Pilz PSEN opII3B Series User manual

PSEN opII3B Series
Operating Manual-1004845-EN-04
}PSEN sensor technology

Preface
This document is the original document.
Where unavoidable, for reasons of readability, the masculine form has been selected when
formulating this document. We do assure you that all persons are regarded without discrim-
ination and on an equal basis.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion 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

Contents
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1 Introduction ............................................................................................................................6
1.1 Validity of documentation.......................................................................................................... 6
1.2 Using the documentation .......................................................................................................... 6
1.3 Definition of symbols................................................................................................................. 6
2 Overview .................................................................................................................................8
2.1 Unit view ................................................................................................................................... 10
2.2 Scope of supply ........................................................................................................................ 11
3 Safety ...................................................................................................................................... 12
3.1 Intended use ............................................................................................................................. 12
3.2 Safety regulations ..................................................................................................................... 13
3.2.1 Safety assessment ................................................................................................................... 13
3.2.2 Use of qualified personnel ........................................................................................................ 13
3.2.3 Warranty and liability ................................................................................................................ 14
3.2.4 Disposal .................................................................................................................................... 14
4 Function description ............................................................................................................. 15
4.1 Basic function ........................................................................................................................... 15
4.2 Automatic start and restart........................................................................................................ 16
4.3 Operation of two safety light curtains with the same alignment................................................ 17
5 Project configuration ............................................................................................................. 18
5.1 Maintaining the safety distance ................................................................................................ 18
5.2 Prevent reaching across a vertical protected field .................................................................... 19
5.3 Prevent creeping underneath and stepping over...................................................................... 20
5.4 Resolution................................................................................................................................. 23
5.5 Protected field perimeters......................................................................................................... 23
5.6 Ambient conditions ................................................................................................................... 23
5.7 Distance from reflective surfaces.............................................................................................. 24
5.8 Minimum distance between parallel, aligned safety light curtains ............................................ 27
5.9 Installation of several adjacent safety light grids ...................................................................... 29
5.10 Use of deviating mirrors............................................................................................................ 30
6 Installation and alignment .................................................................................................... 32
6.1 Attach the safety light curtain to the mounting surface ............................................................. 33
6.2 Orientation ................................................................................................................................ 36
6.2.1 General guidelines.................................................................................................................... 36
6.2.2 Safety light curtain alignment.................................................................................................... 37
7 Wiring ......................................................................................................................................39
7.1 General guidelines.................................................................................................................... 39
7.2 Connector pin assignment ........................................................................................................ 40
7.3 Support with wiring ................................................................................................................... 41
8 Commissioning ......................................................................................................................43
8.1 System connection ................................................................................................................... 43
8.2 Checking the safety light curtain............................................................................................... 45

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9 Operation ................................................................................................................................48
9.1 Display elements ...................................................................................................................... 48
9.2 Status information..................................................................................................................... 49
9.3 Safety light grid restart.............................................................................................................. 51
9.4 Malfunction ............................................................................................................................... 51
10 Regular checks and maintenance ........................................................................................ 52
10.1 Checks...................................................................................................................................... 52
10.1.1 Regular check........................................................................................................................... 52
10.1.2 Checking of safety light curtains with beam coding .................................................................. 52
10.1.3 Check after plant/machine modification.................................................................................... 54
10.2 Maintenance ............................................................................................................................. 54
11 Dimensions ............................................................................................................................55
12 Technical details Order no. 632100-632102 ........................................................................ 56
13 Technical details Order no. 632103-632105 ........................................................................ 59
14 Technical details Order no. 632110-632112 ........................................................................ 62
15 Technical details Order no. 632113-632115 ........................................................................ 65
16 Classification according to ZVEI, CB24I .............................................................................. 68
17 Safety characteristic data ..................................................................................................... 69
18 Order reference ......................................................................................................................70
18.1 Order reference for safety light curtains ................................................................................... 70
18.2 Order reference for accessories ............................................................................................... 71
18.2.1 Mirror column set ...................................................................................................................... 73
18.2.2 Mirror columns .......................................................................................................................... 74
18.2.3 Protective column sets.............................................................................................................. 74
18.2.4 Protective columns ................................................................................................................... 74
18.2.5 Muting accessories ................................................................................................................... 75
18.3 Order reference: Component parts........................................................................................... 76
19 Appendix ................................................................................................................................79
19.1 Check list .................................................................................................................................. 79
19.2 Muting applications with safety controller ................................................................................. 82
19.2.1 Introduction ............................................................................................................................... 82
19.2.2 Prerequisites............................................................................................................................. 83
19.2.3 Wiring........................................................................................................................................ 84
19.2.4 Cross muting............................................................................................................................. 84
19.2.5 L-muting.................................................................................................................................... 86
19.2.6 T-muting (sequential muting) .................................................................................................... 87
19.2.7 Override .................................................................................................................................... 89

Contents
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20 EC declaration of conformity ................................................................................................ 90
21 UKCA-Declaration of Conformity ......................................................................................... 91

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSEN opII3B Series from Version 4.0. It is valid
until new documentation 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
Safety light curtains in the PSEN opII3B Series constitute electrosensitive protective equip-
ment (ESPE type: 3) in accordance with IEC 61496-1 and IEC 61496-2 (AOPD) for work-
spaces in which machines, robots, and automated systems might pose a physical danger to
their operators.
Unit features
}Operating range
– 0.2 - 15 m with resolution 170 mm
– 10 - 55 m with resolution 300 mm
}Infrared protected field is generated
}LED indicator for status information
}Optical synchronisation of transmitters and receivers
}Beam coding A and B for greater insensitivity (see Installing several safety light curtains
in parallel [ 29])
– to stray light and short-term interruptions of the protected field
– to mutual interference when using two safety light curtains with the same alignment
}Muting applications can be implemented using muting accessories (see Order references
for accessories [ 71]) and an appropriate safety controller.
The implementation of muting applications is described in Muting applications with safety
controller [ 82].
}Connection to evaluation devices
– PDP67 ION and PDP67 ION HP: 5-pin M12 two-sided connector (see Order refer-
ence for accessories, connection to PDP67 [ 72])
– all other suitable evaluation devices (see System connection [ 43]): 5-pin M12
one-sided connector and open cable end connection to clamping sleeves (see Order
reference for accessories, connection to other evaluation devices [ 72])
}Aluminium alloy housing
}Die-cast zinc end caps
}Shock resistance
– Bracket swivel mount: 10g
– Bracket Adv Bracket Kit: 50g
}Front panel of PC

Overview
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}Standard installation kit with flexible bracket (swivel mount) (included in delivery) to hold
the transmitter/receiver
– For standard application
– Transmitter/receiver remains rotatable for proper orientation
}PSENopIIAdvBracketKit (available as an accessory [ 71]) as a bracket for trans-
mitter/receiver
– Transmitter/receiver can be rotated on the bracket for alignment purposes
– Protected field heights of 450mm – 600 mm, including: 1PSENopIIAdvBracketKit2
(= 2clamping units per transmitter and receiver)
– Protected field heights of 750mm – 1200mm, including:
1PSENopIIAdvBracketKit3 (= 3clamping units per transmitter and receiver)
– Protected field heights of 1350mm – 1500mm, including:
2PSENopIIAdvBracketKit2 (= 4clamping units per transmitter and receiver)

Overview
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2.1 Unit view
ReceiverTransmitter
[1]
[2] [2]
[3] [3]
[4] [4]
[5]
[5]
Fig.: Front view of the safety light curtain transmitter and receiver, protected field height 450‑1500
mm with connection cable and installation kit
Legend
[1] Overall length
[2] Tinted front panel
[3] LEDs for status information

Overview
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[4] Connection cable M12 connector
[5] Optical centre axis
2.2 Scope of supply
Qty Description Illustration
1 Transmitter
1 Receiver
4 Standard installation kit
consisting of:
4}Flexible bracket (swivel
mount) in which trans-
mitters/receivers can
be fastened and ro-
tated to the proper ori-
entation
4}Holder for connecting
the transmitter/receiver
end caps to the flexible
bracket
16 }Tightening screw
M3x33.4 oval-head
screw, self-tapping
4}Clamping screw with
nut
ISO4762 M4x10 8.8
cylinder screw with nut
8}Mounting screw
ISO4762 M6x20 8.8
cylinder screw with
washer

Safety
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3 Safety
3.1 Intended use
Safety light curtains in the PSEN opII3B Series are electrosensitive protective equipment of
the ESPE type 3. They are used to protect personnel and systems. The safety light curtains
are designed to
}Secure danger zones within buildings and
}Secure access within buildings with the following resolution:
– 170 mm at a range of 0.2 - 15 m
– 300 mm at a range of 10 - 55 m
The safety light curtain may only be used for personal protection on machinery if
}The safety light curtain can stop the hazardous state and
}The safety light curtain controls the machine start-up and
}The safety assessment does not specify a better resolution than that stated in the Tech-
nical details [ 56].
The safety level PL d (Cat. 3)/SIL CL 2 is only achieved if
}The safety outputs must be processed safety-related in 2-channel mode.
The safety light curtain 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 or an accessory. For the implementation
with an accessory Pilz recommends that you use the accessory PSENopIIlockout (see Or-
der reference for accessories [ 71]). The system may not be started in the danger zone
following a protection violation if personnel are still in the danger zone.
Prevent circumvention of the protected field. This means that other safety devices and safe-
guards may be required in addition to the safety light curtain . 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 danger
zone.
Their application must fulfil the site’s relevant national regulations (e.g.EN60204-1,
NFPA79:17-7).
Improper use
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 operating manual,
}Use of the product outside the technical details (see Technical details [ 56]).

Safety
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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.
3.2 Safety regulations
3.2.1 Safety assessment
Before using a device, a safety assessment in accordance with the Machinery Directive is
required.
The product as an individual component fulfils the functional safety requirements in accord-
ance with EN ISO 13849 and EN 62061. However, this does not guarantee the functional
safety of the overall plant/machine. To achieve the relevant safety level of the overall plant/
machine’s required safety functions, each safety function needs to be considered separ-
ately.
3.2.2 Use of qualified personnel
The products may only be assembled, installed, programmed, commissioned, operated,
maintained and decommissioned by persons who are competent to do so.
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 prevention,
}Have read and understood the information provided in the section entitled Safety
}Have a good knowledge of the generic and specialist standards applicable to the specific
application.

Safety
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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-related
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 curtain 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 details,
environmental data section [ 56]).
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.
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 covered by the safety light curtain (170mm or
300mm, see Technical details [ 56]),
}A fault is detected in the safety light curtain,
}Stray light is detected.
If a fault occurs, the OSSDs remain in the OFF state. The state can be returned to the ON
state only after a successful restart [ 51] of the safety light grid.
The safety light grid in the PSEN opII3B Series offers the following functions:
}Automatic start
}automatic restart
}Operation of 2 safety light grids that are parallel to one another and are installed with the
same orientation (noting the information in ambient conditions [ 27] and minimum
separation of parallel, aligned safety light grids [ 27])
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 curtain and any error state is
provided by means of LEDs.
The indicators are described in the section: Status information [ 49].

Function description
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4.2 Automatic start and restart
Automatic start
When the safety light curtain is switched on the safety light curtain starts automatically and
the OSSDs switch to the ON state under the following conditions:
}Both OSSDs are wired correctly and
}No fault has occurred and
}The protected field is clear.
If the protected field is violated, the OSSDs switch to the OFF state.
Automatic restart
The OSSDs automatically switch to the ON state during operation under the following con-
ditions:
}Both OSSDs are wired correctly and
}No fault has occurred and
}the protected field is clear and
}at least 80 ms have elapsed since the switch to the OFF state.
[1] [2] [3] [4] [5]
POWER
OSSD
2 3
4
[6]
t1tt
t
Interrupted
Free
Protected field
OFF
ON
ON
OFF
Fig.: Automatic start and restart timing diagram
Legend
[1] Safety light curtain is switched on
[2] Check completed successfully, OSSDs in the ON state
[3] Protected field broken
[4] OSSDs in the OFF state

Function description
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[5] Protected field is clear again, fault check is restarted
[6] OSSDs in the ON state
t1Check is begun to determine whether the protected field is clear and whether
there are faults
t2Response time (coded/uncoded), until OSSDs switch to the OFF state (see
Technical details [ 56])
t3Minimum time that the OSSDs remain in the OFF state: 80ms
t4Time between the protected field being enabled and the OSSDs changing to
the ON state
}Without beam coding
– If a synchronisation beam pair is interrupted: Response time+10ms
– If both synchronisation beam pairs (first and last light beam pair) are in-
terrupted: see uncoded resynchronisation time in the technical details
}With beam coding
– If a synchronisation beam pair is interrupted: Response time (with beam
coding) +10ms
– If both synchronisation beam pairs (first and last light beam pair) are in-
terrupted: see coded resynchronisation time in the technical details
4.3 Operation of two safety light curtains with the same
alignment
Two adjacent safety light curtains with the same alignment can be operated, without the
two safety light curtains influencing each other (see Minimum distance between parallel,
aligned safety light curtains [ 27]).
For the correct function of the two safety light curtains, a beam coding of the safety light
curtains is required. The beam coding is performed via the connection of the safety light
curtain to the supply voltage (see Connector pin assignment [ 40]).

Project configuration
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5 Project configuration
5.1 Maintaining the safety distance
The minimum distance of the safety light curtain to the dangerous machine component
should be such that the operator cannot reach the danger zone until the movement of the
dangerous machine part has stopped.
In accordance with the standard
}ENISO13855
this distance depends on three factors:
}Response time of the safety light curtain
Time between the beams being interrupted and the OSSDs changing to the OFF state
(see Technical details [ 56])
When beam coding is used, the response time is increased (see Technical Details)
}Machine's stopping time
Time between the OSSDs changing to the OFF state and the hazardous machine move-
ment stopping (including the reaction time of the connected relay)
}Approach speed
The speed with which the object to be detected is nearing the danger zone in mm/s
NOTICE
Increase in safety light curtain's response time
When beam coding is used, the response time is increased (see Technical
Details)
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 danger zone in
mm/s
K = 1600 mm/s
t1Response time of the safety light curtain in seconds
Time it takes for the signal at the OSSD output on the safety light curtain to change
once a protected field has been violated (see Technical details [ 56])
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 850 mm for safety light curtains with body protection

Project configuration
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5.2 Prevent reaching across a vertical protected field
If the possibility of someone reaching across a vertical protected field is present, the min-
imum distance in mm in accordance with ENISO13855 between the protected field and
the danger zone must not be less than the value calculated to the following equation.
S = K * (t1 + t2) + CRO
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 danger zone in
mm/s
K = 1600 mm/s
t1Response time of the safety light curtain in seconds
Time it takes for the signal at the OSSD output on the safety light curtain to change
once a protected field has been violated (see Technical details [ 56])
t2Machine's stopping time in seconds
The time required for the machine to stop after the signal at the OSSD output
changes
CRO Additional distance where a body part can move in the direction of the danger zone
before the safety light curtain’s OSSD triggers
Height of the danger zone Height of the top edge of the protected field’s safety
light curtain
900 1200 1500
2600a0 0 0
2500 400 300 300
2400 550 500 450
2200 800 700 650
2000 950 850 750
1800 1100 950 800
1600 1150 1000 850
1400 1200 1000 850
1200 1200 1000 800
1000 1200 950 700
800 1150 800 450
600 1050 550 0
400 900 0 0
200 600 0 0
Distance CRO when reaching over a vertical protected field

Project configuration
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Application example:
}Height of the danger zone = 1400 mm
}Height of the top edge of the safety light curtain’s protected field = 1200 mm
This results in the distance CRO as an allowance = 1000 mm
Note:
}If various values result when determining the safety distance to these formulas, the
higher value has to be used.
General formula to ENISO13855 S = K * (t1 + t2) + C
Prevent reaching across a vertical protected
field in accordance with ENISO13855
S = K * (t1 + t2) + CRO
5.3 Prevent creeping underneath and stepping over
To prevent anyone crawling underneath in accordance with ENISO13855, the distance
from the reference plane (the floor, for example) to the lowest beam must be max. 300 mm.
The uppermost beam must be at a distance of at least 900mm from the reference plane
(the floor, for example).
Determine the height for a safety light curtain of the PSEN opII3B Series with a
resolution of 170mm (range 15m)
The bottom edge of the safety light curtain must be at the height of 226mm as a maximum.
The height of the lowest beam is then ≤300mm and creeping underneath the protected
field is prevented.
The top edge of the safety light curtain must be at least at the height of 990mm.
The height of the uppermost beam is then ≥900mm and stepping over the protected field
is prevented.
If a risk assessment permits a distance from the reference plane of 400mm, the required
protected field height of the safety light curtain may be reduced to 750mm.