ABB Orion3 Extended Original Instructions Manual
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ABB Orion3 Extended Original Instructions Manual

Safety light grids, type 4 active opto-electronic protective device aopd
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Original instructions
Orion3 Extended
Safety light grids
Type 4 Active Opto-electronic Protective Device (AOPD)
ABB Jokab Safety Varlabergsvägen 11, SE-434 39 Kungsbacka, Sweden
www.abb.com/jokabsafety

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  • Page 1 Original instructions Orion3 Extended Safety light grids Type 4 Active Opto-electronic Protective Device (AOPD) ABB Jokab Safety Varlabergsvägen 11, SE-434 39 Kungsbacka, Sweden www.abb.com/jokabsafety...
  • Page 2 DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. In no event shall responsibility of ABB JOKAB SAFETY for any act exceed the individual price of the product on which liability asserted.

  • Page 3: Table Of Contents

    Mounting with angled fixing brackets ......................20 Electrical connections........................21 Active unit ................................ 21 Important notes on connections ........................22 Connection examples ............................23 Alignment procedure ........................26 Alignment mode .............................. 27 Correct alignment procedure ........................... 28 Functions ............................30 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 4 11 Technical data ........................... 52 12 Model overview ..........................54 13 Dimensions ............................55 13.1 Profiles ................................55 13.2 Angled fixing bracket ............................56 13.3 Fixing bracket with profile ..........................56 14 EC Declaration of conformity ......................57 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 5: Introduction

    1 Introduction 1.1 Scope The purpose of these instructions is to describe the Orion3 Extended light grids and to provide the necessary information required for selection, installation and operation of the safety devices. 1.2 Audience This document is intended for authorized installation personnel.

  • Page 6: Overview

    2 Overview 2.1 General description The Orion3 Extended light grids are Active Opto-electronic Protective Devices (AOPDs) that are used to protect working areas that, in presence of machines, robots, and automatic systems in general, can become hazardous for operators that get in touch, even accidentally, with moving parts.

  • Page 7: Resolution

    See paragraph 12 – “Model overview” for the resolution of each model. 2.3 Protected height The following figures illustrate what is meant with protected height (Hp) for Orion3 Extended. For the values of Hp for each model, see paragraph 12 – “Model overview”.
  • Page 8 Figure 2 – Orion3 Extended with 2 beams Figure 3 – Orion3 Extended with 3 beams Figure 4 – Orion3 Extended with 4 beams Model Protected height (mm) Orion3-4-K1C-050-E Orion3-4-K2C-080-E Orion3-4-K2C-090-E Orion3-4-K2C-120-E 1200 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 9: Minimum Installation Distance

    H2 = height of the uppermost beam H1 ≤ 300 mm* H2 ≥ 900 mm *400 mm can be used for 2 beams when the risk assessment allows it. Figure 5 – Minimum distance for a vertically assembled AOPD 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 10: Horizontally Assembled Aopd

    See the latest version of EN ISO 13855. 2.4.4 Practical examples Let's suppose we have an Orion3 Extended light grid in a vertical position and with no risk of reaching over it. S = K × (T1 + T2) + C Orion3-4-K1C-050-E...

  • Page 11: Safety Information

    2.5 Safety information Warning! For a correct and safe use of the Orion3 Extended light grids, the following points must be observed:  The stopping system of the machine must be electrically controlled.  This control system must be able to stop the hazardous movement of the machine within the total machine stopping time T as per paragraph “2.4 –...

  • Page 12: Installation

    Do not place the AOPD near strong and/or flashing light sources or similar devices.  Strong electromagnetic interferences can jeopardize the function of the AOPD. Please contact your ABB Jokab Safety representative for advice.  The operating distance of the device can be reduced in presence of smog, fog or airborne dust ...
  • Page 13 For a type 4 AOPD, EAA = 5° (α = ± 2.5°). Figure 7 below shows the minimum distance to the reflecting surface (D ), based on the operating distance for a Type 4 AOPD: 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 14 AOPD at longer distances is not recommended. Always check the correct function and that no dangerous reflections towards the receiving optics are generated by shiny objects (See Figure 8). Figure 8 – Reflection by shiny objects 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 15: Minimum Distance Between Adjacent Devices

    ) based on the operating distance (D of the couple Passive A – Active A for a Type 4 AOPD. Figure 10 – Minimum distance to an adjacent device as a function of the operating distance 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 16 Warning! Please note that the Passive A can interfere with Active B in the same way as Passive B with Active A and, if the two pairs of AOPD have different operating distances, the longest one should be used for the calculation of D 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 17: Installation Of Several Adjacent Devices

    Figure 11 provides some examples of correct and incorrect installations when it comes to interferences. Figure 11 – Installation of several devices close to each other 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 18: Active And Passive Unit Orientation

    2 or more mirrors (for more details, refer to the technical specifications of the mirrors used).  Do not use more than three mirrors for each device.  The presence of dust or dirt on the reflecting surface of the mirror causes a drastic reduction in the range. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 19: Checks After First Installation

    OSSD OFF state for the same period of time.  All additional functions behave as expected by activating them in different operating conditions. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 20: Mechanical Mounting

    6 – ”Alignment procedure”. 4.1 Mounting with angled fixing brackets Angled fixing brackets are supplied with all Orion3 Extended models. To mount the AOPD, insert the supplied “double nut plate” (M5) into the grooves on the two units (see Figure 14).

  • Page 21: Electrical Connections

    MUTING B Muting sensor B Grey OSSD1 Safety control module for ex. Pink OSSD2 Safety control module for ex. Blue Supply Muting Muting lamp and +24 VDC lamp Colours according to ABB Jokab Safety standard cables 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 22: Important Notes On Connections

    5.2 Important notes on connections For the correct functioning of the Orion3 Extended light grids, the following precautions regarding the electrical connections have to be respected:  Use a suitably insulated low-voltage supply system type SELV or PELV.  Do not place connection cables in contact with or near high-voltage cables and/or cable undergoing high current variations (e.g.

  • Page 23: Connection Examples

    5.3 Connection examples Figure 15 – Connection to a RT9 safety relay 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 24 NB: Connect both OSSD outputs to the activating device. Failure to connect an OSSD to the activating device jeopardizes the SIL and/or PL of the system that the AOPD controls. Figure 16 – Correct connection of OSSD outputs Figure 17 – Incorrect connection of OSSD outputs 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 25 Figure 18 – Time chart of the OSSD outputs 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 26: Alignment Procedure

    The standard installation described hereinafter is the one shown in Figure 20, i.e. with the connectors pointing down. Obviously, the first and the last couples coincide when the AOPD has only 2 beams. Figure 20 – First and last transmitter/receiver couple 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 27: Alignment Mode

    Figure 22 – Time chart of the Alignment mode Once the optimal alignment has been reached, the device is returned to normal function by turning the active unit off and on. NB: The OSSD outputs are off in alignment mode. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 28: Correct Alignment Procedure

    Every couple over the lower light reception threshold and one couple over the upper OSSD ON light reception threshold Every couple over the upper light reception OSSD ON threshold Maximum light reception Excellent OSSD ON 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 29 Every couple over the lower light reception threshold and one couple over the upper light reception threshold Every couple over the upper light reception threshold Excellent 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 30: Functions

    Warning! The device does not accept configuration changes during normal operation. A change is taken into account after the next powering of the device. Therefore, the management and the use of the configuration dip-switches should be performed with great care. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 31: Reset Function

    Warning! The RESET button must be located in such a way that the operator can check the entire hazard zone during any reset operation. = 150 ms RESET Figure 24 – Time chart for the Manual Reset function Select Automatic or Manual Reset with dip-switches 7, see paragraph 7.1 – “Dip-switch selectable functions”. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 32: Acknowledge Function

    NB: Some errors are critical errors and the device must be turned off and on to return to normal operation mode:  Microprocessor error  Reset selection error  Override sequence error  Dip switch error 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 33: Edm Function

    ≤ 350 ms: the external NC contacts must open within this time after the OSSD outputs have switched on. ≤ 100 ms: the external NC contacts must close within this time after the OSSD outputs have switched off. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 34: Muting

    Particular attention must be paid to the use of the one-way L-muting mode: the muting sensors must be positioned to allow the passage of the material coming out of the hazard zone protected by the AOPD. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 35 . The value of the muting timeout is chosen between 10 min and infinite with dip-switches 1. Warning! An infinite muting (timeout = ) is not compliant with EN 61496-1:2013. Therefore, all possible risks must be considered and related precautions undertaken before selecting the option “”. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 36 If both the integrated lamp and the external lamp are broken and/or not connected, the muting request causes the AOPD to enter Error mode and the OSSD outputs to switch off. The corresponding error is indicated. Warning! The lamp should be as visible as possible. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 37: Muting Direction

    The muting direction is chosen with the dip-switches 2 and T / X-muting is the configuration at delivery (both 2 ON). Warning! Select the configuration carefully: an incorrect configuration can cause a reduction of the SIL/PL reached by the system. For a correct use of the muting, please refer to the relevant standards. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 38: T / X Muting

    The sensors that end with “1” are on the same side of the AOPD and the sensors that end with “2” are on the opposite side of the AOPD. Figure 33 – Connection of T / X-muting Warning! In X-muting, the crossing point of the two muting sensors must be within the hazard zone. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 39 [cm] = V [m/s] × T max [s] × 100 d2max [cm] = V [m/s] × T max [s] × 100 NB: guidance in the positioning of the muting sensors can be found in IEC/TS 62046. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 40 (“10 min” is the default value, see paragraph 7.1) Warning! An infinite muting (timeout = ) is not compliant with EN 61496-1:2013. Therefore, all possible risks must be considered and related precautions undertaken before selecting the option “”. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 41: L-Muting

    = The maximum activation delay allowed between MUTING A and MUTING B. Then d1max [cm] = V [m/s] × T max [s] × 100 NB: guidance in the positioning of the muting sensors can be found in IEC/TS 62046. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 42 (“10 min” is the default value, see paragraph 7.1) Warning! An infinite muting (timeout = ) is not compliant with EN 61496-1:2013. Therefore, all possible risks must be considered and related precautions undertaken before selecting the option “”. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 43: Override

    Warning! The lamp should be as visible as possible. Figure 37 – Integrated lamp When the requirements are met, the display informs the user that an override is possible and required. Figure 38 – Indication that the Override function can be activated 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 44: Override At Start-Up

    If the AOPD is in Manual Reset, it is possible to choose between a Manual Reset and an Automatic Reset for the Override function. See paragraph 7.6.3. 5 s < T < 9 s Figure 39 – Time chart for the Override function at start-up 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 45: Override At Run Time

    If the AOPD is in Manual Reset, it is possible to choose between a Manual Reset and an Automatic Reset for the Override function. See paragraph 7.6.3. Figure 40 – Time chart for the Override function at run time 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 46: Reset Mode Of The Override Function

    Therefore, all possible risks must be considered and related precautions undertaken. It is recommended to:  Assign all control operations to a well-trained and skilled personnel,  Make sure that the operator running the override function has a total visibility of the whole area. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 47: Diagnostic Functions

    Remove the object from the Beam(s) interrupted. Interlock detection zone and push the OSSD outputs off. RESET button. OSSD ON OSSD outputs on. OSSD OFF OSSD outputs off. Normal operation mode, EDM function activated. OSSD OFF, interlock 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...
  • Page 48 OSSD error, one or both. or with the supply voltage. Error mode OSSD outputs off. Then Acknowledge. If the error persists, contact your ABB Jokab Safety representative. Turn AOPD off and on. If the error Error mode Microprocessor error. persists, contact your (critical) OSSD outputs off.
  • Page 49 If the error persists, contact your ABB Jokab Safety representative. It is not possible to acknowledge a critical error. The device must be switched off and on. If the error persists, contact your ABB Jokab Safety representative. 2TLC172292M0201 Rev B www.abb.com/jokabsafety...

  • Page 50: Periodical Checks

    Access to the hazard zone of the machine from any unprotected area is not possible.  The AOPD and the external electrical connections are not damaged. The frequency of the checks depends on the particular application and on the operating conditions of the AOPD. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 51: Device Maintenance

    10 Device maintenance Orion3 Extended light grids do not require special maintenance operations. To avoid the reduction of the operating distance, optic protective front surfaces must be cleaned at regular intervals. Use soft cotton cloths damped in water. Do not apply too much pressure on the surface in order to avoid making it opaque.

  • Page 52: Technical Data

    11 Technical data Manufacturer Address ABB JOKAB SAFETY Varlabergsvägen 11 SE-434 39 Kungsbacka Sweden Electrical data +24 VDC  20 % Power supply: Active unit consumption (RX): 2.5 W max (normal operation without load) Outputs: 2 PNP Short-circuit protection: 1.4 A max at 55 °C Output current 0.5 A max / output...
  • Page 53 EN IEC 61508-1:2010, SIL 3 EN IEC 61508-2:2010, EN IEC 61508-3:2010, EN IEC 61508-4:2010 EN IEC 62061:2005/A1:2013 SIL CL 3 Prob. of Dangerous Failure/Hour (1/h) 8.57x10 Life span (years) Mean Time to Dangerous Failure (years) MTTF 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 54: Model Overview

    Article number height time distance (mm) (mm) (mm) beams (ms) Orion3-4-K1C-050-E 2TLA022307R0000 0.5..8 519,75 Orion3-4-K2C-080-E 2TLA022307R0100 0.5..8 399,75 Orion3-4-K2C-090-E 2TLA022307R0200 0.5..6.5 319,75 Orion3-4-K2C-120-E 2TLA022307R0300 1200 0.5..8 419,75 Orion3-4-M1C-050 2TLA022306R1000 Orion3-4-M2C-080 2TLA022306R1100 Orion3-4-M2C-090 2TLA022306R1300 Orion3-4-M2C-120 2TLA022306R1400 1200 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 55: Dimensions

    Orion3-4-K2C-090-E (See Figure 43) 1006.35 920.5 Orion3-4-K2C-120-E (See Figure 43) 1306.35 1220.5 Orion3-4-M1C-050 (See Figure 44) 580.5 520.5 Orion3-4-M2C-080 (See Figure 44) 880.5 820.5 Orion3-4-M2C-090 (See Figure 44) 980.5 920.5 Orion3-4-M2C-120 (See Figure 44) 1280.5 1220.5 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 56: Angled Fixing Bracket

    13.2 Angled fixing bracket Figure 45 – Dimensions of the angled fixing bracket 13.3 Fixing bracket with profile Figure 46 – Dimensions of the angled fixing bracket with a profile NB: All dimensions in millimeters. 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

  • Page 57: Ec Declaration Of Conformity

    14 EC Declaration of conformity 2TLC172292M0201 Rev B www.abb.com/jokabsafety 2018-04-19...

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