Pilz PSEN op4B/1 Series User manual

PSEN op4B/1 Series
Operating Manual-1003356-EN-02
PSEN sensor technology

Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Content
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Section 1 Introduction 6
1.1 Validity of documentation 6
1.2 Using the documentation 6
1.3 Definition of symbols 6
Section 2 Overview 8
2.1 Product types 8
2.2 Unit features 9
2.3 Types 9
2.3.1 Safety light grid without integrated muting sensors 9
2.3.2 Safety light grid with integrated muting sensors 11
2.4 Scope 13
Section 3 Safety 15
3.1 Intended use 15
3.2 Safety regulations 15
3.2.1 Safety assessment 15
3.2.2 Use of qualified personnel 16
3.2.3 Warranty and liability 16
3.2.4 Disposal 16
Section 4 Function description 17
4.1 Basic function 17
4.1.1 Function settings when delivered 17
4.2 Restart after safety light grid is activated 18
4.3 Reset function 19
4.4 EDM 20
4.5 Muting 21
4.5.1 Technical implementation 23
4.5.2 Time monitoring - Timeout 26
4.6 Override 27
4.7 Test function 28
4.8 Convert type without muting sensors to L/T-type 29
Section 5 Project configuration 30
5.1 Maintaining the safety distance 30
5.2 Ambient conditions 30
5.3 Distance from reflective surfaces 31
5.4 Installation of several adjacent safety light grids 32
5.5 Use of deviating mirrors 33
5.6 Use of the muting function 35
Section 6 Installation and wiring 39
6.1 Attach safety light grid without muting sensors to mounting surface 39
6.2 Attach safety light grid with muting sensors to mounting surface 39
6.3 Conversion of safety light grids without muting sensors 40
6.4 Installation of external muting sensors 41

Content
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6.5 Wiring 41
6.5.1 General guidelines 41
6.5.2 Connector pin assignment 42
6.5.3 TEST/START button 44
6.5.4 EDM 44
6.5.5 Earthing the safety light grid 44
6.5.6 Connections for muting 45
6.5.7 Wiring of external sensors on the safety light grid 46
Section 7 Commissioning 47
7.1 Setting the functions 47
7.1.1 Open DIP switch cover 47
7.1.2 Activate muting 47
7.1.3 Set muting timeout 48
7.1.4 Activate EDM 48
7.1.5 Restart after unit is triggered 48
7.2 Orientation 49
7.2.1 General guidelines 49
7.2.2 Safety light grid alignment 50
7.2.3 Muting sensor alignment 51
7.2.4 LED support during alignment 52
7.3 Checking the safety light grid 52
7.4 System connection 53
Section 8 Operation 54
8.1 Status information during operation 54
8.2 Perform test 55
8.3 Diagnostics and troubleshooting 55
8.3.1 Indicators for fault diagnostics 55
8.3.2 Perform reset 57
Section 9 Regular checks and maintenance 58
9.1 Checks 58
9.1.1 Regular checks 58
9.1.2 Daily check 58
9.1.3 Check after plant/machine modification 58
9.2 Maintenance 58
Section 10 Dimensions 60
Section 11 Technical details 62
11.1 Safety characteristic data 67
Section 12 Order reference 68
12.1 Order reference for safety light grids 68
12.2 Order reference for accessories 68

Content
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Section 13 Appendix 71
13.1 Check list 71

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSEN op4B/1 Series. It is valid until new docu-
mentation is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
1.2 Using the documentation
This document is intended for instruction. Only install and commission the product if you
have read and understood this document. The document should be retained for future ref-
erence.
1.3 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.

Introduction
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INFORMATION
This gives advice on applications and provides information on special fea-
tures.

Overview
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2 Overview
2.1 Product types
Product type
Protected field
Max. height
in mm
Max. width
in m
PSEN op4B-2-050/1 515 50
PSEN op4B-3-080/1 815 50
PSEN op4B-4-090/1 915 50
PSEN op4B-4-120/1 1215 50
Table of product types – Safety light grid without integrated muting sensors
Product type
Protected field
Max. height
in mm
Max. width
in m
PSEN op4B-L-050/1
}Safety light grid 515 50
}Muting sensor 3
PSEN op4B-L-080/1
}Safety light grid 815 50
}Muting sensor 3
Table of product types – Safety light grid with L-muting
Product type
Protected field
Max. height
in mm
Max. width
in m
PSEN op4B-T-050/1
}Safety light grid 515 50
}Muting sensor 3
PSEN op4B-T-080/1
}Safety light grid 815 50
}Muting sensor 3
Table of product types – Safety light grid with T-muting
Height
The height of the protected field describes the effective protected height, in which a matt,
opaque object corresponding to the specific resolution will be detected.

Overview
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Width
The maximum width of the protected field is determined by the maximum operating range
of the light beam sent from the transmitter to the receiver.
In the table of product types, the maximum width for types with integrated muting sensors is
divided into a maximum width for the safety light grid and a maximum width for the muting
sensors.
}If the safety light grid is used without muting sensors, the width stated for the safety
light grid will apply.
}If the safety light grid is used with muting sensors, the width stated for the muting
sensors will apply.
The minimum width of the protected field corresponds to the minimum operating range
stated in the Technical details [ 62].
2.2 Unit features
Safety light grids in the PSEN op4B/1 Series are multibeam optoelectronic protective
devices for work areas in which
}machines,
}robots and
}automated plants
could endanger the physical integrity of operators.
Features of the safety light grid
}Type 4
}Safeguards protected fields with body resolution
}Muting
All safety light grids in the PSEN op4B/1 Series are able to process data from connec-
ted muting sensors
}Infrared protected field is generated
}Transmitter and receiver are synchronised optically
}Override
}LED for status information
}LED for support during alignment
2.3 Types
2.3.1 Safety light grid without integrated muting sensors
}Safety light grid with body resolution
The safety light grid is equipped for muting applications. External muting sensors with
reflective sensors or with transmitter and receiver sensors can be used for muting ap-
plications (see Order reference for accessories, section on muting
accessories [ 70]).

Overview
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[1]
[2]
[3]
[4]
[5]
[6] [7]
Fig.: View of safety light grid without integrated muting sensors
Legende
[1] Receiver
[2] Transmitter
[3] LED onreceiver/transmitter
[4] Height of the protected field
[5] Width of the protected field
[6] 8-pin and 5-pin connector of receiver
[7] 4-pin and 5-pin connector of transmitter

Overview
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2.3.2 Safety light grid with integrated muting sensors
[1] [2]
[3]
[8]
[8]
[4]
[5]
[6]
[9]
[7]
[9]
[1] [2]
[3]
[8]
[8]
[4]
[5]
[6]
[9]
[7]
[9]
[9] [9]
Safety light grid with body resolution with L-
muting set
Safety light grid with body resolution with T-
muting set
[1] Receiver
[2] Transmitter
[3] LED onreceiver/transmitter
[4] Width of the protected field
[5] Height of the protected field
[6] 8-pin and 5-pin connector of receiver
[7] 4-pin and 5-pin connector of transmitter
[8] Muting sensors
[9] 4-pin connector of muting sensors for connection to receiver/transmitter
L-muting application
Use L-type with muting sensors in one direction when material is moved through the danger
zone from one direction
}PSEN op4B-L-050/1
}PSEN op4B-L-080/1

Overview
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A1
B1
A1
B1
Fig.: L-type muting in one direction (integrated muting sensors)
Legende
A1 Position of the first light beam on the muting sensor
B1 Position of the second light beam on the muting sensor
T-muting application
Use T-types with muting sensors in two directions when material is moved through the
danger zone from two directions
}PSEN op4B-T-050/1
}PSEN op4B-T-080/1

Overview
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A1
B1
A1
B1
A2
B2
A2
B2
Fig.: T-type muting in two directions (integrated muting sensors) - View of the travel direction from
right to left
Legende
A1 Position of the first light beam on the muting sensor
B1 Position of the second light beam on the muting sensor
A2 Position of the third light beam on the muting sensor
B2 Position of the fourth light beam on the muting sensor
2.4 Scope
Safety light grid with body resolution, without integrated muting sensors
Order reference Description
PSEN op4B-2-050/1 or
PSEN op4B-3-080/1 or
PSEN op4B-4-090/1 or
PSEN op4B-4-120/1
Safety light grid, consisting of
}Transmitter
}Receiver
}Mounting kit

Overview
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Safety light grid with body resolution and integrated muting sensors (for muting in
one direction)
Order reference Description
PSEN op4B-L-050/1 or
PSEN op4B-L-080/1
Safety light grid, consisting of
}Transmitter
}Receiver
}Mounting kit
}2 integrated muting sensors
}Cable for connecting the muting sensors
}Mounting kit for muting sensors
Safety light grid with body resolution and integrated muting sensors (for muting in
two directions)
Order reference Description
PSEN op4B-T-050/1 or
PSEN op4B-T-080/1
Safety light grid, consisting of
}Transmitter
}Receiver
}Mounting kit
}4 integrated muting sensors
}Cable for connecting the muting sensors
}Mounting kit for muting sensors

Safety
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3 Safety
3.1 Intended use
Safety light grids in the PSEN op4B/1 Series constitute electrosensitive protective equip-
ment. They are used to protect personnel and plants. The safety light grids are designed to
}Safeguards protected fields with body resolution
}Safeguard danger zones and
}Safeguard access.
The safety light grid may only be used for personal protection on machinery if
}The hazardous state can be stopped by the safety light grid and/or
}The machine can be prevented from starting up.
Ensure that the start-up method meets the defined safety requirements.
}Without restart interlock (status when delivered) or
}With restart interlock
Intended use includes making the electrical installation EMC-compliant.
The product is designed for use in an industrial environment. Interference may occur if used
within a domestic environment.
Before using the safety light grid, check whether the safety light grid's housing material can
withstand the chemical substances used in the production process (see Technical
details [ 62]).
The following is deemed improper use:
}Using the safety light grids outdoors
}Using the safety light grids to protect against flying parts
}Using the safety light grids in a radioactive environment
}Using the safety light grids outside the areas described in this manual
}Using the safety light grids outside the documented Technical Details [ 62].
INFORMATION
Other safety devices and protective measures may be required in addition
to the safety light grid. These should be determined via a safety assessment
based on the specific application area and specific local conditions (e.g. offi-
cial specifications).
3.2 Safety regulations
3.2.1 Safety assessment
Before using a unit it is necessary to perform a safety assessment in accordance with the
Machinery Directive.

Safety
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Functional safety is guaranteed for the product as a single component. However, this does
not guarantee the functional safety of the overall plant/machine. In order to achieve the re-
quired safety level for the overall plant/machine, define the safety requirements for the
plant/machine and then define how these must be implemented from a technical and organ-
isational standpoint.
3.2.2 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is someone who, because of their training, experience and current pro-
fessional activity, has the specialist knowledge required to test, assess and operate the
work equipment, devices, systems, plant and machinery in accordance with the general
standards and guidelines for safety technology.
It is the company’s responsibility only to employ personnel who:
}Are familiar with the basic regulations concerning health and safety / accident preven-
tion
}Have read and understood the information provided in this description under "Safety"
}And have a good knowledge of the generic and specialist standards applicable to the
specific application.
3.2.3 Warranty and liability
All claims to warranty and liability will be rendered invalid if
}The product was used contrary to the purpose for which it is intended
}Damage can be attributed to not having followed the guidelines in the manual
}Operating personnel are not suitably qualified
}Any type of modification has been made (e.g. exchanging components on the PCB
boards, soldering work etc.).
3.2.4 Disposal
}In safety-related applications, please comply with the mission time TM in the safety-re-
lated characteristic data.
}When decommissioning, please comply with local regulations regarding the disposal of
electronic devices (e.g. Electrical and Electronic Equipment Act).

Function description
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4 Function description
4.1 Basic function
The safety light grid consists of a transmitter and receiver, which are housed in rugged alu-
minium profiles and therefore protected from external damage.
The protected area is covered by infrared light beams, which are emitted from the transmit-
ter to the receiver. The protected field that is produced is able to detect an opaque object.
As soon as an object or part of the operator’s body interrupts the beams sent by the trans-
mitter, the output signal switching device (OSSD) is immediately switched off and the con-
nected machine is stopped immediately as a result. The object or body part must be at
least the size of the resolution covered by the safety light grid.
The functions of the safety light grid are set via DIP switches, which are located beneath a
flap on the connector side of the safety light grid. The electrical connection is made via an
M12 connector, which is positioned underneath the profiles.
The following functions are set via DIP switches:
}Timeout muting
}Muting
}EDM
}Restart after unit is triggered
The transmitter and receiver are synchronised optically, so the two units do not have to be
connected directly to each other.
The infrared beams that are transmitted and received are controlled and monitored via mi-
croprocessors, which provide the user with information about the operating state of the
safety light grid and the potential error state via LED indicators. During the installation
phase, two yellow LEDs simplify the alignment of the two units.
The indicators are described under:
}Status information during operation [ 54],
}LED support during alignment [ 52],
}Indicators for fault diagnostics [ 55].
4.1.1 Function settings when delivered
The safety light grid is delivered with all DIP switches in the ON position.
1 2 345678
ON
Fig.: DIP switches all ON
As a result the functions are set as follows:

Function description
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Function DIP switch Position Set function
Timeout muting 1 and 5 ON 10 minutes
Muting 2 and 6 ON T-configuration (4 beams) or
cross muting
When using the L-configuration,
DIP switches 2 and 6 must be set
to OFF.
EDM 3 and 7 ON Deactivated
Restart interlock 4 and 8 ON Without restart interlock
Functions can be selected via DIP switch - settings when delivered
4.2 Restart after safety light grid is activated
If the safety light grid has switched off the OSSDs, the connected machine is stopped.
Once the protected field is clear again, the safety light grid must be reset to its normal oper-
ating state.
The restart can be achieved in two ways:
}Without restart interlock (status when delivered)
The safety light grid is automatically reset to its normal operating state.
}With restart interlock
The light grid is not reset to its normal operating state until
– The TEST/START button has been operated for at least 0.5 s and
– The area of the protected field is clear again and the light beams are no longer in-
terrupted.
NOTICE
The machine may only be restarted via a TEST/START button.
It must not be possible to operate the pushbutton from inside the danger
zone. The button must be located at a position from which there is a full, un-
obstructed view of the danger zone.

Function description
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t
Restart
(Test/Start
button) 1
0
Status of
OSSD
Normal
operation
Safe
condition
> 0.5 s
Status LED
High Align On
Off
> 0.5 s
Fig.: Timing diagram for restart in operating mode with restart interlock
The type of restart that will be used is set during commissioning via DIP switches 4 and 8
(see Setting the functions [ 47]).
4.3 Reset function
In the event of an internal error on the safety light grid, the safety light grid switches to a
safe condition and stops the connected machine. In order to restore normal operating con-
ditions, the safety light grid must be reset.
Internal errors are:
}Malfunction of the outputs or
}Optical malfunction or
}Malfunction of the muting display or
}Incorrect operation of the EDM function.

Function description
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t
Test/Start
button 1
0
Status of
safety light
grid
Error
Normal
operation
5 s 5 s
Fig.: Timing diagram - Reset after malfunction
4.4 EDM
Contactors outside the safety light grid can be monitored (External Device Monitoring =
EDM, also known as feedback loop monitoring).
EDM only needs to be activated if the contactors are controlled directly.
A test is performed to see that the N/C contacts switch if the state of the OSSD changes
and so is used to monitor and detect malfunctions on the contactors. If a malfunction is de-
tected, the safety light grid switches to a safe condition and stops the connected machine.
This check is carried out each time the OSSD is triggered and before restarting.