F3SP-U3P-TGR Users Manual
Contents
1. nennen 10 5 CONNECTIONS vis cec cece stecccec cette ctecstieceeestieceesstiecetestiecneestiveneventiees 11 5 1 REFERENCES ON THE TERMINAL 11 5 2 iino er s ar IER d e pert dein 12 5 3 itii me neas sped pe kota panik 13 6 ALIGNMENT PROCEDURE eene nennen 15 7 OPERATING PROCEDURES eene enn 16 7 1 DIP SWITCHES 16 7 2 CONFIGURATION OF THE NUMBER OF 16 7 3 MUTINGTUNCGTION c eet etre dee deed 17 TOA DESCRIPTION pann Ge A aie 17 7 3 2 INSTALLATION rient one d E SEHR RR 18 1 4 ees A er retro dee e Mad ei ied 20 7 5 STARTING THE OVERRIDE FUNCTION 20 7 6 MUTING RESTRICTIONS MUTING 2 2 21 8 LED DIAGNOSTIC tected a te 22 9 FINAL CHEGCKS eren enn oak anka tan ewa kanon nn nt 23 10 ROUTINE MAINTENANCE OPERATIONS 23 11 GENERAL INFORMATION AND USEFUL DATA 24 12 TECHNICAL DATA 25 13 OVERALL DIMENSIONS eene eene 26 F3SP U3P TGR User s manual 1 BEFORE USING THE DEVICE 1 1 GENERAL INSTRUCTI2. Muting sensor connection 24 Voc i e hs 29 contact of A 7 MUTEA 8 MUTEB oe contact of B F3SP U3P TGR terminals D minimum distance so that the muting sensors keep active the request it depends on the parcel length D lt L di necessary maximum distance so that the muting request is accepted it depends on the parcel speed dmax v m s 3 s 100 This distance must not allow to activate both sensors and the muting with the accidental passage of a person To allow the muting function only for the first photocells it s necessary to set the unit with the dip switch number 3 in ON To allow the muting function for both the photocells the dip switch number 3 must be setted OFF 19 F3SP U3P TGR User s manual e The TEST and START pushbuttons must be positioned in such way that the operator can see the protected area when he carries out start fest or override operations e The F39 A11 muting lamp must be positioned a place where it can be seen from any operative point e f the muting sensors are installed very near the protection photocells it is necessary to install the sensor receivers on the photocell sender side to avoid interference e The system is anyway protected from possible failures due to the cable damage it is necessary to prepare the wiring of all connections so as to avoid damage to the connection cables e
3. control unit must be located in a cabinet with protection degree of at least IP54 7 4 OVERRIDE This function makes it possible to force a muting condition if it is necessary to start the machine despite one or more rays have been interrupted by the material The aim is that of removing from the protected area the material which has possibly gathered before the photocells for instance because of a failure of the machine cycle Let s suppose that a pallet has stopped before one or more used optical devices the conveyor belt cannot be started again because the control unit after having detected one or more interrupted rays will not close the safety outputs thus making it impossible to free the controlled area By starting the override function it will be possible to carry out this operation 7 5 STARTING THE OVERRIDE FUNCTION Switch off the device e Make sure that the TEST e START buttons are connected N C for the TEST button N O for the START button Switch on the device e Within 10 seconds press together the test and reset buttons and keep pressing At each switching on operation a test is carried out to check that the buttons are not locked e The override function has been activated The muting lamp blinks to signal the barrier disconnection e The maximum duration of the override function amounts to 60 seconds after that the unit is connected again even if the buttons are pressed Obviously if the bu
4. E e 13 F3SP U3P TGR Please note A A All models can be connected in all the possible combinations for a maximum of two pairs of sensors with at least one pair connected In the following paragraph you can find the codes of the available models which can be used in the configuration The power supply which is necessary to power the system must conform to standard EN 60742 double insulation or with equal insulation for instance VDE 0551 It is necessary to protect the control unit with an outer fuse having a nominal interruption current equal to 1 A The TEST and RESET pushbuttons must be positioned in such a way that the operator can see the protected area when he restarts or carries out a fest or override operation The Muting lamp F39 A11 must be positioned in a place where it can be seen from any operative point Read the paragraph relating to the muting function and its use for the positioning of the activation sensors of this function Both safety contacts OUT1 and OUT2 must be connected If the machine has a single locking circuit the two normally opened contacts must be connected in series Photocells of the type E3FS 55 5 and 510 5 are delivered with wired cable or standard M12 connector and the wiring on the control unit is indicated according to the cable colour or to the male connector pin number Photocells of the type S30 5 are available also in the version with terminal board
5. details 4 1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE The safety distance S must be sufficient to guarantee that the dangerous area cannot be reached by the operator up to the moment in which the machine with moving part stops The safety distance must be calculated according EN999 European Standards Safety of Machinery The positioning of protective equipment in respect of approach speeds of part of the human body Using EN 999 formula S K T C S 7 safety distance T 1 2 whereas 1 machine response time in seconds T2 unit response time in seconds including Safety sensor response time K 1600 mm s speed of the body approaching the dangerous area C additional distance depend on resolution of SLC and applicable standard 1 Multiple separate beams EN999 clause 6 1 4 K 1600 mm s 850mm Heights recommended 4 Beams 3 Beams 2 Beams in EN999 Heights of 1 300 mm 300 mm 400 mm Heights of 2 ray 600 mm 700 mm 900 mm 2 Single height beam EN999 clause 6 1 5 WHERE THE RISK ASSESSMENT ALLOWS THE USE OF A SINGLE BEAM THE FOLLOWING VALUES CAN BE USED K 1600 mm s C 1200 mm The height of beam from the ground or reference plan 750mm EN 999 F3SP U3P TGR User s manual A WARNING Always maintain the safety distance between the safety PES and a hazardous part of a machine 4 2 REFLECTIVE SURFACES In case that reflective surface exist the d
6. ONS Read this manual and the manual of safety PES safety photoelectric switch carefully and completely Make sure the user information provided is understood before attempting to operate the safety PES Keep the manual in a secure and convenient location and confirm information if necessary To guarantee correct installation carefully follow the instructions of this manual e Do not touch non insulated cables unless they have been disconnected from the power supply e Make sure that the cables connected to the control unit are not taut and that they do not hinder the movement of persons or objects e Before carrying out any outer operation turn off the power Failure to do so may result in lethal or serious injury 1 2 PRECAUTION OF SAFETY The following symbols are used for highlighted items in order to ensure safe and proper use of the F3SP U3P TGR Highlighted items are critical for safe operation and must be heeded at all time A WARNING 1 3 ROUTINE MAINTENANCE Be sure to conduct inspection regularly Please refer to sec 10 and the safety PES instruction manual Omron Europe and Techno GR refuses to accept any responsibility for damage to persons or object due to the incorrect use installation of the control unit and safety PES F3SP U3P TGR User s manual 2 GENERAL INFORMATION AND MAIN APPLICATIONS The single beam safety control unit F3SP U3P TGR has been designed and produced to me
7. Single Beam Safety Control Unit Safety Level 2 USER S MANUAL F3SP U3P TGR User s manual Cat No E04E EN 01 F3SP U3P TGR series Single beam safety control unit safety level 2 from 1 to 2 pairs of photocells E3FS USER S MANUAL F3SP U3P TGR C User s manual The device conforms with the EC requirements in compliance with the following standards MANUFACTURER USER MANUAL Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC Machinery Directive 89 392 EEC 4 61496 1 1997 IEC 61496 2 ed 2 IEC 2001 CDV draft 8 DIN V VDE 0801 1990 and amendment A1 1994 EN 61000 4 2 3 4 5 6 EN 55022 1994 DIN EN 60204 1 1993 EN 50178 1998 4 664 1 1997 TECHNO GR s r l via Torino 13 15 10046 Poirino TO ITALY Tel 39 011 9452041 FAX 39 011 9452090 Version 3 0 of 12 06 2003 F3SP U3P TGR User s manual INDEX 1 BEFORE USING THE DEVICE ener enn 5 1 1 GENERAL 5 1 2 PRECAUTION OF SAFETY tpe tacere REX Ye EE 5 1 3 ROUTINE trennen 5 2 GENERAL INFORMATION AND MAIN APPLICATIONS 6 3 OPERATION ineo entere nne chere e anbake 8 4 PRECAUTIONS AND INSTALLATION CRITERIA 9 4 1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE 9 4 2 REFLECTIVE
8. The connection cables of the photocells of muting request start and test must be masked with minimum section 22AWG The screen braids must be all earthed towards the control unit side User s manual 14 F3SP U3P TGR 6 ALIGNMENT PROCEDURE After having carried out the correct mechanical assembly and the correct connections as described in the previous paragraphs it is necessary to align the pairs of photocells Follow the operative modes as follows Turn off the power supplying the control unit Open the TEST pushbutton Power the control unit Align the photocells by observing the LEDs on the control unit If the alignment of the relevant pair of photocell is correct the corresponding LED will turn on After the alignment turn off the power supplying the control unit close the TEST pushbutton and re power the control unit again Wait for the control unit to carry out the initial tests At the end of this operation the unit indicates the right alignment with the guard led green on Carry out all the checks described in the final checks and in the routine maintenance operations User s manual During aligning operations or normal working check that the photocells connected to the same or other units do not interfere which each other modifying their mutual position for instance by positioning some pairs of transmitters on the other receiver side NOTICE The control unit can detect the mutual interference between safe
9. causes the opening of the safety outputs and the consequent stopping of the connected machine It is necessary for the safety sensors to be connected in the right position in such a way that there isn t any possibility to climb over or defeat the system Here is a list of the commonly used applications 9 Machines for the processing of wood glass and ceramic products 9 Automatic warehouses 9 Conveying lines 9 Palletizers F3SP U3P TGR User s manual The unit has been designed in accordance to the following standards IEC 61496 1 1997 FDIS IEC 61496 2 1997 Safety of machinery electro sensitive protective devices General requirements and test Safety of machinery electro sensitive protective devices Particular requirements for system using active opto electronic devices F3SP U3P TGR User s manual 3 OPERATION The electronic control system of the device is made up of a microprocessor By means of the suitable hardware it continuously control and check the connected photocells No interference among the photocells is possible as they are controlled sequentially it will be thus possible to install one or two adjacent photocells When one or more beams are interrupted the electronic system opens the outputs The photocells have been triggered are displayed by LEDs on the housing The control unit can work in two different modes please refer to par 7 page 14 which he can carry out the following operatio
10. et the need to protect persons in areas where it is necessary to guarantee the safety of the operator using machinery robots or in general automation systems which are considered dangerous or subject to casual or undesired access to unsafe parts The system conforms with the requirements for safety devices of type 2 in compliance with international standards e g IEC 61496 1 2 This safety device is made up of a control unit protected by a plastic container so that it can be installed on a DIN OMEGA guide it has 16 removable screw terminals to which it is possible to connect from 1 to 2 pairs of photocells This version of the single beam safety control unit has the muting function integrated by means of this function it is possible to connect or disconnect one or more pairs of photocells in order to allow for instance the material passage without stopping the machine The additional override function enables system to keep the output relays closed even with intruded rays to enable material transport after a system shutdown Both muting and override functions represent a system that require additional precautions to limit the reduction of the safety level This precautions have to be considered carefully The muting and override function is available by simply connecting the F39 A11 muting lamp or similar yellow bulb type lamp for 24VDC 3W to 7 W supplied separately The presence of a limb or an object interrupting a beam
11. he muting sensors must recognise the material pallets vehicles etc in all its length 2 The sensors must be arranged in such a way that the material is recognised even when it must be lifted for the relevant processing 3 In case of different transport speeds in the muting area always bear in mind their influence on the muting total duration 4 All the safety photocells and the muting sensors must be arranged in such a way that the previous material has already passed the last muting sensor before the new material has reached the first sensors In the previous figures an installation example of a protection arranged on a conveyor is drawn The protection photocells S are connected to the F3SP U3P TGR control unit and are temporarily interrupted at the package passage by means of the muting A1 A2 B1 and B2 activated sensors Sensors A and B are optical mechanical proximity etc sensors with closed contact in the presence of the object to be detected 18 F3SP U3P TGR Typical application with four muting sensors User s manual Muting sensor connection 24 Vpc e contact of A1 s s l v x in L Ped dd 2 1111 0 kol contact of A2 7 MUTEA 1 1 1 1 3 43 37 aou M A jee 8 MUTEB B2 A2 B4 Al contact of B1 4 5 A di F3SP U3P TGR D A terminals contact of B2 Application with two muting sensors passage permitted only for package 1
12. istance must be sufficient to avoid the possibility of passive reflections Top View reflective material RX bar A cs TX bar Je l Object 2 21 A reflective material Distance between emitter and Minimum installation distance receiver detection distance L D 0 3 to 3m 0 27 m 3m or more L x tan 2 L x 0 034 m A WARNING Do not install the safety PES in a location affected by shiny surface reflections 10 F3SP U3P TGR 5 5 1 CONNECTIONS REFERENCES ON THE TERMINAL BOARD TERMINAL BLOCK ASSIGNMENT User s manual TERMIN OUTER CONNECTION AL 1 2 Connectto the 24 Vdc power supply 1 to 24Vcc and 2 to OVcc Connect the muting signaller LMS Connect to the ground of plant TEST button connect a normally closed button N C RESET button connect a normally open button N O Input ofthe muting A sensor Connect to the N O contact of the muting sensor photocell proximity switch other ma Input ofthe muting B sensor Connect to the N O contact of the muting sensor photocell proximity switch other Connect the photocells test input of transmitters TX1 Black wire pin 4 of connector 10 Connect to the PNP output of the receivers RX1 Black wire pin 4 of connector 11 Connect the photocells test input of transmitters TX2 Black wire pin 4 of connector Connect to the PNP output of the receivers RX2 Black wire pin 4 of co
13. must be repeated each time you move or mechanically re align the photocells 10 ROUTINE MAINTENANCE OPERATIONS Here is a list of checks recommended to the user to be carried out periodically by skilled workers Check that the unit locks by inserting an object detecting the single elements of each photocell By opening the fest contact check that the safety relays are opened red LED switched on and machine under test stopped Make sure that the access to the machine dangerous areas is not possible from any non protected area and that the minimum distance from the beam dangerous parts is not lower than the one calculated with reference to the formula reported at paragraph 4 1 Check that it is not possible for a person to stop between the beams and the dangerous parts of the machine Make sure that there is no outer damage to the unit and or the outer electrical connections Make sure that the response time including the unit and the machine ones does not exceed the established limits The frequency of these operations depends on the special applications and operative conditions according to which the unit is working 23 F3SP U3P TGR User s manual 11 GENERAL INFORMATION AND USEFUL DATA CET Safety MUST be part of our consciousness The safety devices are useful only if installed correctly by respecting the indications reported on the standards If you believe not to have the sufficient competence to correctly install the
14. nnector 13 14 OUT1 safety output 1 with contact 15 16 OUT2 safety output 2 with N O contact 11 User s manual F3SP U3P TGR PIN OVERVIEW 5 2 91 v Zino 9 2100 22 vL V LINO iid 1531 LYVLS V ONILNW GUARD BREAK STATUS 2 status 1 ONLLAW HLYVA V AND 1X3 110 ZXY 161 LL Ino IXY OL HA 1SL IXL 6 12 F3SP U3P TGR User s manual 5 3 WIRING EXAMPLE Connection of 2 safety PES to the control unit GND Muting MAIN SUPPLY A B NON T R TOP VIEW 8 s T E N C N EXTERNAL 1 A FUSE amp F39 A11 2 90 2 2 92 92 92 1 2 3 4 5 6 7 8 F3SP U3P TGR control unit 9 1011 12 13 14 15 16 A 9 90 0 2 v 90 2 P _ P Safety output 2 TIN N o E p E P S S 0 ly Tly 0 Safety output 1 e T T E3FS E3FS E3FS E3FS Transmitter Receiver Transmitter Receiver
15. ns The two external buttons that have to be connected are for e TEST This is used to check if the whole system works effectively By pressing the TEST button opening of the contact this simulates the interruption of one or more safety PESs This operation makes the machine stop so the system checks can be made according to the established time and modes If pressed after a failure detection of the unit see the table error code reset of the system is required e RESET button It is used to start the system also for manual reset condition after relay triggering or after an error which can be reset see table related to the error codes Two different operating modes are available 1 Automatic reset The system will start automatically after the beam intrusion have been removed 2 Manual reset The system will remain in safe off condition until the RESET button have been pressed This manual reset allows to start the system only on a wanted action of the user During the unit working no operation set by the user interface involves functions which can influence the system safety F3SP U3P TGR User s manual 4 PRECAUTIONS AND INSTALLATION CRITERIA The safety products used must be suitable for the required application and other influences must be also taken into account such as a room temperature electromagnetic interference intense light sources etc Please refer to the manual for specification or contact the manufacturer for
16. rotection class of photocells IP 67 Protection class of the cabinet containing the control unit IP54 at least Weight control unit 300 g Features of fuses muting signalling lamp internal re settable fuse 315mA 60V Muting signalling F39 A11 25 F3SP U3P TGR 13 OVERALL DIMENSIONS 99 mm Control unit F3SP U3P TGR pL User s manual MANUFACTURER Via Torino 13 15 10046 Poirino TO ITALY Tel 39 011 9452041 FAX 39 011 9452090 TECHNO GR s r l GENERAL AGENCY OMRON EUROPE B V SENSOR BUSINNES UNIT Carl Benz Str 4 71154 Nufringen GERMANY Tel 49 7032 811 0 FAX 49 7032 811 199 Authorized distributor
17. safety devices apply to our advisory service or request the installation We recommend to leave free space on the cover side to allow a possible easy access to the inner parts Trouble that cause voltage interruption on power supply may cause temporary openings of the outputs that are not damaging in any case the safety work of the unit The guarantee is complete for a period of 12 months starting from the delivery date of the device Defects which are clearly due to damage caused by an incorrect use accidental causes or catastrophic events are not covered by the guarantee 24 F3SP U3P TGR User s manual 12 TECHNICAL DATA Voltage 24 Vdc 1096 Electrical input 420 mA max Combinable photocells OMRON ESFS series and Techno GR S5 10 S30 series Number of photocells two pairs max Wire range size AWG 16 24 Solid Stranded Wire type 60 75 C copper Cu conductor only Torque on terminals 0 9 N m Indicators 5 green LEDs 1 red LED Response time 30 ms Working temperature 10 a 55 C Moisture from 1596 to 95 not condensing Output contacts 2 NO 115 Vac 2 5 A max Switch capability 1 500 VA 180W Electrical life expectance 100 000 op minimun at 1 800 oprs hr Operative distance according to the type of photocell E3FS 10m 55 5 8m 5 10 8m 530 5 50m Outer controls start control test muting and override Housing plastic case for installation on a din omega guide Protection class of control unit IP 20 P
18. t are correctly passed if blinking an error occurred e REDLED BREAK if switched on the unit has detected an object or an error has occurred which can be possibly recovered by pressing the reset button in this condition the safety outputs are opened e GREEN LED GUARD if switched on in green the barrier is working regularly and there are no detected obstacles in this condition the safety outputs are closed The F3SP U3P TGR has inside an easy diagnosis with the four green leds to detect the most common errors or failure that can be presents e One led flashing Probable error in a photocells pair e Two leds flashing Probable incorrect setting of numbers of beams connected e Tree leds flashing Probable fail in muting lamp connection e Four leds flashing Probable internal error All these errors are resettable by the TEST pushbutton if the error condition can be removed THE TWO LED OUT 1 AND OUT 2 CAN INDICATE A STATUS ONLY IF THE OPTICAL BEAMS ASSOCIATED TO THE LED FLASHING ARE FREE F THE BEAMS ARE INTERRUPTED THE LEDS CAN ONLY BE OFF 22 F3SP U3P TGR User s manual 9 FINAL CHECKS Check that the area protected by the beams is free from any obstacle check the correct triggering of the safety relay opening by interrupting the protection rays red LED switched on controlled machine stopped CAUTION If the red LED switches on and off check the correct mechanical assembly NOTE This check
19. trol unit is locked 16 F3SP U3P TGR User s manual 7 5 MUTING FUNCTION 7 3 1 DESCRIPTION As mentioned in the introduction the muting function can be enabled with any unit by simply connecting the F39 A11 muting lamp when the unit is switched off This presence of this indicator is recognised every time the unit is powered on If its presence is detected the unit will enable the muting function and if its presence is not detected the unit will ignore any request for muting It is important to note that if the muting indicator is connected during the F3SP U3P TGR is powered on it will not be recognised and the muting function will not be enabled Once enabled if the indicator develops a fault or is removed without first disconnecting the unit s power supply it will signal an error as described in section 8 To disable the muting function the unit s power supply must be turned on without the F39 A11 muting lamp connected In brief this function present on all units is enabled and disabled by means of the following simple procedure Disconnect the unit s power supply Connect the appropriate F39 A11 muting lamp and the muting sensors Restore the unit s power supply Bypass the muting function as follows Disconnect the unit s power supply Disconnect the F39 A11 muting lamp and the muting sensors Restore the unit s power supply 17 F3SP U3P TGR User s manual 7 3 2 INSTALLATION CRITERIA CE 1 T
20. ttons are released before this time has elapsed the override function will be immediately stopped 20 F3SP U3P TGR User s manual 7 6 MUTING RESTRICTIONS muting function a The request of muting must occur according to the correct time sequence it is necessary to activate input MUTE_A at first and then input MUTE B The request of this last one must arrive within a maximum time of 3 seconds If not the muting request will not be activated A wrong sequence on the entrances of muting does not activate this function b Since when the muting state is active an object can remain for a period of time not longer than 60 s otherwise the muting function is switched off This mechanism is optional and can be deactivated when the barrier is set up with the dip switch c For all the cases in which the muting function is automatically disabled because of time out the request must be cut out and re activated to generate the following muting state ON MUTE STATE OFE OFF 60 max It is not possible to carry out a muting request if the barrier is in the opened relay state 21 F3SP U3P TGR User s manual 8 LED DIAGNOSTIC Information of the units operative state by means of four LEDs The LED state has the following meaning e GREEN LEDS OUT if switched on the related photocells work regularly and no object is detected the relays are closed e GREEN LED STATUS if switched on all the unit tes
21. ty PESs The control unit forces the output contact to open when it detects external disturbance light including mutual interference light The safety PESs should be installed the following way to avoid mutual interference The safety PESs are installed with sufficient distance Emitters and receivers of safety PES are installed alternately as follows 1 o 1 100 15 F3SP U3P TGR User s manual 7 OPERATING PROCEDURES 7 1 DIP SWITCHES CONFIGURATION The configuration indicated in the table must be selected on the dip switch available in the front x _ E B muting A B act on the sensor couples 1 and 2 ON muting A B act on the sensor couple 1 1 Off muting 60 s On muting 5 E Off manual restoring On automatic restoring The control unit is manufactured from the factory with the following configuration e Automatic reset all 2 sensors in muting the maximum duration of the muting is of sixty seconds infinite muting duration this feature must be used carefully because it s against the norm Using this the user must know that it works under its sole responsibility 7 2 CONFIGURATION OF THE NUMBER OF PHOTOCELLS In case you use only a pair of photocells operate as follows Turn off the power and short the terminal 11 12 At least one pair of photocells must be connected otherwise the con
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