Pilz PSEN op2H-A Series User manual

PSEN op2H-A series
Operating Manual-1003069-EN-03
Safety light curtain

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

1GENERAL INFORMATION .........................................................5
1.1 General description................................................................................................. 5
1.1.1 General description of the safety light curtain.......................................................... 5
1.1.2 Package content ..................................................................................................... 6
1.2 Guidelines for selecting the protective device ......................................................... 7
1.2.1 Resolution............................................................................................................... 7
1.2.2 Height of protected field .......................................................................................... 8
1.2.3 Minimum safety distance ........................................................................................ 9
1.3 Typical application areas .......................................................................................12
1.4 Safety information..................................................................................................13
2INSTALLATION ........................................................................14
2.1 Precautions to be taken during selection and installation of a light curtain .............14
2.2 General information on positioning the device........................................................15
2.2.1 Minimum distance from reflective surfaces ............................................................16
2.2.2 Distances between identical light curtains..............................................................17
2.2.3 Aligning transmitter and receiver............................................................................20
2.2.4 Using deviating mirrors ..........................................................................................20
2.2.5 Inspections following a first-time installation...........................................................21
3MECHANICAL ASSEMBLY......................................................23
4ELECTRICAL CONNECTIONS.................................................25
4.1 Connection guidelines............................................................................................27
5ALIGNMENT .............................................................................30
6SETTING THE FUNCTIONS .....................................................32
6.1 Reset to factory configuration ................................................................................33
6.2 Function list ...........................................................................................................33
7FUNCTIONS.............................................................................. 35
7.1 Restart function......................................................................................................35
7.2 Test .......................................................................................................................37
7.3 Reset .....................................................................................................................38
7.4 EDM ......................................................................................................................38
7.5 EDM selection........................................................................................................39
7.6 Reduced range ......................................................................................................40
7.7 Muting....................................................................................................................40
7.7.1 Disabling the muting function .................................................................................41
7.7.2 Muting display devices...........................................................................................41
7.7.3 Typical muting application and sensor connection .................................................42
7.7.4 Muting direction .....................................................................................................42
7.7.5 Muting timeout .......................................................................................................46
7.7.6 Partial muting.........................................................................................................47
7.8 Override.................................................................................................................47
7.8.1 Override mode .......................................................................................................48
8DIAGNOSTICS.......................................................................... 50
8.1 Status of LEDs.......................................................................................................50
9REGULAR CHECKS AND MAINTENANCE .............................53
9.1 Regular checks ......................................................................................................53
9.2 Maintenance ..........................................................................................................53

10 TECHNICAL DETAILS..............................................................54
11 LIST OF AVAILABLE MODELS ...............................................55
12 DIMENSIONS............................................................................56
13 FITTINGS ..................................................................................57
14 ACCESSORIES ........................................................................59
14.1 Rotating Mounting Bracket.....................................................................................59
14.2 Connection cable ...................................................................................................60
14.3 Axial connection cable, unshielded ........................................................................61

OPERATING MANUAL PSEN op2H-A series
1 GENERAL INFORMATION
1.1 General description
1.1.1 General description of the safety light curtain
The safety light curtains in the PSEN op2H-A series are multibeam active optoelectronic
protective devices for work areas in which machines, robots and automated plants in general
could endanger the physical integrity of operators who could come into contact with moving
parts, even if only by chance.
Light curtains in the PSEN op2H-A series are designed as inherently safe Type 2 systems for
accident prevention in accordance with applicable international safety standards, in particular
the following:
IEC 61496-1:2004 Safety of machinery: Electrosensitive protective equipment. Part 1:
General requirements and tests.
IEC 61496-2: 2006 Safety of machinery: Electrosensitive protective equipment –
Particular requirements for equipment using active optoelectronic protective devices.
A light curtain pair consists of a transmitter and a receiver. They produce an infrared
protected field, which is able to detect an opaque object within the specific resolution. Both
the transmitter and the receiver have control and monitoring functions. The connections are
made via an M12 connector, which is located in the lower profile area. 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 a microprocessor, which provides the user with information about the operating
state of the light curtain via LED indicators (see Chapter 8).
A light curtain pair consists of 2 units, which may comprise one or more transmitter and
receiver modules, depending on the respective model. The receiver is the main control unit
for all functions. If an error occurs, it checks all the safety actions and decides on the
measures that are to be implemented in terms of safety, as well as performing other general
functions.
During the installation phase the user interface makes it easier to align the two units (see
Chapter 5).
As soon as the beams emitted from the transmitter are interrupted by an object, a limb or the
body of an operator, both output signal switching devices (OSSD) are opened immediately.
This controls the stopping of the corresponding machine, which is connected to the OSSD.
Some parts or paragraphs of this manual, which are of particular importance to the user or
installation engineer, are highlighted as follows:
The information contained in paragraphs marked by this symbol is
particularly relev
ant to safety and is important for accident
prevention.
This information must be read with particular attention and must be
strictly observed.
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OPERATING MANUAL PSEN op2H-A series
This manual contains all the information you need to select and operate the protective
devices.
Specialised knowledge of safety issues is required to integrate a safety light curtain correctly
in a plant.
PILZ’s technical customer service team is available to provide any information you need
regarding the functionality of the PSEN op2H-A safety light curtains and the safety
regulations concerning correct installation.
1.1.2 Package content
The following components are included:
•Receiver (RX)
•Transmitter (TX)
•Shortform for installing the safety light curtains in the PSEN op2H-A series
•CD with operating manual and other documents
•4 fastening brackets and corresponding mounting accessories
•2 fastening brackets for models with a height between 1200 and 1800 mm
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OPERATING MANUAL PSEN op2H-A series
1.2 Guidelines for selecting the protective device
Once the hazards have been assessed appropriately, there are at least three essential
features to consider when selecting a safety light curtain:
1.2.1 Resolution
The device’s resolution is understood to be the minimum size that an opaque object must be
to safely interrupt at least one of the beams that form the area of the protected field.
The resolution is closely linked to the part of the body that requires protection.
R = 30 mm Hand protection
As shown in Fig. 1, the resolution depends solely on the geometric properties of the lenses,
the diameter and the distance and so is unaffected by the light curtain’s ambient and
operating conditions.
Fig. 1– Resolution
1
=
Opaque object
2
=
Height of protected
field
3
=
Operating range
The resolution value can be calculated using the following formula:
R = I + d
where:
I = Distance between two adjacent lenses
d = Lens diameter
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OPERATING MANUAL PSEN op2H-A series
1.2.2 Height of protected field
The height of the protected field is understood to be the height protected by the safety light
curtain.
Fig. 2 – Height of protected field
1
=
Protected field
2
=
Height of protected
field
3
=
Operating range
The height monitored by the PSEN op2H-A corresponds to the overall height of the light
curtain.
With reference to the previous diagram, the height of the protected field can be taken from
the table below.
Model
Height of protected field
(mm)
PSEN op2H-A-30-030/1 300
PSEN op2H-A-30-045/1 450
PSEN op2H-A-30-060/1 600
PSEN op2H-A-30-075/1 750
PSEN op2H-A-30-090/1 900
PSEN op2H-A-30-105/1 1050
PSEN op2H-A-30-120/1 1200
PSEN op2H-A-30-135/1 1350
PSEN op2H-A-30-150/1 1500
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OPERATING MANUAL PSEN op2H-A series
PSEN op2H-A-30-165/1 1650
PSEN op2H-A-30-180/1 1800
1.2.3 Minimum safety distance
The protective device must be positioned at a specific safety distance (Fig. 3), which
guarantees that the operator cannot reach the danger zone until the hazardous machine
movement has come to a standstill by triggering the light curtain.
In accordance with the standard ISO 13855, this distance depends on 4 factors:
•Response time of the light curtain (the time that elapses between the beams being
effectively interrupted and the OSSD contacts opening).
•Machine’s stopping performance (time that elapses between the light curtain contacts
opening and the hazardous machine movement effectively stopping).
•Light curtain’s resolution
•Approach speed of the object to be detected.
Fig. 3 – Safety distance (vertical)
H1
=
≥900 mm at a resolution > 40 mm
H2
=
≤300 mm at a resolution > 40 mm
S
=
Minimum safety distance in mm
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OPERATING MANUAL PSEN op2H-A series
The safety distance is calculated using the following formula:
S = K (t1 + t2) + C
Therefore:
S
Minimum safety distance in mm
K
Speed of the object (limb or body) approaching the danger zone in mm/s
t1
Light curtain’s response time in seconds (see Chapter 11)
t2
Machine’s stopping performance in seconds
C
Additional distance based on the possibility of placing the body or limb into the danger
zone before the protective device responds
C
8 (d -14) for devices with a resolution ≤ 40 mm
C
850 mm for devices with a resolution > 40 mm
d
Device’s resolution
Note:
The value K corresponds to:
•2000 mm/s, if the calculated value S is ≤ 500 mm
•1600 mm/s, if the calculated value S is > 500 mm
When using light curtains with a resolution of > 40 mm, the upper beam must be positioned
at a height of ≥ 900 mm (H2) from the supporting base, while the lower beam must be
positioned at a height of ≤ 300 mm (H1).
Where the light curtain must be installed horizontally (Fig. 4), the distance between the
danger zone and the most distant optical beam must correspond to the value calculated
using the following formula:
S = 1600 mm/s (t1 + t2) + 1200 – 0.4 H
Therefore:
S
Minimum safety distance in mm
t1
Light curtain’s response time in seconds (see Chapter 11)
t2
Machine’s stopping performance in seconds
H
Height of the beams above the floor. This height must always be less than 1000 mm.
Fig. 4 – Safety distance (horizontal)
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OPERATING MANUAL PSEN op2H-A series
Application examples
This example is based on a light curtain with a height = 600 mm.
To calculate the distance of the device from the light curtain in a vertical position, the
following formula is applied:
S = K*T + C
Therefore:
T = t1+ t2
t1= Response time of light curtain + release time of relay (specific time of PNOZ S3: 20ms)
With a reaction time of the light curtain of 15 ms the result is a max. of 35 ms for t1
t2= Machine’s overall stopping performance in seconds
C = 8 * (d – 14) for devices with resolution <= 40 mm
D = Resolution
In each case, if K = 2000 mm/sec, then S > 500 mm. The safety distance will then need to be
recalculated, based on K = 1600 mm/sec.
WARNING: In this case the reference standard is EN ISO 13855
“Safety of machinery –
Positioning of protective equipment in
respect of approach speeds of parts of the human body”.
The information provided here should be regarded as a summary
and is non-binding. Please refer to the complete standard ISO
13855 for details of how to calculate safety distances correctly.
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OPERATING MANUAL PSEN op2H-A series
1.3 Typical application areas
Example 1: Protecting the operating area on drilling machines
The operator inserts the workpiece and removes it after
machining. The operator must be protected from injury
during the machining process.
Solution: The safety light curtain PSEN op2H-A is
particularly suitable for this application, as the device
needs to be installed directly on the machine.
Benefits: The small dimensions of the light curtain
guarantee maximum flexibility during installation, as it
can be adapted to the machine dimensions.
Rotatable mounting brackets are included,
guaranteeing fast, simple attachment.
Example 2: Bending presses
The safety device must protect the bending
process operator from the crushing hazard
that exists between the upper and lower tool
or from the workpiece that is being
machined, if this approaches at high speed.
Solution:Even if just one light axis on the
safety light curtain PSEN op2H-A is
interrupted during the downward phase, the
movable workpiece carrier is stopped
immediately.
Benefits: The simple installation options and the small dimensions of the safety light curtain
mean it can be used in most bending operations. PSEN op2H-A not only guarantees a high
level of reliability but also increases production on the plant, as the standstill times needed
for access, settings and machine maintenance can be reduced.
Example 3: Paper cutting machine
A typical application for these protective devices is on paper cutting machinery for magazines
and special formats. The purpose of the light
curtain is to protect the operator from cuts or
abrasions from the cutting machine.
Solution:The safety light curtain PSEN
op2H-A is particularly suitable for this
application, as the device needs to be
installed directly on the machine.
Benefits: The small dimensions of the light
curtain and the guide rails at either end
guarantee maximum flexibility, as they can
be adapted to the machine’s mechanical
dimensions.
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OPERATING MANUAL PSEN op2H-A series
Example 4: Moulding machine
The moulding machine is used to create
complex shapes from metallic parts or parts
made from other materials. In this case it is
necessary to prevent the operator’s hands or
other limbs being dragged, entangled or cut
by the tool itself or being injured by the
spindle.
Solution:The safety light curtain from the
PSEN op2H-A series is the best solution for
protecting the operator in terms of the required safety level and the application type. As soon
as even a single beam on the light curtain is interrupted, the machine is stopped
immediately.
Benefits: The small dimensions of the light curtain with no dead zones guarantees maximum
flexibility during installation, as it can be adapted to the machine dimensions.
1.4 Safety information
To use the safety light curtains in the PSEN op2H-A series safely
and correctly, the following information must be considered:
•The system intended to stop the machine must be electrically controllable.
•This control system must be able to stop hazardous machine movements
- inside the overall stopping performance of the machine T,
- in accordance with the details in Chapter 1.2.3 of the operating manual (see CD provided)
- and in each phase of the processing cycle.
•The protective device must be positioned at a distance that exceeds the minimum safety
distance S or that corresponds to it, which guarantees that the operator cannot reach the
danger zone until the hazardous machine movement of the object has come to a standstill by
triggering the light curtain.
•The safety light curtains may only be installed and connected by qualified personnel. It is
essential to follow the instructions provided in the relevant sections of the manuals provided
(see Chapters 2, 3, 4 and 5) and to comply with the applicable directives.
•Ensure that the correct operation of the light curtain is not disturbed by strong electromagnetic
interference.
•Avoid installing the light curtain, particularly the receiver, close to particularly intense and/or
flashing light sources.
•The safety light curtain must be positioned so that it safely prevents access to the danger zone
without interrupting the beams (see Chapters 2, 3).
•Only qualified personnel with appropriate knowledge of all the operating procedures of the
safety light curtain should be permitted to work within the danger zone.
•The RESET button must be positioned outside the area of the protected field and in such a
way that the operator can see into the danger zone when carrying out a reset and test
procedure.
•Reflective surfaces close to the beams emitted from the protective device (whether from
above, below or from the side) can cause passive reflections that adversely affect the
operation of the light curtain.
The instructions provided for correct operation must be strictly followed before switching on
the light curtain.
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OPERATING MANUAL PSEN op2H-A series
2 INSTALLATION
2.1 Precautions to be taken during selection and installation of a light
curtain
Ensure that the safety level guaranteed by the PSEN op2H-A
(Type 2) complies with the actual risk assessment of the machine
to be monitored, as well as the leve
l defined by the standard
EN 13849.
Ensure that the light curtain’s outputs (OSSD) are used as
machine stopping devices and not as control devices. The
machine must have a separate START control.
Ensure that the correct operation of the light curtain is not
disturbed by strong electromagnetic interference.
Ensure that the light curtain, particularly the receiver, is not
installed close to particularly intense and/or flashing light sources.
•The size of the smallest object to be detected must be greater than the device’s
resolution.
•The light curtain must be installed in an environment that complies with the technical
properties stated in Chapter 11.
•Smoke, mist or dust in the working environment can reduce the operating range of the
protective device.
•Sudden, large-scale temperature variations, particularly with low temperatures can
generate a slight layer of condensation on the device’s lens, adversely affecting its
function.
•Reflective surfaces close to the beams emitted from the protective device (whether from
above, below or from the side) can cause passive reflections that adversely affect the
operation of the light curtain.
•The protective device must be positioned at a distance that exceeds the minimum safety
distance S or that corresponds to it, which guarantees that the operator cannot reach the
danger zone until the hazardous machine movement of the object has come to a
standstill by triggering the light curtain.
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OPERATING MANUAL PSEN op2H-A series
2.2 General information on positioning the device
Special care should be taken when positioning the safety light curtain to ensure it provides
efficient protection. The device must be installed so that the danger zone cannot be
accessed without interrupting the protected field.
Fig. 5 shows some possibilities for accessing the machine from above
and below. Situations like this could turn out to be extremely dangerous.
For this reason, the safety light curtain must be installed at a height from
which access to the danger zone can be covered in full (Fig. 6).
Fig. 5 – Device positioned incorrectly
Fig. 6 – Device positioned correctly
Under normal operating conditions, the machine may only be started if the operator is
outside the danger zone.
If it is impossible to install the light curtain in the immediate vicinity of the danger zone, the
possibility of access from the side must be excluded, for example, by installing a second
horizontal light curtain. See Fig. 8.
If the operator is able to enter the danger zone, additional
mechanical protection must be installed to exclude access.
NO
YES
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OPERATING MANUAL PSEN op2H-A series
Fig. 7
Fig. 8
2.2.1 Minimum distance from reflective surfaces
Reflective surfaces close to the beams emitted from the protective device (whether from
above, below or from the side) can cause passive reflections. These passive reflections can
adversely affect how the object is detected within the protected area. If the receiver RX
detects a secondary beam (reflected by the side-reflecting surface), the object may not be
detected even if it interrupts the main beam.
DANGER ZONE
Reflective surface
Reflective surface
Fig. 9 Minimum distance from reflective surfaces
When installing the safety light curtain it is important to maintain a minimum distance from
reflective surfaces.
NO
YES
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OPERATING MANUAL PSEN op2H-A series
This minimum distance depends on the following factors:
•The distance between the transmitter (TX) and receiver (RX)
•The actual opening angle of the light curtain; in particular:
when Type 2 light curtain = 10° (α= ± 5°)
The illustration in Fig. 10 shows the minimum distance from the reflective surface (Dsr) based
on the operating range:
Fig. 10
Formula for calculating Dsr:
Dsr (m)
=
0.15
With operating ranges < than 3 m
D
sr
(m)
=
0.5 x operating range (m) x
tg 2
α
With operating ranges ≥than 3 m
2.2.2 Distances between identical light curtains
Should it be necessary to install several protective devices in adjacent areas, care must be
taken to ensure that the transmitter on one of the pairs does not dangerously interfere with
the receiver on another pair.
The interfering transmitter, TX B, must be installed outside the minimum distance Ddo from
the TX A - RX A axis of the transmitter/receiver pair.
Fig. 11 – Distance between devices of the same type
This minimum distance Ddo depends on the following factors:
•The distance between the transmitter (TX A) and receiver (RX A);
•The actual opening angle of the light curtain.
Light
curtain
Type 2
Operating range
Distance from
reflective surface
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OPERATING MANUAL PSEN op2H-A series
The following graphic shows the distance from the interfering devices (Ddo), based on the
operating range (Dop) of the pair (TX A – RX A).
Fig. 12
For the purpose of simplification, the table below states the values of the minimum safety
distances required for installation, with reference to some operating ranges.
Operating range
(m)
Minimum safety distance
(m)
3
0.3
6
0.4
10
0.5
19
0.6
WARNING: The interfering transmitter (TX B) must be positioned at
the same distance Ddo , as calculated above,
even if the distance
from the other transmitter TX A is shorter than from the receiver
RX A.
Reichweite
Operating range
Distance between two
devices of the same type
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OPERATING MANUAL PSEN op2H-A series
Fig. 13 shows an example of an installation in which interference may occur, along with two
potential remedies.
Opaque partition
Fig. 13 – Interference between adjacent light curtains
NO
YES
YES
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OPERATING MANUAL PSEN op2H-A series
2.2.3 Aligning transmitter and receiver
The light curtain pair must be arranged in parallel to each other. Transmitter and receiver
have connections underneath. Both units must be installed at the same time.
Make sure that the light curtains are not configured as shown in Fig. 14.
Fig. 14 – Light curtain alignment
2.2.4 Using deviating mirrors
If a single safety device is used, danger zones with different but adjacent access sides can
be monitored using well-positioned deviating mirrors.
Fig. 15 shows a possible solution, which can be used to protect three access sides using two
mirrors. The deviating mirrors should be positioned at a 45° angle to the light axes.
Fig. 15- Using deviating mirrors
When deviating mirrors are used, the following precautions must be taken and conditions
considered:
•When deviating mirrors are used, the alignment of the transmitters and receivers
requires higher precision. Perfect alignment can be lost even with only a minor angular
displacement of the mirror. In this case we recommend you use the laser pointer, which
is available as an accessory.
•The minimum safety distance (S) must be maintained for all sections of the beam.
•Use of a single deviating mirror reduces the effective operating range by about 15%.
This percentage increases when two or more deviating mirrors are used (more detailed
information is provided in the technical specifications for the relevant mirror).
NO
NO
Mirror
Mirror
DANGER
ZONE
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