Pilz PSEN op4F-SL Series User manual

PSEN op4F-SL Series
Operating Manual-1004306-EN-01
}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.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
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

Contents
Operating Manual PSEN op4F-SL Series
1004306-EN-01 3
Introduction 6
Validity of documentation 6
Using the documentation 6
Definition of symbols 6
Overview 7
Unit view 8
Scope 9
Safety 9
Intended use 9
Safety regulations 10
Safety assessment 10
Use of qualified personnel 11
Warranty and liability 11
Disposal 11
Function description 11
Basic function 11
Automatic and monitored start 12
Manual restart 13
EDM 13
Cascading 14
Project configuration 14
Maintaining the safety distance 14
Resolution 15
Protected field perimeters 15
Ambient conditions 15
Distance from reflective surfaces 16
Minimum distance between parallel, aligned safety light grids 18
Installation of several adjacent safety light grids 19
Use of deviating mirrors 19
Cascaded safety light grid 20
Minimum distance for cascaded safety light grids 20
Resolution for cascaded safety light grids 20
Installation 22
Attach safety light grids using C-brackets 23
Attach safety light grids using O-brackets 24
Attach safety light grids using L-brackets 27
Attach safety light grids using L and C-brackets 29
Cascaded safety light grid 30
Wiring 30
General guidelines 30
Connector pin assignment 31
Earthing the safety light grid 33

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Operating Manual PSEN op4F-SL Series
1004306-EN-01 4
Cascaded safety light grid 34
Alignment 35
Alignment options depend on the installation type 35
Orientation 35
Safety light grid alignment 35
LED indicators in alignment mode 36
Commissioning 36
System connection 36
Checking the safety light grid 37
Operation 39
Display elements 39
Status information 40
Safety light grid restart 41
Malfunction 42
Regular checks and maintenance 42
Checks 42
Regular check 42
Check after plant/machine modification 42
Maintenance 43
Dimensions 43
Technical details Order no. 631140-631142 44
Technical details Order no. 631143-631145 46
Technical details Order no. 631146-631148 48
Technical details Order no. 631149-631151 50
Technical details Order no. 631152-631154 52
Technical details Order no. 631155-631157 54
Technical details Order no. 631158-631160 56
Safety characteristic data 58
Order reference 58
Safety light grid 58
Accessories 59
Appendix 61
Check list 61

Contents
Operating Manual PSEN op4F-SL Series
1004306-EN-01 5
Identification 63
EC declaration of conformity 63

PSEN op4F-SL Series
Operating Manual PSEN op4F-SL Series
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Introduction
Validity of documentation
This documentation is valid for the product PSEN op4F-SL 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.
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.
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.

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INFORMATION
This gives advice on applications and provides information on special fea-
tures.
Overview
Safety light grids in the PSEN op4F-SL Series constitute electrosensitive protective equip-
ment (ESPE type: 4) in accordance with DIN EN 61496-1 and DIN EN 61496-2 (AOPD) for
workspaces in which machines, robots, and automated systems might pose a physical
danger to their operators.
Unit features
}Resolution: 14 mm
}Infrared protected field is generated
}LED indicator for status information
}Optical synchronisation of transmitters and receivers
}Connection to evaluation devices (see System connection [ 36])
with 5-pin M12 one-sided connector and open cable end connection to clamping
sleeves
}EDM (when connected to a relay with positive-guided contacts)
}Cascading
Max. 2 slave units to one master unit
}Front panel of PMMA
}No dead zone in any protected field heights
}Dimensions of safety light grid profile: 15 x 32 mm
}Three different brackets used to install the safety light grid
– PSEN op SL Bracket C (included) for lateral attachment to the safety light grid pro-
file
for minimum length of installation
– PSEN op SL Bracket O (included) for attachment to the safety light grid caps
for minimum width of installation
– PSEN op SL Bracket L (can be combined with PSEN op SL Bracket C)
for attachment where there is strong vibration
}Die-cast zinc end caps (Zamak)

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Unit view
[5]
12,512,5
[5]
[2]
[1]
[3]
[4]
[4]
[2]
[1]
[3]
40,7
[6]
6
[6]
[2]
[1]
6[3]
Fig.: Views of safety light grids with connection cable – Attachment using O-bracket, C-bracket or L-
bracket
Legend
[1] Protected field height
[2] Connection cable, M12 connector
[3] Cover for the contacts used to connect a slave unit when cascading
[4] C-bracket
[5] O-bracket
[6] L-bracket

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Scope
Quant-
ity Description Illustration
1 Transmitter
1 Receiver
4/6 }C-bracket
– with slotted hole
washer and hexagon
socket cylinder head
screws 2xM4x10 DIN
7984, 1xM3x8 DIN
EN ISO 12474
– 4 brackets for protec-
ted field height
150mm – 540mm
– 6 brackets for protec-
ted field height
600mm – 1200mm
4}2 O-brackets
– with washer and
hexagon socket cylin-
der head screw M4x10
DIN7984
Safety
Intended use
Safety light grids of the PSEN op4F-SL Series are electrosensitive protective equipment of
the 4. They are used to protect personnel and systems. The safety light grids are designed
for
}securing hazardous areas within buildings and
}securing access within buildings with a resolution of 14 mm.
The safety light grid may only be used for personal protection on machinery if
}the hazardous state can be removed by the safety light grid and
}the starting of the machine is controlled by the safety light grid and
}the safety assessment prescribes no better resolution than 14 mm.
The safety level PL e (Cat. 4 )/SIL CL 3 is only achieved if
}the safety outputs use 2-channel processing.

PSEN op4F-SL Series
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The safety light grid is not equipped with a restart interlock.
If the safety assessment necessitates a restart interlock, this feature must be ensured
within the plant’s programmable safety system. The system may not be started in the haz-
ardous area following a protection violation if personnel are still in the hazardous area.
Prevent circumvention of the protected field. This means that other safety devices and safe-
guards 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. official specifications).
Refer to IEC/TS 62046 to determine other necessary safeguards for securing the hazard-
ous area.
Their application must fulfil the site’s relevant national regulations (e.g.EN60204-1,
NFPA79:17-7).
The following is deemed improper use in particular:
}Any component, technical or electrical modification to the product
}Use of the product outside the areas described in this manual
}Use of the product outside the technical details (see Technical details [ 44]).
NOTICE
EMC-compliant electrical installation
The product is designed for use in an industrial environment. The product
may cause interference if installed in other environments. If installed in other
environments, measures should be taken to comply with the applicable
standards and directives for the respective installation site with regard to in-
terference.
Safety regulations
Safety assessment
Before using a unit it is necessary to perform a safety assessment in accordance with the
Machinery Directive.
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.

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Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by competent persons.
A competent person is a qualified and knowledgeable person who, because of their train-
ing, experience and current professional activity, has the specialist knowledge required. To
be able to inspect, assess and operate devices, systems and machines, the person has to
be informed of the state of the art and the applicable national, European and international
laws, directives and standards.
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"
}Have a good knowledge of the generic and specialist standards applicable to the spe-
cific application.
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.).
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
Basic function
The safety light grid consists of a transmitter and a receiver.
Their shape and design
}protect the transmitter and receiver from external damage
}protect the safety light grid from malfunctions caused by vibration (see Technical de-
tails, environmental data section [ 44]).
The protected area is covered by infrared light beams, which are emitted from the transmit-
ter to the receiver. The protected field thus produced is able to detect an opaque object.
The control and monitoring of the transmitted and received infrared rays is performed by
microprocessors.

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The output signal switching devices (OSSDs) switch to the OFF state when one of the fol-
lowing conditions is met:
}one or more light beams are interrupted by an object, a body part, or an opaque object
that is at least as large as the resolution (14 mm) covered by the safety light grid,
}an error is detected by one of the OSSDs,
}or interfering light is detected.
If an error occurs, the OSSDs remain in the OFF state. The state can be returned to the ON
state only after a successful restart [ 41] of the safety light grid.
The safety light grid in the PSEN op4F-SL Series offers the following functions:
}Automatic start
}Monitored start
}EDM (when connected to a relay with positive-guided contacts)
}Cascading
Transmitters and receivers are each electrically connected with a cable with an M12 con-
nector that is assigned to the transmitter and receiver on the LED side.
The transmitter and receiver are optically synchronised and therefore need not be directly
connected to each other.
Information about the operating status of the safety light grid and any error state is provided
by means of LEDs.
The indicators are described in the Status Information [ 39] section.
Automatic and monitored start
Automatic start
During safety light grid commissioning, the safety light grid starts automatically, and the
OSSDs switch to the ON state under the following conditions:
}both OSSDs are wired correctly and
}no error has occurred and
}the protected field is clear.
If the protected field is violated, the OSSDs switch to the OFF state.
Monitored start
The OSSDs automatically switch to the ON state during operation under the following con-
ditions:
}both OSSDs are wired correctly and
}no error has occurred and
}the protected field is clear and
}at least 80 ms have elapsed since switching to the OFF state and
}the start button has been operated for at least 0.5 s. The start occurs with a falling
edge.

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Manual restart
OSSD
t1
On
Off
Light beams
Free
Interrupted
Start button
Operated
Not operated
Fig.: Timing diagram for manual restart
Legend
t1Operate the start button for 0.5s to 5s to trigger a manual restart
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 state and stops the connected machine. This
check is carried out each time the OSSD is triggered and before restarting.

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OSSD
EDM
2
t1t
On
Off
24 V
0 V
Fig.: Timing diagram for EDM
Legend
t1After the OSSD outputs are switched on, the EDM circuit must open within 350 ms
t2After the OSSD outputs are switched off, the EDM circuit must close within 100 ms
Use control elements whose dynamics match the times stated at t1 and t2.
The function is activated or deactivated with the Wiring [ 31].
Cascading
During cascading, the safety outputs of a safety light grid are connected to an evaluation
device. A second safety light grid can be connected to this first safety light grid. The first
safety light grid is the master unit; the safety light grid connected to the master unit is the
slave unit.
}Max. 2 slave units to one master unit
}Max. overall length: 3600mm
}The master unit collects the results from the slave units and ensures synchronisation
between them, so that mutual interference is avoided
}Each transmitter/receiver in the PSEN op4F-SL Series can be used both as a master
unit and a slave unit
}Up to three areas can be monitored when two safety outputs are connected
Project configuration
Maintaining the safety distance
The minimum distance between the safety light grid and the hazardous machine compon-
ent should be such that the operator cannot reach the hazardous area until the hazardous
machine part has come to a standstill.

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In accordance with the standard
}ENISO13855
this distance depends on three factors:
}Response time of the safety light grid
Interval between interruption of the beams and the OSSD’s change to the OFF state
}Machine's stopping time
Interval between the change of the OSSD to the OFF state and the stopping of the haz-
ardous machine movement (including the reaction time of the connected relay)
}Approach speed
The speed with which the object to be detected is nearing the hazardous area in mm/s
The general formula for calculating the minimum distance in accordance with
ENISO13855 is as follows:
S = K * (t1 + t2) + C
S Minimum distance in mm, measured from the start of the protected field to the
danger source
K Approach speed with which the object to be detected is nearing the hazardous area
in mm/s
K = 1600 mm/s when S > 500 mm
K = 2000 mm/s when S ≤ 500 mm
t1Response time of the safety light grid in seconds
Time it takes for the signal at the OSSD output on the safety light grid to change
once a protected field has been violated
t2Machine's stopping time in seconds
The time required for the machine to stop after the signal at the OSSD output
changes
C Additional distance of 0 mm for safety light grids with finger protection
Resolution
The safety light grids may only be used for protected fields in which a detection capability of
14 mm is sufficient.
Protected field perimeters
During planning, ensure sufficient protected field height to secure the danger zone.
The protected field perimeter is defined in dimensions [ 43].
Ambient conditions
}Install the safety light grids in an environment that corresponds to the environmental
data provided in the Technical details [ 44].
}Do not install the safety light grid near particularly intense and/or flashing light sources;
this applies to the receiver in particular.

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}The transmitter of one safety light grid must not interfere with the receiver of another
safety light grid.
}The transmitters and receivers of two different safety light grids must not be synchron-
ised.
}Avoid strong electromagnetic interference when operating the safety light grid.
}When operating the safety light grid, avoid the development of smoke, mist, or dust that
would reduce the grid’s operating range.
Distance from reflective surfaces
If there are reflective surfaces near the beams emitted from the safety light grid (whether
from above, below, or from the side), passive reflections can cause an object within the pro-
tected field to remain undetected (see diagrams).
This means that there must be a certain minimum distance between the safety light grid
and reflective surfaces.
[1]
[2] [3]
[5]
[6]
[4]
[4] [4]
[4]
[7]
[8]
Fig.: Interference with the function of the safety light grid due to reflective surfaces – top view

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[1]
[2] [3]
[4]
[4]
[4]
[4]
[5]
[1]
[5]
Legend
[1] Reflective surface
[2] Transmitter
[3] Receiver
[4] Half of the opening angle [ 44] (= ⍺) of the light beams emitted by the safety
light grid
[5] Minimum distance D between the safety light grid and the reflective surface
[6] Passive reflections on the surface
[7] Distance between transmitter and receiver (working distance)
[8] Hazardous area
The minimum distance D depends on two factors:
}Working distance between transmitter and receiver
}the maximum opening angle [ 44] of the light beams emitted by the safety light grid
at:
5° = ± 2.5° in relation to the optical axis
Minimum distance of the safety light grid to reflective surfaces
The formula for calculating the minimum distance D is:
}For a working distance of less than 3 m: D = 0.131 m
}For a working distance of 3 m or more: D = working distance in m x tan ⍺

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[2]
0,35
0,174
0,131
0 3 4 8 [1]
[3]
Fig.: Relationship between minimum distance and working distance
Legend
[1] Working distance in m
[2] Distance from reflective surfaces in m
[3] Minimum distance D
Minimum distance between parallel, aligned safety light grids
Please note:
Safety light grids that are installed so as to be parallel and aligned must have a minimum
spacing corresponding to the information in distance to reflective surfaces [ 16].
[1] [2]
[3] [4]
[5]
[6]
[7]
[8]
[7]
Legend
[1] Transmitter from the first safety light grid
[2] Receiver from the first safety light grid
[3] Transmitter from the second safety light grid
[4] Receiver from the second safety light grid

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[5] Minimum distance of 2 x D between two safety light grids that are aligned
[6] Working distance
[7] Minimum distance D, dependent on the working distance
[8] Working distance (= 3m) with constant minimum distance D=0.131m
Installation of several adjacent safety light grids
An arrangement of several adjacent safety light grids can be achieved by various methods.
When installing of several adjacent safety light grids, note the ambient conditions [ 15].
[1] [2] [3]
[4] [5] [4] [5] [4]
[5]
Hazardous area
Fig.: Using several adjacent safety light grids
Legend
[1] Connecting the safety light grid with an opaque surface to shield the safety light
grid on the right
[2] Connection of the safety light grid aligned with [1]
[3] Connection of safety light grid without shielding, but in the orientation opposite to
[2]
[4] Receiver
[5] Transmitter
Use of deviating mirrors
Danger zones with different but adjacent access sides can be monitored using a safety light
grid in conjunction with deviating mirrors [ 60].
The diagram below shows an example solution for monitoring three different access sides
using two deviating mirrors. The deviating mirrors must be positioned at an angle of 45° to
the beams from the safety light grid.
When using deviating mirrors, please note:
}Even a minor angular displacement of the mirror can lead to misalignment, adversely
affecting or preventing the function of the safety light grid.
}The minimum safety distance to the dander zone must be maintained for all sections of
the light path.
}Use of a single deviating mirror reduces the operating range by about 20%. This per-
centage increases when an additional deviating mirror is used (more detailed informa-
tion is provided in the technical data for the relevant mirror). Please consider this reduc-
tion when positioning the safety light grid.

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}The height of the deviating mirror must be at least 100mm greater than the protected
field height of the safety light grid.
}You should not use more than one mirror per device.
}Any dust or dirt on the mirror’s reflective surface will drastically reduce the operating
range.
Number of mirrors per device
Maximum operating range [ 44] in
m
1 4.8 m
Cascaded safety light grid
Minimum distance for cascaded safety light grids
When safety light grids are cascaded with two slave units, be sure to maintain the minimum
distance between the master unit and slave unit 2.
Width of the protected field Minimum distance
< 3 m 263 mm
> 3 m see Minimum distance between parallel,
aligned safety light grids [ 18]
Resolution for cascaded safety light grids
When safety light grids are cascaded, the resolution may vary from that stated in the tech-
nical details, depending on the brackets used for installation.
Installation using C-brackets
[2]
[1]
Legend
[1] Unchanged resolution of 14 mm at the ends of the safety light grid
[2] C-brackets