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- Page 1 — SA F E T Y PR OD U CTS Orion2 Extended Safety light grids Product Manual Type 4 Active Opto-electronic Protective Device (AOPD) 2TLC172291M0201 Rev.D PRODUCT MANUAL new.abb.com/low-voltage/products/safety-products...
- Page 2 Suitability for use ABB shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer’s application or use of the product. Third party certificates for the products are available at https://new.abb.com/low- voltage/products/safety-products.
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Page 3: Table Of Contents
Table of Contents 1 Introduction ..........................5 Purpose of document .........................5 Intended audience ........................5 Reading prerequisites .........................5 Special notes ..........................5 Abbreviations..........................5 2 Safety ............................6 Safety precautions ........................6 3 Product description........................7 Resolution ............................7 Protected height ......................... 8 Minimum installation distance .................... - Page 4 Override ............................37 8.7.1 Override at start-up ....................38 8.7.2 Override at run time ....................39 9 Diagnostic functions ....................... 40 Visualization of the status of the AOPD ................40 LEDs on the transmitter ......................40 LEDs on the receiver ......................... 40 9.3.1 Alignment mode ......................
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Page 5: Introduction
This document is intended for authorized personnel. Reading prerequisites It is assumed that the reader of this document has knowledge of the following: • Basic knowledge of ABB safety products • Knowledge of machine safety Special notes Pay attention to special notes in the document:... -
Page 6: Safety
The safety precautions must be followed during installation, operation, maintenance and troubleshooting. Warning! For a correct and safe use of the Orion2 Extended light grids, the following points must be observed: • The stopping system of the machine must be electrically controlled. -
Page 7: Product Description
The Orion2 Extended light grids are Type 4 intrinsic safety systems used as accident- prevention protection devices and are manufactured in accordance with applicable standards. -
Page 8: Protected Height
The resolution depends only on the geometrical characteristics of the lenses, diameter and distance between centers, and is independent of any environmental and operating conditions of the AOPD. For the resolution of each model see chapter “Model overview”. Protected height It is important to distinguish between the “Height of the sensitive area”... -
Page 9: Vertically Assembled Aopd
Orion2 cannot be used horizontally. 3.3.3 Angled assembled AOPD See the latest version of EN ISO 13855. 3.3.4 Practical examples Let's suppose we have an Orion2 Extended light grid in a vertical position and with no risk of reaching over it. 2TLC172291M0201 Rev.D... - Page 10 S = K × (T1 + T2) + C Orion2-4-K2-050-E Orion2-4-K4-120-E T1: response time of AOPD 0.014 s 0.016 s (see chapter “Model overview”) T2: stopping time machine + safety control 0.380 s 0.380 s system (value as ex.) C: for AOPD with resolution > 40 mm...
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Page 11: 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 ABB for advice. • The operating distance of the device can be reduced in presence of smog, fog or airborne dust. - Page 12 Figure 4: Distance to reflecting surfaces It is thus important to respect a minimum distance between the AOPD and reflecting surfaces. The minimum distance, D , depends on: • operating distance between transmitter (TX) and receiver (RX) • effective aperture angle (EAA) of the AOPD: For a Type 4 AOPD, EAA = 5°...
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Page 13: Minimum Distance Between Adjacent Devices
The formula to get for a Type 4 AOPD: (m) = 0.15 for operating distance < 3 m (m) = 0.5 × operating distance (m) × tan (2α) for operating distance ≥ 3 m Warning! If the reflecting surface is the floor, whatever the calculated D , the minimum installation distance to the floor must still be respected, see chapter “Minimum installation distance”. -
Page 14: Installation Of Several Adjacent Devices
Figure 7: Minimum distance to an adjacent device as a function of the operating distance The formula to get for a Type 4 AOPD: (m) = 0.3 for operating distance < 3 m (m) = operating distance (m) × tan (2α) for operating distance ≥ 3 m Warning! Please note that TX can interfere with RX in the same way as TX... -
Page 15: Transmitter And Receiver Orientation
Figure 8: Installation of several devices close to each other 4.2.5 Transmitter and receiver orientation The two units shall be assembled parallel to each other and with the markings on active and passive units on the same side, both up or both down for example. The configurations shown in Figure 12 must be avoided. - Page 16 Figure 10: Use of deviating mirrors Note! The following precautions must be respected when using the deviating mirrors: • The alignment of the transmitter and the receiver can be a very critical operation when deviating mirrors are used. Even a very small displacement of the mirror is enough to loose alignment.
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Page 17: Checks After First Installation
Checks after first installation Control operations to carry-out after the first installation and before machine start-up. The controls must be carried-out by authorized personnel, either directly or under the strict supervision of the person in charge of machinery safety. Check that: •... -
Page 18: Mechanical Mounting
“Alignment procedure”. Mounting with angles fixing brackets Angled fixing brackets are supplied with all Orion2 Extended models. To mount the AOPD, insert the supplied threaded pins into the grooves on the two units (see Figure 12). -
Page 19: Electrical Connections
Brown Supply +24 VDC White (Not used) Blue Supply 0 VDC Black (Not used) Caution! All wire colors according to ABB standard cables. Receiver (RX) Pin Wire Function Connection to Chapter Auto. Reset with no +24 VDC RESET/ function 8.2,... -
Page 20: Important Notes On Connections
Caution! All wire colors according to ABB standard cables. Important notes on connections For the correct functioning of the Orion2 Extended light grids, the following precautions regarding the electrical connections shall be respected: • Use a suitably insulated low-voltage supply system type SELV or PELV. -
Page 21: Connection Examples
Connection examples Figure 13: Orion2 Extended connection See connections examples at ABB web: Optical safety devices - Safety Products | ABB https://new.abb.com/low-voltage/products/safety-products/optical-safety-devices Orion connection diagrams (abb.com) https://search.abb.com/library/Download.aspx?DocumentID=2TLC010029T0001&Language Code=en&DocumentPartId=&Action=Launch Note! Do not use varistors, RC circuits or LEDs in parallel with the relay inputs or in series with the OSSD outputs. - Page 22 Figure 15: Incorrect connection of OSSD outputs Figure 16: Time chart of the OSSD outputs 2TLC172291M0201 Rev.D...
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Page 23: Alignment Procedure
Alignment procedure The alignment between the transmitter and the receiver is necessary to obtain the correct functioning of the AOPD. A good alignment prevents outputs instability caused by dust or vibrations. The alignment is perfect if the optical axes of the first and the last beams of the transmitter coincide with the optical axes of the corresponding elements of the receiver. - Page 24 • Fix the two units firmly using pins and brackets. • Disconnect the power supply. • Re-connect the power supply. • Check that the green LED on the receiver is on when the beams are not interrupted. Then check that the green LED ( ) turns off and the red LED ( ) turns on when one single beam is interrupted.
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Page 25: Functions
Functions Dip-switch selectable functions A slot situated on the front side of the receiver (see Figure 18) and easily opened with a screwdriver, facilitates the access to the internal dip-switches. Dip-switches Figure 18: Location of the dip-switches Figure 19: Lock over the dip-switches To open the lid, insert the tip of a flat screwdriver into the groove of the hinged lid and lever it up slightly until the snap happens. -
Page 26: Configuration At Delivery
Configuration at delivery The device is supplied with the following configuration: Muting timeout = 10 min T/X-muting EDM deactivated Automatic Reset Note! The Muting function can only be activated if the muting sensors are properly connected to the Muting A and Muting B inputs and if one of the lamps operates correctly. -
Page 27: Acknowledge Function
Figure 21 below illustrates how Automatic Reset and Manual Reset work: Figure 21: Automatic/Manual Reset The selection of the Manual/Automatic Reset function is made with the dip-switches placed under the lid on the receiver: dip-switches 4 and 8 must be ON for the Automatic Reset function and OFF for the Manual Reset function. -
Page 28: Edm Function
Figure 23: Time chart of the Acknowledge function EDM function The AOPD has a function for monitoring actuation external devices (EDM). This function can be activated or deactivated. Figure 24: Dip-switches 3 and 7 OFF to activate the EDM function To use this function correctly: •... -
Page 29: Muting
Figure 26: Time chart of the EDM function and T are the times between the change of state of the OSSD outputs and the change of state of the NC contact of the external device. ≤ 200 ms: the external NC contacts must open within this time after the OSSD outputs have switched ON. -
Page 30: Typical Muting Application And Connection Of The Aopd
8.6.1 Typical muting application and connection of the AOPD Figure 28: Typical muting application The figure above shows a typical muting application: the box on the conveyor may go through the AOPD without stopping the machine but the worker may not. Following a correct activation sequence of the A1, B1, A2 and B2 sensors, the AOPD is temporarily bypassed. - Page 31 Figure 29: Integrated lamp • When the Muting function is on, the integrated lamp on the top of the receiver is on and the lamp output (pin 8) is driven. • 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.
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Page 32: Muting Direction
NORMAL OPERATION OSSD ON Figure 30: The muting lamp is on when the muting function is activated 8.6.2 Muting direction The AOPD can be used with: • T/X-muting when the “boxes” can move in both directions. This is the default setting. T-muting demands four muting sensors and X-muting only two. -
Page 33: T/X-Muting
8.6.3 T/X-muting Suitable when the objects/”boxes” can move in both directions. This is the default setting: Dip-switches 2 and 6 ON for T/X-muting Figure 31: • T-muting demands four muting sensors, A1, B1, A2 and B2. • X-muting demands two muting sensors, A1 and B2. The sensors named A1/A2 are connected to MUTING A and the sensors named B1/B2 are connected to MUTING B. - Page 34 D must be less than L, D < L d1max [cm] = V [m/s] × T max [s] × 100 d2max [cm] = V [m/s] × T max [s] × 100 Note! Guidance in the positioning of the muting sensors can be found in IEC/TS 62046.
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Page 35: L-Muting
8.6.4 L-muting Suitable only when the objects/“boxes” move in one direction. Figure 34: Dip-switches 2 and 6 OFF for L-muting • L-muting demands two muting sensors, A and B. The sensor named A is the farthest from the AOPD and must be activated first. If the sensor named B is activated first, the Muting function is not activated. - Page 36 Warning! L-muting must be used exclusively for materials going out of the hazard zone. Figure 36: Time chart of the L-muting function L-muting 0.01 s End of muting (t 2 x t Moff from when MUTING A goes low 10 minutes if dip-switches 1 and 5 ON Muting timeout Infinite if dip-switches 1 and 5 OFF (maximum muting time if the...
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Page 37: Override
Override The override function is used to bypass the AOPD completely and switch on the OSSD outputs when it is necessary to start the machine despite one or more beams of the AOPD being interrupted. The purpose is usually to clear the detection zone and move a “box” that has stopped there because of a cycle anomaly. -
Page 38: Override At Start-Up
8.7.1 Override at start-up • Switch off the power supply. • Restore the power supply and press the RESET button after approx. 5 s but within 9 s and keep it pressed for at least 5 s. The OSSD outputs switch on and remain activated for a maximum time of 600 s. -
Page 39: Override At Run Time
8.7.2 Override at run time • One or both muting inputs must be active. • Press and release the RESET button 3 times < 1 s. The OSSD outputs will be activated for more than 2 s and 600 s max. •... -
Page 40: Diagnostic Functions
Diagnostic functions Visualization of the status of the AOPD The operator can check the status of the AOPD using four LEDs on the receiver and two LEDs on the transmitter (Figure 40). Figure 40: LED display on the receiver and the transmitter LEDs on the transmitter •... -
Page 41: Diagnostic Messages
Description Action Generic error on Check the power supply. ON green transmitter side If the error persists, contact ABB and replace both units. Flashing yellow Power supply error Check the power supply. If the error persists, contact ABB. The power supply Check the power supply. -
Page 42: Receiver
Microprocessor in the same position as dip-switches 1-4. error Switch the devices off and on. Flashing yellow If the error persists, contact ABB. This is NOT an error. Flashing yellow Override possible Activate the Override function to remove the material from the detection zone. -
Page 43: Periodical Checks
Periodical checks The following is a list of recommended checks and maintenance operations that should be periodically carried-out by authorized personnel. Check that: • The AOPD remains in OSSD OFF state ( ) during beam interruption along the entire detection zone, using the suitable “Test Piece” and following the Figure 11 scheme (see chapter “Checks after first installation”). -
Page 44: Device Maintenance
Device maintenance Orion2 Base 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 to avoid making it opaque. -
Page 45: Model Overview
Model Overview Response Inter- Protected Operating Resolution time Type Article number height distance axis (mm) (mm) beams (ms) (mm) Orion2-4-K2-050-E 2TLA022305R0000 0.5..50 Orion2-4-K3-080-E 2TLA022305R0100 0.5..50 Orion2-4-K4-090-E 2TLA022305R0200 0.5..50 Orion2-4-K4-120-E 2TLA022305R0300 1215 0.5..50 2TLC172291M0201 Rev.D... -
Page 46: Dimensions
Dimensions 13.1 Profiles All dimensions are in mm. Figure 41: Dimensions Model [mm] [mm] [mm] Orion2-4-K2-050-E 538.4 Orion2-4-K3-080-E 838.4 Orion2-4-K4-090-E 1017 1064 938.4 Orion2-4-K4-120-E 1317 1364 1238.4 2TLC172291M0201 Rev.D... -
Page 47: Angled Fixing Bracket
13.2 Angled fixing bracket Figure 42: Dimensions angled fixing bracket 13.3 Fixing bracket with profile A MOUNTING B MOUNTING Figure 43: Dimensions angled fixing bracket with a profile 2TLC172291M0201 Rev.D... -
Page 48: Technical Data
Technical data Further information about the product and accessories is found at: new.abb.com/low-voltage/products/safety-products Manufacturer Address ABB Electrification Sweden AB SE-721 61 Västerås Sweden Electrical data Power supply (Vdd) +24 VDC 20 % (SELV/PELV) ± Internal capacitance 23 nF (TX) /120 nF (RX) Consumption (TX) 0.5 W during normal operation... - Page 49 Caps material PBT Valox 508 (grey RAL 7035) Lens material PMMA Weight 1.2 Kg max./ m for each single unit Functional safety data Prob. of Dangerous Failure/Hour = 2.62·10 (1/h) Life span (years) T1 = 20 Mean Time to Dangerous Failure MTTF = 384 (years)
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Page 50: Declarations Of Conformity
Declarations of conformity EC Declaration of conformity 2TLC172291M0201 Rev.D... - Page 51 UK Declaration of conformity 2TLC172291M0201 Rev.D...
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