Omron OS32C Quick Reference Manual

OS32C
Safety Laser Scanner
Quick Reference Guide
Original Instructions
© OMRON Corporation 2010−2018 All Rights Reserved.
Safety Precautions
The Alert symbols and their meanings ensure safe use of the products. In order to use the OS32C safely,
the precautions listed in this manual are indicated by alert symbols. The descriptions must be followed,
failure to follow all precautions and alerts may result in an unsafe installation or operation.
The following indications and symbols are used.
Indicates a potentially hazardous situation which, if not avoided, will result in minor or
WARNING moderate injury, or may result in serious injury or death. Additionally there may be
significant property damage.
Indicates a potentially hazardous situation which, if not avoided, will result in minor or
CAUTION
moderate injury, or there may be property damage.
Meaning of alert Symbols
Indicates prohibited actions.
Indicates mandatory actions.
If more information is needed, refer to the OS32C user's manual (Z296-E1).
Alert Statements in this Manual
WARNING
An OS32C is an electro-sensitive protective equipment designed to guard
personnel working around hazardous machinery.
Whether a specific machine application and the OS32C system installation complies with
safety regulations depends on the proper application, installation, maintenance and operation
of the OS32C system. These items are the responsibility of the purchaser, installer and user.
User
WARNING
The administrator is responsible for the selection and training of personnel to
properly install, operate, and maintain the machine and its safeguarding systems.
An OS32C system should only be installed, verified and maintained by a qualified
person. A qualified person is defined as "an individual who understands, is trained
on, and demonstrates competence with the construction, operation or mainte-
nance of the machinery and the hazards involved." (ANSI/PMMI B155.1- 2006)
The machine requirements
WARNING
The guarded machine must be able to stop anywhere in its cycle. Do not use an
OS32C on a press with a full-revolution clutch.
The guarded machine must have a consistent stopping time and adequate control
mechanisms.
All safety-related machine control elements must be designed so that an alarm in
the control logic or failure of the control circuit does not lead to a failure to danger.
Do not use the auxiliary output or warning output for safety applications. A human body
may not be detected even if a failure of OS32C occurs, resulting in serious injuries.
Installation
WARNING
The main unit must be securely mounted and its cable connectors must be tightly
attached.
The OS32C must not be mounted behind glass or within a secondary enclosure. Failure to
do so will cause a reduction in detection capability, which can cause serious injury or death.
A start switch to release interlock must be installed where an operator can
observe the monitored/guarded zone as a whole and cannot operate the switch
within the hazardous zone.
Per the International standard IEC 61496-3, area scanners used in applications
where the angle of approach exceeds +/- 30 degrees with respect to the detection
plane, must use reference boundary monitoring (RBM) of the detection zone.
Make sure to remove any retro-reflector from the field of view of the OS32C when
in RBM mode.
A protective mechanism must be installed to prevent a hazardous condition in the event of a
subsequent machine component failure. The OS32C does not protect against ejected flying
material.
Severe smoke and particulate matter may degrade the efficiency of an OS32C,
causing it to unexpectedly enter a Machine Stop state.
Use of mirrors or mirror-like objects in the protection plane must be avoided, as
they can hide part of the area to be monitored/guarded.
Additional guarding may be required to prohibit access to dangerous areas not
covered by the OS32C system.
Perform the test procedure described in the OS32C user's manual at installation,
after maintenance, adjustment, repair or modification to the machine controls,
tooling or the OS32C system.
Perform only the test and repair procedures outlined in the OS32C user's manual.
Additional measurement error resulting from reflective backgrounds may need to
be added to the measurement error of the OS32C
To use the protective function of the OS32C, a safety zone must be properly
defined and configured.
If the response time is changed, re-calculation of the safety distance is required. This
may require re-configuration of the safety zones or re-installation of the OS32C. If
the safety distance is not appropriate for the application, the machine may not stop
before contact with the hazardous part, resulting in serious injuries or death.
The activation of RBM Only mode will increase the response time. This additional time
must be taken into consideration when calculating the safety guarding distance.
When using more than one OS32C, mutual interference should be prevented. This
may require different scanner positions or physical shields to be installed.
To ensure a protection degree of IP65, DO NOT use this product without proper
sealing of the cable connector, I/O block, and scan window.
If the external zone switching device momentarily exceeds the configured number
of active zone set select inputs during the zone switch, an additional Zone Delay
may be incurred in the event that wiring of a zone set select input fails. The
external zone switching device must properly sequence so the configured number
of active inputs is not exceeded in order to guarantee that failed zone set select
input wiring will be detected within the normal Zone Switching Time.
If an insufficient Zone Delay is used for the actual worst case switching time of the
installation, the scanner might start monitoring the wrong zone during the switching period.
Also, if an insufficient Zone Delay is used for the actual worst case switching time of the
installation, there might be a fault condition during the zone switching period.
If tstart (switching start time) is configured without consideration of TmaxReaction
(total maximum reaction time), object detection within the new safety zone after
switching and turning OFF of the safety outputs may be delayed.
Monitoring zone parameters are subject to a number of constraints that include
projective consistency, maximum radius, and angle limits. As a result, an imported
zone may not correspond exactly to the zone defined in the file. The user must
visually verify the imported zone when the zone coordinate import process is
complete. Refer to Checkout and Test Procedure Log in the OS32C user's manual.
The installer is responsible for assessing the risk and to ensure that the zone of
limited detection does not create a safety hazard. If a hazard exists additional
countermeasure must be taken, this may require additional guarding measures.
Others
WARNING
Do not modify the main unit of the OS32C. Do not replace or fix any component of
the OS32C other than the ones specified in the user's manual. Doing so may result
in a failure of the device to function correctly.
If there is any damage to the window, replace it as soon as possible. Otherwise it
may result in a failure of the OS32C. Take preventive measures when performing
replacement work so that dust does not enter the OS32C.
Always detach all cables from the OS32C before replacing the scan window.
Otherwise the motor may start rotating, resulting in injuries.
The window replacement procedure must only be performed by qualified personnel
in a clean environment at ambient temperature (5 to 35°C) to prevent the internal
optical surface from contamination. Make sure the inside and the outside of the
replacement window is clean and free from scratch, dust, and finger print.
The calibration procedure must only be performed by qualified personnel. Before
performing window calibration of the new scan window, make sure the window is
clean and free from scratch, dust, and finger print. The window calibration
procedure must be performed at ambient temperature 5 to 35°C. Failure to inspect
the window or set the proper environmental condition during window calibration
procedure may cause a reduction in the detection capability of the scanner.
The test outlined in this test procedure (See "Checkout and Test Procedure Log" in the OS32C
user's manual) must be performed at time of installation, according to the employer's regular
inspection program and after any maintenance, tooling change, set up, adjustment, or
modification to the OS32C system or the guarded machine. Where a guarded machine is used
by multiple operators or shifts, it is suggested that the test procedure be performed at each shift
or operation change and also if there is a change in the OS32C operating mode or defined zone
sets. Testing ensures that the safety laser scanner and the machine control system are working
properly to stop the machine. Failure to test properly could result in serious injury to personnel.
If the OS32C is operated under automatic start, make sure that the machine stops
and does not restart as long as an object is detected in a safety zone. Check the
operation by placing a test piece into the safety zone. It is recommended to
perform the test at least after a shift change or 24 hours of operation.
If the safety system or the machine fails any of these tests, do not run the machine. Immediately
tag or lock out the machine to prevent its use and notify the appropriate supervisor.
System and zone status parameters monitored over EtherNet/IP are to be used for
diagnostic purposes only, and must not be used in safety-critical functions.
Measurement data monitored over EtherNet/IP are to be used for diagnostic
purposes only, and must not be used in safety-critical functions.
CAUTION
When transferring data from the PC to the OS32C and more than one OS32C is
connected to the network, it is necessary to visually check the diagnostic code on
the status/diagnostic display. It is recommended that the OS32C be installed in a
position where the status/diagnostic display will be visible.
Before sending the changes to the sensor, verify that the safety parameters are
configured as intended for the application.
Take precautions to prevent dirt, dust or debris from entering the sensor and I/O
block connectors.
It is recommended that this be done on a clean workstation as contaminants may
degrade the performance of the OS32C.
Adhesion of dust to the scan window may cause a false operation. The OS32C will
require periodic cleaning of the scan window and dust detection surface.
Operation of the OS32C may be affected by light in the environment, such as
incandescent light, strobe light and light from a photosensor using infrared light.
Operation of the OS32C may be affected by substances in the environment, such
as fog, smoke, steam and other small particles.
Ensure the measurement report configuration matches the expected measurement
data format.
Precautions for Safe Use
Make sure to follow all the safety precautions that are necessary to ensure safe
use of the product.
• Thoroughly read this installation manual and understand the installation,
operation checks, and maintenance procedures before using the product.
• Loads must satisfy both of the following conditions:
- Not short-circuited
- Not used with a current that is higher than the OSSD rating (250 mA sourcing)
• The main unit must be properly mounted with the proper mounting hardware.
• Do not drop the product, serious damage will occur.
• Comply with all the laws, regulations, and standards of the country/region where the product is used.
• Dispose of the product in accordance with the relevant rules and regulations of
the country/region where the product is used.
Precautions for Correct Use
Observe the precautions described below to prevent operation failure, malfunctions, or
undesirable effects on product performance.
■ Installation environment
Do not install the OS32C in the following types of environments:
• Areas where OS32C may be exposed to intense interference light, such as direct sunlight
• Areas with high humidity where condensation is likely to occur
• Areas subject to condensation resulting from severe changes in temperature
• Areas where corrosive gases are present
• Areas exposed to vibration or shock levels higher than in the specification provisions
• Areas where the product may come into contact with water
• Areas where the product may get wet with oil
• Areas where smoke and/or water vapor exists on the laser scanning plane
• Keep the OS32C far enough from devices that generate high frequency noise or eliminate the noise.
• Be sure to route the OS32C cable separate from high-potential power lines or route through an exclusive conduit.
This is a class A product. In residential areas it may cause radio interference, in which case
the Responsible Person may be required to take adequate measures to reduce interference.
■ Wiring and installation
• Make sure to perform wiring while the power supply is OFF. Otherwise, the OS32C may fail
to operate due to the diagnostics function.
• Properly perform the wiring after confirming the signal names of all the terminals.
• Do not operate the control system until 14 seconds or more after turning ON the power of the OS32C.
• Be sure to route the OS32C cable separate from high-potential power lines or through an exclusive conduit.
• When using a commercially available switching regulator power supply, make sure to
ground the FG terminal (frame ground terminal).
• Sharing the power supply with other devices may cause the OS32C to be affected by noise or voltage drop. It
is recommended that the safety-related devices use a dedicated power supply, not shared with other devices.
■ Cleaning
Do not use thinner, benzene, or acetone for cleaning. They will adversely affect the product's resin parts and paint on the case.
■ Object detection
The OS32C has a configurable minimum object resolution of 30mm, 40mm, 50mm, or 70mm. It cannot
detect transparent or translucent objects, or objects with reflective surfaces, of less than 1.8% reflectivity.
System Components
(10)
(9)
(11)
(8)
(7)
(6)
(12)
(13)
(5)
(1)
(2) (3) (4)
Function
No. Component
(1) RUN output indicator (green) Will turn ON when safety zone is clear and OSSDs are ON.
Interlock Indicator (yellow) Will turn ON when in interlock state, blink under lockout (@ 1Hz), and blink under configuration (@ 4Hz).
(3) Status/Diagnostic Display The scanner's status ,configuration/operation, or failure is displayed.
(4) Warning Output Indicator (orange) Will turn ON when the warning output is ON.
STOP output indicator (red) Will turn ON when safety zone is blocked, OSSD are OFF or under interlock state.
(5)
(6) Dust Ring Dust detection cover with reflective surface, for dust accumulation detection
(7) Individual Sector Indicators (ISI) Will turn ON when an intrusion is detected in the safety zone (default), 8 sectors total. Each sector = 33.75°.
Will flash when dust or contamination is detected on the scan window.
(8) Scan Window The window where the laser light is emitted and received.
(9) Communication Connector
Provides for Ethernet interface.*1
(10) Power Connector
For power connections, 18-pin connector (pigtail). *1
(11)
I/O Block Connector module
(12) Center of Rotation Indicates the location of the axis around which the laser irradiates from.
(13) Sensor Sensor Head; field replaceable.
*1: The communication and power connections can also be mounted on the left side of the I/O block.
Rating/Performance
Sensor Type Type 3 Safety Laser Scanner
Performance Level (PL)/ PL d, Safety Category 3 (ISO13849-1)
Safety Category
Functional Safety of
SIL 2, PFH = 8.3 x 10 -8 (IEC61508)
D
Electrical/Electronic/
Programmable Electronic
Safety-related Systems
Detection Capability Configurable; Non-transparent with a diameter of 30, 40, 50, 70mm (1.8% reflectivity or greater)
Monitoring Zone Monitoring Zone Set Count (Safety Zone + 2 Warning Zones) : 70 sets max.
Safety Zone: 1.75 m (min. obj. resolution of 30 mm)
Operating Range
2.5 m (min. obj. resolution of 40 mm)
OS32C-xxx 3.0 m (min. obj. resolution of 50 mm or 70 mm)
Warning Zone: 10.0 m
Safety Zone: 1.75 m (min. obj. resolution of 30 mm)
Operating Range
2.5 m (min. obj. resolution of 40 mm)
OS32C-xxx-4M
3.0 m (min. obj. resolution of 50 mm or 70 mm)
4.0 m (min. obj. resolution of 70 mm)
Warning Zone: 15.0 m
100 mm (at range of 3 m or less) *1
Maximum Measurement Error
110 mm (at range greater than 3 m and up to 4 m) *1
Detection Angle 270°
Angular Resolution 0.4 degree
Laser Beam Diameter 6mm at optics cover, 14mm (typical) at 3m.
Laser Scan Plane Height 67mm from the bottom of the scanner (see "OS32C Dimensions" above for more detail)
Response Time Response time from ON --> OFF: From 80 ms (2 scans) to 680ms (up to 17 scans) *8
Response time from OFF --> ON: Configurable.
Zone Switching Time From 20 to 320ms
Line voltage 24VDC +25%/-30% (ripple p-p 2.5V max.) *2
Power Consumption
Normal operation: 5Wmax., 4W typical (without output load)*3
Standby mode: 3.75W (without output load)
Emission Source Infrared Laser Diode (905nm)
(Wavelength)
Class 1 : IEC/EN60825-1
Laser Protection Class
Class 1 : JIS C 6802
Class I : CFR21 1040.10, 1040.11
PNP transistor x 2, load current of 250mA max., residual voltage of 2V max., load
Safety Output (OSSD)
capacitance of 2.2 µF max., leak current of 1mA max *3, *4, *5.
Auxiliary Output
NPN/PNP transistor x 1, load current of 100mA max., residual voltage of 2V max.,
(Non-Safety)
leak current of 1mA max *4, *5, *7
Warning Output
NPN/PNP transistor x 1, load current of 100mA max.,residual voltage of 2V max.,
(Non-Safety)
leak current of 1mA max *4, *5, *7
Operation Mode Auto Start, Start Interlock, Start/Restart Interlock
External Device ON: 0V short (input current of 50mA), OFF: Open
Monitoring
Start ON: 0V short (input current of 20mA), OFF: Open
Input
Zone Select ON: 24V short (input current of 5mA), OFF: Open
Standby ON: 24V short (input current of 5mA max.), OFF: Open
Connection Type Power Cable: 18-pin mini-connector (pigtail)
Communication Cable: M12, 4-pin connector
Connection with PC Communication: Ethernet *6
OS Supported: Windows XP, Windows 7, Windows 8.1, Windows 10
Indicators
RUN Indicator : Green, STOP Indicator : Red, Interlock Indicator : Yellow,
Warning Output Indicator : Orange
Status/Diagnostic Display: 2 x 7-segment LEDs
Individual Sector Indicators: Red LED x 8
Protective Circuit Protection against output load short and reverse power connection
Ambient Temperature Operation: -10 to 50 °C, Storage: -25 to 70 °C
Ambient Humidity Operation & Storage: 95%RH max., non-condensing
Ambient Operation Incandescent lamp: Illumination on receiving surface 1500lx max. (an angle of
Illumination laser scanning plane and disturbance light must be +/-5 degrees or more)
Insulation resistance 20 MΩ or higher (500VDC)
Dielectric withstand voltage 350 VAC, 1minute
Enclosure Rating IP65(IEC60529)
Enclosure Sensor Head: Die-cast aluminum
Optics Cover: Polycarbonate
I/O Block: Die-cast aluminum
Dimensions (WxHxD) 133.0 x 104.5 x 142.7mm (except cable)
Impact Resistance 98m/s 1000 times for each of X, Y, and Z directions (IEC60068-2-29) 2
Vibration 10 to 55 Hz double-amplitude of 0.7mm, 20 sweepings for X, Y, and Z directions
(IEC60068-2-6)
Weight (Main Unit only) 1.3kg
Power Cable Up to 30m
Communication Cable Up to 100m for 100 BASE-TX cable *9
Certificated by: TÜV Rheinland, UL
EN61496-1 (Type 3 ESPE), EN61496-3 (Type 3 AOPDDR), EN61508 (SIL2),
Approvals
IEC61496-1 (Type 3 ESPE), IEC61496-3 (Type 3 AOPDDR), IEC61508 (SIL2),
UL508, UL1998, CAN/CSA-C22.2 No. 14, CAN/CSA-C22.2 No. 0.8
*1. An additional measurement error may need to be added due to reflective backgrounds (See user's manual for
details).
*2. For power source specification, see Power Supply Unit in the OS32C user's manual.
*3. Rated current of OS32C is 1.025A max. (OS32C 210mA + OSSD A load + OSSD B load + Auxiliary output load
+ Warning output load + Functional Inputs).
Where functional inputs are:
EDM input ... 50mA
Start input ... 20mA
Standby input ... 5mA
Zone X input ... 5mA x 8 (eight zone set select inputs)
*4. Output voltage is Input voltage - 2.0VDC.
*5. Total consumption current of 2 OSSDs, auxiliary output, and warning output must not exceed 700mA.
*6. An Ethernet cable with an M12, 4-pin connector is required.
*7. Output polarity (NPN/PNP) is configurable via the configuration tool.
*8. Pollution tolerance in RBM mode will increase the scan period, resulting in an increase of the response time.
*9. Omron only supplies up to a 15 m Ethernet cable. For longer lengths a connection to a network switch/router is
needed.