).
11 Input of the muting C sensor.
Connect to the N.O. contact of the muting sensor (photocell, proximity switch, other).
12 Earth. Connect to the plant’s earth.
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 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 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 supply to receivers (RX) of 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 supply to receivers (RX) of 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.

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BREAK / GUARD
FTC.4
FTC.3
FTC.2
FTC. 1
5.2 PINOUT TOP VIEW

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5.3 WIRING EXAMPLE.
Connection of 4 safety PES to the control unit.
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
MAIN SUPPLY
24 VDC
EXTERNAL
FUSE
F39-A11
T
E
S
T
N.
C.
S
T
A
R
T
N.
A
.
GND
Muting
sensor
contatcs
N.O.
F3SP-U5P-TGR PIN Assignment
Safety output 2
Safety output 1
E3FS Transmitter
E3FS
Receiver
E3FS
Receiver
E3FS Transmitter
E3FS
Receiver
E3FS Transmitter
+-test
+-pnp out
brown
bleu
black
black
brown
bleu
black
black
Muting
A
-B
Muting
C-D
Top view

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Please, note:
•To configure the control unit in such a way that it works only with
three photocells, it is necessary to connect the unused transmitter
output to the corresponding receiver input, in this case to terminal
TEST-TX3 with PNP_OUT-RX3.
•All models can be connected in all the possible combinations for a
maximum of four pairs of sensors with at least one pair connected.
•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) 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.
•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 contact.
•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 LED
corresponding LED will turn 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.
•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.
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
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 both the dip-
switches available in the front cover.
1 Function
X not used
2 Function
Off muting A-B act on the sensor couples 1
and 2.
muting C-D act on the sensor couples 3
and 4.
On muting A-B act on the sensor couple 1.
muting C-D act on the sensor couple 2.
The sensor couples 3-4 continue to
function normally.
3 function 4 function
Off muting 60 s Off manual restoring
On muting ∞s * On automatic restoring
The control-unit is manufactured from the factory with the following configuration:
•Automatic reset, all four 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 a number of photocells which is lower than 4, operate as
follows: to disconnect the photocells do not use and therefore do not connect
to the control unit; carry out a connection among the following terminals:
unused photocell connection
1 19 to 27
2 20 to 28
3 23 to 31
4 24 to 32
At least one pair of photocells must be connected, otherwise (condition of all
the disconnected photocells) the control unit is locked.
1
2
3
4
ON
4
3
2
1 ON
SW2SW1

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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-U5P-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 page, an installation example of a protection arranged on a
conveyor is drawn; it must allow the passage of package 1, preventing
other packages from passing or it must allow the passage of packages 1
and 2, preventing package 3 from passing. The protection photocells S
are connected to the F3SP-U5P-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.
In both cases, the configuration dip-switch 2 must be set in the on
position.
S1
S2
S3
B2 A2 B1 A1
GOODS 1 GOODS 2 GOODS 3

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Application with four muting sensors, passage permitted only for package 1:
Application with four muting sensors, passage permitted only for packages 1 and 2:
A
1B1
S
A
2B2
d1
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
24 VDC
F3SP-U5P-TGR
terminals
9MUTE A
8MUTE B
D
L
v
11 MUTE C
10 MUTE D
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
F3SP-U5P-TGR
terminals
9MUTE A
8MUTE B
11 MUTE C
10 MUTE D
N
.C.
N
.C.
N
.C.
A
1B1
S
A
2B2
d1
Muting sensor connection:
contact of A1
contact of A2
contact of B1
contact of B2
24 VDC
F3SP-U5P-TGR
terminals
D
L
v
9MUTE A
8MUTE B
11 MUTE C
10 MUTE D
N
.C.