Pilz PSEN op2B/1 Series User manual

PSEN op2B/1 Series
Operating Manual-1003357-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 8
2.3 Types 9
2.3.1 Safety light grid without integrated muting sensors 9
2.3.2 Expansion for muting in one direction 9
2.3.3 Expansion for muting in two directions 10
2.4 Scope 10
Section 3 Safety 11
3.1 Intended use 11
3.2 Safety regulations 11
3.2.1 Safety assessment 11
3.2.2 Use of qualified personnel 12
3.2.3 Warranty and liability 12
3.2.4 Disposal 12
Section 4 Function description 13
4.1 Basic function 13
4.1.1 Function settings when delivered 14
4.2 Restart after unit is triggered 14
4.3 Reset function 15
4.4 EDM 16
4.5 Muting 17
4.5.1 Technical implementation 19
4.5.2 Time monitoring - Timeout 22
4.6 Override 23
4.7 Test function 24
4.8 Convert type without muting set to L/T-type 25
Section 5 Project configuration 26
5.1 Maintaining the safety distance 26
5.2 Ambient conditions 26
5.3 Distance from reflective surfaces 27
5.4 Installation of several adjacent safety light grids 28
5.5 Use of deviating mirrors 29
5.6 Use of the muting function 31
Section 6 Installation and wiring 35
6.1 Attach safety light grid without muting sensors to mounting surface 35
6.2 Conversion of safety light grids without muting sensors 35
6.3 Installation of external muting sensors 36

Content
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6.4 Wiring 37
6.4.1 General guidelines 37
6.4.2 Connector pin assignment 37
6.4.3 TEST/START button 39
6.4.4 EDM 39
6.4.5 Earthing the safety light grid 40
6.4.6 Connections for muting 40
6.4.7 Wiring of external sensors on the safety light grid 41
Section 7 Commissioning 42
7.1 Setting the functions 42
7.1.1 Open DIP switch cover 42
7.1.2 Activate muting 42
7.1.3 Set muting timeout 43
7.1.4 Activate EDM 43
7.1.5 Restart after unit is triggered 43
7.2 Orientation 44
7.2.1 General guidelines 44
7.2.2 Safety light grid alignment 45
7.2.3 Muting sensor alignment 46
7.2.4 LED support during alignment 47
7.3 Checking the safety light grid 47
7.4 System connection 48
Section 8 Operation 49
8.1 Status information during operation 49
8.2 Perform test 50
8.3 Diagnostics and troubleshooting 50
8.3.1 Indicators for fault diagnostics 50
8.3.2 Perform reset 52
Section 9 Regular checks and maintenance 53
9.1 Checks 53
9.1.1 Regular checks 53
9.1.2 Daily check 53
9.1.3 Check after plant/machine modification 53
9.2 Maintenance 53
Section 10 Dimensions 55
Section 11 Technical details 56
11.1 Safety characteristic data 58
Section 12 Order reference 59
12.1 Order reference for safety light grids 59
12.2 Order reference for accessories 59

Content
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Section 13 Attachment 62
13.1 Check list 62

Introduction
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1 Introduction
1.1 Validity of documentation
This documentation is valid for the product PSEN op2B/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 op2B-2-050/1 515 50
PSEN op2B-3-080/1 815 50
PSEN op2B-4-090/1 915 50
PSEN op2B-4-120/1 1215 50
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.
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.
The minimum width of the protected field corresponds to the minimum operating range
stated in the Technical details [ 56].
2.2 Unit features
Safety light grids in the PSEN op2B/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 2
}Safeguards protected fields with body resolution
}Muting
All safety light grids in the PSEN op2B/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

Overview
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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 [ 60]).
[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
2.3.2 Expansion for muting in one direction
Order reference Description
PSEN op2.1 L-Muting Set L-muting sensors to retrofit
PSEN op muting bracket kit Mounting bracket for one muting sensor
PSEN op cable M12 4-p. 0.75m
L-muting
Connection cable for L-muting,
4‑core, shielded

Overview
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2.3.3 Expansion for muting in two directions
Order reference Description
PSEN op2.2 T-Muting Set T-muting sensors to retrofit
PSEN op muting bracket kit Mounting bracket for one muting sensor
PSEN op cableset Connection cable for T-muting,
4‑core, shielded
2.4 Scope
Safety light grid with body resolution, without integrated muting sensors
Order reference Description
PSEN op2B-2-050/1 or
PSEN op2B-3-080/1 or
PSEN op2B-4-090/1 or
PSEN op4B-4-120/1
Safety light grid, consisting of
}Transmitter,
}Receiver
}Mounting kit

Safety
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3 Safety
3.1 Intended use
Safety light grids in the PSEN op2B/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 [ 56]).
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 [ 56].
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 functions
}Timeout muting and
}Muting
can only be used if muting sensors are connected to the safety light grid.
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 [ 49]
}LED support during alignment [ 47]
}Indicators for fault diagnostics

Function description
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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 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 unit is triggered
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 [ 42]).
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.

Function description
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t
24 V
0 V
EDM
Status of OSSD
Normal
operation
Safe
condition
TcT0
Fig.: Timing diagram EDM
Tc ≥ 350ms After the OSSD outputs are switched on, the EDM circuit must open
within 350ms
T0 ≥ 100 ms After the OSSD outputs are switched off, the EDM circuit must close
within 100ms
Use control elements whose dynamics match the times stated at Tc and T0.
The function is controlled via DIP switches 3 and 7 (see Setting the functions [ 42]).
4.5 Muting
If the safety light grid is equipped with separate muting sensors, the muting function can be
used to overwrite the safety light grid during operation, subject to special operating condi-
tions.
}Example of a special operating condition:
– Material is transported into the protected field on a conveyor and the safety light
grid is overridden for the time it takes the material to pass through
Muting proves to be particularly suitable when, under certain operating conditions, an object
is permitted to pass through the danger zone but a person is not.
The following diagrams illustrate application examples for the three product types.

Function description
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A1
B1
A1
B1
Fig.: Muting in one direction: Expansion with L-muting set
A1
B1
A1
B1
A2
B2
A2
B2
Fig.: Muting in two directions: Expansion with T-muting set

Function description
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Fig.: Muting in two directions: Expansion with external muting sensors
CAUTION!
If the safety light grid is in a muting status, the OSSDs continue to be
switched on
The connected machine remains in operation and so represents a potential
hazard.
– Prevent access to the danger zone during muting.
Identification of the conveyed material (pallets, vehicles...) must be guaranteed with all
}Material dimensions and
}Conveyor speeds
that are intended to arise during operation.
Different conveyor speeds in the area of the safety light grid should be prevented.
4.5.1 Technical implementation
The safety light grid has two inputs, Muting1 and Muting2, to activate the muting function.
The muting sensors are connected to these inputs. The muting sensors must be positioned
and installed at a right angle to the receiver and transmitter (see Installation and
wiring [ 35]).
}The muting status occurs
– when the first sensor and the second sensor detect a conveyed material simultan-
eously or
– when the first sensor has detected a conveyed material and the second sensor also
detects it max.4s afterwards.

Function description
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CAUTION!
Transport speed too low
If the transport speed is too low, the conveyed material will not trigger a
muting status.
The transport speed should be selected so that the conveyed material
passes the second sensor within a max. 4 s of it being detected by the first
sensor.
CAUTION!
Ending the muting status
Use a mechanical barrier (see diagram) to prevent access to the danger
zone once muting is ended.
Fig.: Application for muting in one direction - Danger zone is safeguarded once muting is ended
}The muting status is displaying by the muting lamp, which is positioned on the top of
the receiver.
}If the muting lamp is defective, the muting function cannot be activated. Any attempt to
activate the function will immediately trigger the safety light grid and instantly switch off
the OSSD; the muting lamp fault indicator will also light (seeIndicators for fault dia-
gnostics).