Wenglor OPT154 Series User manual

OPT154x
Sensors for Roller Conveyor Systems
Operating Instructions
Translation of the Original Operating Instruction
Subject to change without notice
Available as PDF version only
Status: 27.02.2018
Version: 2.1.0
www.wenglor.com
EN

2Table of Contents
Table of Contents
1. General.....................................................................................................................................................4
1.1 Information Concerning these Instructions ..........................................................................................4
1.2 Explanations of Symbols ......................................................................................................................4
1.3 Limitation of Liability..............................................................................................................................5
1.4 Copyrights.............................................................................................................................................5
2. For Your Safety.........................................................................................................................................6
2.1 Use for Intended Purpose.....................................................................................................................6
2.2 Use for Other than the Intended Purpose.............................................................................................6
2.3 Personnel Qualifications ......................................................................................................................6
2.4 Modification of Products .......................................................................................................................7
2.5 General Safety Precautions ..................................................................................................................7
2.6 Laser/LED Warnings .............................................................................................................................7
2.7 Approvals and protection class ............................................................................................................7
3. Technical Data..........................................................................................................................................8
3.1 Dimensional Drawings ..........................................................................................................................9
3.2 Pin assignment Connection Diagrams ...............................................................................................10
3.3 Complementary Products (see catalog).............................................................................................10
3.4 Layout.................................................................................................................................................. 11
3.5 Control Panel.......................................................................................................................................11
3.6 Scope of Delivery ................................................................................................................................11
4. Transport and Storage...........................................................................................................................12
4.1 Transport .............................................................................................................................................12
4.2 Storage................................................................................................................................................12
5. Installation and Electrical Connection..................................................................................................13
5.1 Installation ...........................................................................................................................................13
5.1.1 Installation with the ZPTX001/3 Quick Mounting System....................................................... 14
5.1.2 Installation with ZPTX002 Mounting Bracket ..........................................................................15
5.1.3 Permissible Object Dimensions ..............................................................................................16
5.2 Electrical Connection ..........................................................................................................................16
5.3 Diagnostics.......................................................................................................................................... 17

3
Sensors for Roller Conveyor Systems
6. Functions................................................................................................................................................19
6.1 Default Settings ...................................................................................................................................19
6.2 Function definition...............................................................................................................................19
6.2.1 Basic Function.........................................................................................................................19
6.2.2 Operating Modes.....................................................................................................................20
6.2.3 Functions .................................................................................................................................22
7. Settings ..................................................................................................................................................25
7.1 Adjusting Switching Distance .............................................................................................................25
7.2 Setting Inputs and Outputs.................................................................................................................25
7.2.1 Input.........................................................................................................................................25
7.2.2 Output...................................................................................................................................... 26
8. NFC interface .........................................................................................................................................27
9. Software .................................................................................................................................................27
9.1 General................................................................................................................................................27
9.2 User Interface ......................................................................................................................................28
10. Maintenance Instructions......................................................................................................................29
11. Proper Disposal .....................................................................................................................................29
12. Appendix ................................................................................................................................................29
12.1 List of Abbreviations............................................................................................................................29
12.2 Change Index, Operating Instructions................................................................................................29
12.3 EU Declaration of Conformity .............................................................................................................29

4General
1. General
1.1 Information Concerning these Instructions
• These instructions apply to the products listed in the technical data.
• They make it possible to use the product safely and efficiently.
• These instructions are an integral part of the product and must be kept on hand for the entire duration of
its service life.
• Local accident prevention regulations and national work safety regulations must be complied with as well.
NOTE!
The operating instructions must be read carefully before using the product and must be
kept on hand for later reference.
1.2 Explanations of Symbols
• Safety precautions and warnings are emphasized by means of symbols and attention-getting words.
• Safe use of the product is only possible if these safety precautions and warnings are adhered to.
The safety precautions and warnings are laid out in accordance with the following principle:
ATTENTION-GETTING WORD
Type and Source of Danger!
Possible consequences in the event that the hazard is disregarded.
• Measures for averting the hazard.
NOTE!
A note draws attention to useful tips and suggestions, as well as information regarding
efficient, error-free use.

5
Sensors for Roller Conveyor Systems
1.3 Limitation of Liability
• The product has been developed in consideration of the current state-of-the-art and applicable standards
and guidelines. Subject to change without notice.
• A valid declaration of conformity can be accessed at www.wenglor.com in the product’s separate
download area.
• wenglor sensoric elektronische Geräte GmbH (hereinafter referred to as “wenglor”) excludes all liability in
the event of:
• Non-compliance with the instructions
• Use of the product for purposes other than those intended
• Use by untrained personnel
• Use of unapproved replacement parts
• Unapproved modification of products
• These operating instructions do not imply any guarantee from wenglor with regard to the described
procedures or specific product characteristics.
• wenglor assumes no liability for printing errors or other inaccuracies contained in these operating
instructions, unless wenglor was verifiably aware of such errors at the point in time at which the operating
instructions were prepared.
1.4 Copyrights
• The contents of these instructions are protected by copyright law.
• All rights are reserved by wenglor.
• Commercial reproduction or any other commercial use of the provided content and information, in
particular graphics and images, is not permitted without previous written consent from wenglor.

6For Your Safety
2. For Your Safety
2.1 Use for Intended Purpose
These sensors are used to detect objects on conveyors and for controlling material flow.
Sensors for Roller Conveyor Systems
These sensors have been specially designed for use in accumulation roller conveyors. Their compact design
allows for installation between rollers below the transport level. High-precision background suppression
makes it possible to reliably detect even black objects at up to 900 mm. Thanks to the innovative fast-clip
mounting system and quick wiring, the sensors are installed and ready for use in no time flat.
This product can be used in the following industry sectors:
• Conveyor technology
• Logistics
• Automotive industry
• Food industry
• Packaging industry
• Pharmaceuticals industry
• Woodworking industry
2.2 Use for Other than the Intended Purpose
• Not a safety component in accordance with 2006/42/EC (Machinery Directive).
• The product is not suitable for use in potentially explosive atmospheres.
• The product may only be used with accessories supplied or approved by wenglor, or combined with
approved products. A list of approved accessories and combination products can be accessed at
www.wenglor.com on the product detail page.
DANGER!
Risk of personal injury or property damage in case of use for other than the
intended purpose!
Use for other than the intended purpose may lead to hazardous situations.
• Observe instructions regarding use for intended purpose.
2.3 Personnel Qualifications
• Suitable technical training is a prerequisite.
• In-house electronics training is required.
• Trained personnel who use the product must have uninterrupted access to the operating instructions.

7
Sensors for Roller Conveyor Systems
DANGER!
Risk of personal injury or property damage in case of incorrect initial
start-up and maintenance!
Personal injury and damage to equipment may occur.
• Adequate training and qualification of personnel.
2.4 Modification of Products
DANGER!
Risk of personal injury or property damage if the product is modified!
Personal injury and damage to equipment may occur. Non-observance may result
in loss of the CE marking and the guarantee may be rendered null and void.
• Modification of the product is impermissible.
2.5 General Safety Precautions
NOTE!
• These instructions are an integral part of the product and must be kept on hand for the
entire duration of its service life.
• In the event of possible changes, the respectively current version of the operating
instructions can be accessed at www.wenglor.com in the product’s separate download
area.
• Read the operating instructions carefully before using the product.
• Protect the sensor against contamination and mechanical influences.
2.6 Laser/LED Warnings
NOTE!
• IR radiation from this product
• Risk group 1 per EN 62471
2.7 Approvals and protection class
RoHS

8Technical Data
3. Technical Data
Order No.
Technical Data OPT1540-1542 OPT1543-1545 OPT1546
Optical Data
Detection Range 900 mm
Depends on the
connected sensor
Switching Hysteresis < 5 %
Light Source art Infrarot
Wavelength 860 nm
Opening Angle 3°
Risk Group (EN 62471) 1
max. Ambient Light 90.000 Lux
Service Life (Tu = +25°C) 100.000 h
Electrical Data
Supply power 20,6 V – 30,0 V 12,0 V – 30,0 V 20,6 V – 30,0 V
Current consumption (Ub = 24 V) < 16 mA
EcoMode yes
Switching frequency 100 Hz
Response time 5 ms
Temperature drif < 5 %
Temperature range −40...60 ° C
Switching Output Voltage Drop < 0,9 V
PNP Switching Output/Switching Current 200 mA
Short-circuit proof, reversed polarity and
overload proof
yes
Interface NFC
Protection class III
Logic yes
Pneumatic Solenoid Valve Unit K04 – K04
Mechanical Data
Setting method NFC
Housing Plastic ABS
Lens material PMMA
Degree of Protection IP65 IP67 IP65
Connection M12 x 1; 4-pin
Cable Length OPT1540: 1m
OPT1541: 1,5m
OPT1542: 2m
OPT1543: 1m
OPT1544: 1,5m
OPT1545: 2m
1m

9
Sensors for Roller Conveyor Systems
3.1 Dimensional Drawings
OPT1540-1542
OPT1540-1542
OPT1546
= Transmitter Diode
= Receiver Diode
//= Plug (see section “3.2 Pin assignment Connection Diagrams”, page 10)
Screw M4 = 0,5 Nm

10 Technical Data
3.2 Pin assignment Connection Diagrams
OPT1540-1542 OPT1543-1545 OPT1546
1
3
4
3
1
3
2
4
A1
A4 BZ/E4
4
5
1
3
2
4
E1
BZ
2
LOGIC
E A2
E A3
ba
146
1
3
4
3
1
3
2
4
A1
BZ/E4
4
5
1
3
2
E1
2
LOGIC
E A2
E A3
A4 4
BZ
147
148
//= Plug
Legend
Wire Colors according to
DIN IEC 757
Platinum measuring resistor
not connected
Test Input
Test Input inverted
Trigger Input
Analog Output
Ground for the Analog Output
Block Discharge
Valve Output
Valve Control Output +
Valve Control Output 0 V
Synchronization
Receiver-Line
Emitter-Line
Grounding
Switching Distance Reduction
Ethernet Receive Path
Ethernet Send Path
Interfaces-Bus A(+)/B(–)
Emitted Light disengageable
Magnet activation
Input confirmation
Contactor Monitoring
Encoder A/A (TTL)
Encoder B/B (TTL)
Black
Brown
Red
Orange
Yellow
Green
Blue
Violet
Grey
White
Pink
Green/Yellow
Supply Voltage +
Supply Voltage 0 V
Supply Voltage (AC Voltage)
Switching Output (NO)
Switching Output (NC)
Contamination/Error Output (NO)
Contamination/Error Output (NC)
Input (analog or digital)
Teach Input
Time Delay (activation)
Shielding
Interface Receive Path
Interface Send Path
Ready
Ground
Clock
Output/Input programmable
Power over Ethernet
Safety Input
Safety Output
Signal Output
Ethernet Gigabit bidirect. data line (A-D)
Encoder 0-pulse 0-0 (TTL)
Encoder A
Encoder B
Digital output MIN
Digital output MAX
Digital output OK
Synchronization In
Synchronization OUT
Brightness output
Maintenance
PT
3.3 Complementary Products (see catalog)
wenglor offers Connection Technology for field wiring.
Suitable Mounting Technology No.
421
Suitable Connection Technology No.
2
2s
S02
ZNNG021 NFC adapter
Quick mount ZPTX001, ZPTX003

11
Sensors for Roller Conveyor Systems
3.4 Layout






= NFC interface (sensing face)
= Solenoid valve (OPT1540-42, OPT1546)
= Switching Status Indicator/Error Indicator
= I/O plug
= Logic daisy chaining plug
= Logic daisy chaining cable
3.5 Control Panel
3a
OP3
2a
2a = NFC interface
3a = Switching Status Indicator/Error Warning
3.6 Scope of Delivery
• OPT154x
• Quickstart instruction

12 Transport and Storage
4. Transport and Storage
4.1 Transport
Upon receipt of shipment, inspect the goods for damage in transit. In the case of damage, conditionally
accept the package and notify the manufacturer of the damage. Then return the device making reference to
damage in transit.
4.2 Storage
The following points must be taken into condition with regard to storage:
• Do not store the product outdoors.
• Store the product in a dry, dust-free place.
• Protect the product against mechanical impacts.
• Protect the product against exposure to direct sunlight.
ATTENTION:
Risk of property damage in case of improper storage!
The product may be damaged.
• Comply with storage instructions.

13
Sensors for Roller Conveyor Systems
5. Installation and Electrical Connection
5.1 Installation
• Protect the product from contamination during installation.
• Observe all applicable electrical and mechanical regulations, standards, and safety rules.
• Protect the product against mechanical influences.
• Make sure that the sensor is mounted in a mechanically secure fashion.
• Specified torque values must be complied with (see section “3.1 Dimensional Drawings”, page 9).
The sensors must be mounted between the rollers (Minimum clearance at the side: 2 mm) roughly 10 mm below
the height of the conveyed goods. Adjustment of the sensors is not absolutely necessary. Permissible
object dimensions must be complied with (see section “5.1.3 Permissible Object Dimensions”, page 16).
Mounting is possible with wenglor’s ZPTX001 or ZPTX003 quick mounting system or the ZPTX002 mounting
bracket (not included in scope of delivery). The sensors can also be attached to any retaining system via the
mounting holes with M4 screws.
NOTE!
• It’s advisable to mount the sensor in an upwardly inclined position for the detection
of high-gloss, black plastic containers on narrow conveyor systems (lane width
< 500 mm).
10 mm

14 Installation and Electrical Connection
5.1.1 Installation with the ZPTX001/3 Quick Mounting System
First of all, the retaining plate is clipped to the conveyor with the help of the percussion rivets included with
the ZPTX001 (A). A 7 mm diameter hole is required to this end. The sensor is then inserted into the bottom
guide and snapped into the retaining plate by pushing it to the back (B).

15
Sensors for Roller Conveyor Systems
The sensor can be removed by pressing gently with a screwdriver at the top in order to release the
mechanism and then pulling the sensor out to the front (C). The retaining plate can be removed by
unscrewing the percussion rivets with a screwdriver (D).
Optionally, the retaining plate can be attached to the conveyor using M5 screws. The drill-hole pattern
corresponds to the ZPTX002. The screws are not included in the scope of delivery.
If the ZPTX003 quick mounting system is used, no mounting holes are provided in the retaining plate.
These must be individually positioned in accordance with the installation situation. A suitable drill or
stamping tool must be used to this end. The method used to mount the retaining plate to the conveyor must
be selected individually as well. The percussion rivets included with the ZPTX001 quick mounting system
can be ordered separately under order number ZPTE001 if required.
5.1.2 Installation with ZPTX002 Mounting Bracket
The sensor is attached to the bracket with two M4 screws. The screws, washers and nuts are included
with the ZPTX002. The sensor can be adjusted (tilted back by up to 5.5°) until the screws are tightened.
The bracket is mounted to the conveyor with two M5 screws. The mounting holes in the bracket are
pre-threaded. The M5 screws are not included in the scope of delivery and must be selected in accordance
with the installation situation.
→↔↓↕
M5 thread for individual
mounting with M5 screws
Screws, washer,
nuts M4
5,5 °

16 Installation and Electrical Connection
5.1.3 Permissible Object Dimensions
Permissible object dimensions depend on conveyor
system’s lane width and the utilized mounting system.
The sensor’s inclination angle is not changed when
mounted with the ZPTX001 or ZPTX003 quick mounting
system.
When mounted with the ZPTX002 mounting bracket, the
sensor can be tilted up by as much as 5.5°.
This makes it possible to detect narrower packages,
but the minimum package height is also increased as a
result.
Lane Width
Package Size ≤600 mm ≤900 mm
Mounting ZPTX001/3 ZPTX002 ZPTX001/3 ZPTX002
Px min. 150 mm 100 mm 150 mm 100 mm
Py min. 50 mm 120 mm 100 mm 220 mm
5.2 Electrical Connection
The sensors are equipped with a quick wiring system. This reduces the effort required for completing electri-
cal connections. It must be assured that the socket with the white marking and the plug on the OPT with the
corresponding marking are aligned to each other.
The connection is locked into place by turning the sleeve 180° after the connector socket has been fully
pushed onto the plug.
½
Lane width
Px
7°
Py
3°

17
Sensors for Roller Conveyor Systems
The sensors are connected to each other in series using the M12 cables (see figure 1). The maximum num-
ber of sensors which can be operated in a single chain depends on the utilized power supply. The direction of
conveyance must be taken into consideration in this respect.
Supply power can be fed to plug (pins 1 and 3) at any point within the chain. Alternatively, supply power
can be fed via plug (pins 1 and 3). However, supply power is normally connected at the end of the chain.
single discharge (pin 2) or block discharge (pin 4) can be activated at the end of the chain via plug .

I/O
➂ ➂
➃➄ ➃
➂
➄
➄
➃
CHAIN
Conveyor directionConveyor direction
Image 1
It’s also possible to freely assign various functions to pins I/O1 und I/O2 via plug .
See section “7.2 Setting Inputs and Outputs”, page 25 with regard to configuring the pins.
5.3 Diagnostics
The following diagnosis functions are detected:
Indicator LED Diagnosis/Cause Elimination
Device malfunctions
Continuous blinking
at approx. 8 Hz
Contamination Carefully clean the emitter and the
receiver with a cloth.
Aged emitter diode Replace the device.
Short Circuit Check electrical wiring and eliminate the
short-circuit.
• Solenoid valve connected incorrectly
• Solenoid valve defective
• Check electrical connection of the
solenoid valve to the sensor.
• Replace the solenoid valve.
Unreliable working range • Increase sensing distance.
• Reduce distance between the sensor
and the object.
Process error
Material jam detected Clear material jam so that accumulation
logic continues:
• Clear by means of block discharge
• Clear by means of manual removal
of the jam

18 Installation and Electrical Connection
Indicator LED Diagnosis/Cause Elimination
NFC Kommunication
The LED indicator only functions when the sensor is connected to supply power.
4 rapid, consecutive
blinks
Successful receipt of data via NFC
LED off Data transmission via NFC not
successful
Transmit data to the sensor again
Device malfunctions can be additionally detected via the error output. One of the freely programmable I/Os is
specified as an error output to this end. This output is switched as soon as one of the device malfunctions is
detected.
The process error can also be configured to an output, so that it switches as soon as a material jam is
detected.
Conduct in case of fault:
NOTE!
• Analyze and eliminate the cause of error on the basis of the diagnostics information.
• If the error cannot be eliminated, please contact wenglor’s support department.

19
Sensors for Roller Conveyor Systems
6. Functions
6.1 Default Settings
Deactivated OPT1540-1542 OPT1543-1545 OPT1546
Pin function, I/O3 Output,
object detected
nc External sensor input
Pin function, I/O2 Single discharge
input
Solenoid valve / motor
output
nc
Switching distance ~ 63 % (corresponds to approx. 550 mm)
Single Discharge Fixed zones
Block discharge Standard
Automatic roll cutoff Deactivated
Jam monitoring Deactivated
Loading delay Deactivated
Unloading Delay Deactivated
Accumulation delay Deactivated
Braking delay Deactivated
6.2 Function definition
6.2.1 Basic Function
Material Inlet and Material Accumulation
An object on the conveyor system is advanced to the foremost position. If it’s detected at this position by the
sensor, the rollers at the first accumulation position are deactivated and the object comes to a standstill. Infor-
mation indicating that the accumulation position is occupied is forwarded to the next sensor within the chain,
so that any subsequent object is advanced to the next unoccupied location. This procedure is repeated until
the conveyor path is full and all accumulation positions are occupied.
The single discharge and block discharge modes are available for further forwarding of accumulated objects.

20 Functions
6.2.2 Operating Modes
Single Discharge
Fixed Zones
An individual object is released from its accumulation position and forwarded. Subsequent objects can be
moved up one by one.
The accumulation position must always be at least as large as the largest object.
Manual removal of an object activates the same function as applying a signal to the corresponding input.
Dynamic Zones
An individual object is released from its accumulation position and forwarded. Subsequent objects can be
moved up one by one.
The special feature of this type of single discharge is the fact that the objects can be larger than the accu-
mulation positions. The system detects the object’s size and automatically activates as many accumulation
positions as required by the object.
Manual removal of an object activates the same function as applying a signal to the corresponding input.