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ABB Orion1 Product Manual

ABB Orion1 Product Manual

Extended safety light curtains
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SA F E T Y PR OD U CTS
Orion1 Extended Safety light curtains
Product Manual
Type 4 Active Opto-electronic Protective Device (AOPD)
2TLC172290M0201 Rev.D
PRODUCT MANUAL
new.abb.com/low-voltage/products/safety-products

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  • Page 1 — SA F E T Y PR OD U CTS Orion1 Extended Safety light curtains Product Manual Type 4 Active Opto-electronic Protective Device (AOPD) 2TLC172290M0201 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.

  • 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 8.3.3 Function list on the transmitter ................34 9 Functions ........................... 35 Reset function ........................... 35 9.1.1 Automatic Reset ...................... 35 9.1.2 Manual Reset ......................36 9.1.3 Configuration of the Reset function..............37 Test function ..........................37 Acknowledge function ......................37 EDM ..............................

  • 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 Orion1 Extended light grids, the following points must be observed: • The stopping system of the machine must be electrically controlled.

  • Page 7: Product Description

    The Orion1 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

    Figure 1: Resolution 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 Figure 2: Protected height 2TLC172290M0201 Rev.D...

  • Page 9: Minimum Installation Distance

    The protected height by the Orion1 Extended is the whole height of the AOPD. Referring to the figure above the protected height is reported in the table below. Model Protected height Hp (mm) Orion1-4-xx-030-E Orion1-4-xx-045-E Orion1-4-xx-060-E Orion1-4-xx-075-E Orion1-4-xx-090-E Orion1-4-xx-105-E 1050...

  • Page 10: Horizontally Assembled Aopd

    = minimum distance in mm H1 = height of the lowest beam 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 3: Minimum distance for a vertically assembled AOPD = (K ×...

  • Page 11: Angled Assembled Aopd

    See the latest version of EN ISO 13855. 3.3.4 Practical examples Orion1-4-xx-060 in a vertical position and with no risk of reaching Let's suppose we have an over it. S = K × (T1 + T2) + 8 × (d -14)

  • 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 ABB for advice. • The operating distance of the device can be reduced in presence of smog, fog or airborne dust.
  • Page 13 Figure 6: Correct device positioning Under normal operating conditions, it must be impossible to start the machine while operators are inside the hazard zone. When the installation of the AOPD close to the hazard zone is not possible, a second AOPD must be mounted in a horizontal position to prevent any lateral access (see Figure 8).

  • Page 14: Minimum Installation Distance

    4.2.1 Minimum installation distance See chapter 3.3 “Minimum installation distance”. 4.2.2 Minimum distance to reflecting surfaces Reflecting surfaces placed near the light beams of the AOPD (over, under or laterally) can cause passive reflections. These reflections can compromise the recognition of an object inside the detection zone.

  • Page 15: Minimum Distance Between Adjacent Devices

    The diagram below shows the minimum distance to the reflecting surface (D ), based on the operating distance for a Type 4 AOPD: Figure 10: Distance to a reflective surface as a function of the operating distance The formula to get for a Type 4 AOPD: (m) = 0.15 for operating distance <...

  • Page 16: Installation Of Several Adjacent Devices

    The diagram below shows the distance to the interfering devices (D ) based on the operating distance (D ) of the couple (TX – RX ) for a Type 4 AOPD. Figure 12: 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 <...
  • Page 17 Some examples of correct and incorrect installations when it comes to interferences. Figure 13: Installation of several devices close to each other If two AOPDs have to be mounted close to each other as in the first example of Figure 13, the coding function can be a solution (refer to chapter “Coding function”).

  • Page 18: Transmitter And Receiver Orientation

    4.2.5 Transmitter and receiver orientation The two units shall be assembled parallel to each other, with the beams arranged at right angles to the transmitting and receiving surfaces, and with the connectors pointing towards the same direction. The configurations shown in Figure 14 must be avoided. Figure 14: Incorrect orientation 4.2.6 Use of deviating mirrors...

  • Page 19: Checks After First Installation

    • The minimum installation distance (S) must be respected for each single section of the beams. • The effective operating range decreases by about 15% by using only one deviating mirror, the percentage further decreases by using 2 or more mirrors (for more details, refer to the technical specifications of the mirrors used).
  • Page 20 • The AOPD is correctly aligned: press slightly the product side in both directions and check that the red LED (named OSSD on the receiver) does not turn on. • The OSSD outputs switch off (red LED “OSSD” on the receiver turns on and the controlled machine stops) when the Test function (on the transmitter) is activated.

  • Page 21: Mechanical Mounting

    “Alignment procedure”. Mounting with angles fixing brackets Angled fixing brackets are supplied with all Orion1 Extended models. To mount the AOPD, insert the supplied threaded pins into the dedicated location in the end cap (see Figure below). Then let the pins slide towards the metallic groove. Fix the bracket against the profile by tightening the M5 hexagonal nuts.

  • Page 22: Electrical Connections

    Transmitter, cable M12-C02PT2T Pin Wire Function Connection to Chapter Brown Supply +24 VDC White TEST NO contact to +24 VDC Blue Supply 0 VDC Black EARTH Earth Grey (Not used) Caution! All wire colors according to ABB standard cables. 2TLC172290M0201 Rev.D...

  • Page 23: Receiver, Cable For Muting, M12-C02Pt62Rm

    Receiver, cable for muting, M12-C02PT62RM 6.2.1 Receiver cable for muting, M12-12 connector Pin Wire Function Connection to Chapter Brown Supply +24 VDC Blue Supply 0 VDC Auto. Reset with no Not connected function RESET/ Auto. Reset with NO contact to ACKNOW- White Acknowledge function...

  • Page 24: Receiver Cable For Muting, M12-5 Connector

    This output can fluctuate at start-up independently of the Override function. 12 Red- EARTH Earth Blue Caution! All wire colors according to ABB standard cables. 6.2.2 Receiver cable for muting, M12-5 connector Pin Wire Function Connection to Chapter Brown Supply...

  • Page 25: Important Notes On Connections

    Caution! All wire colors according to ABB standard cables. Important notes on connections For the correct functioning of the Orion1 Extended light curtains, the following precautions regarding the electrical connections shall be respected: • Use a suitably insulated low-voltage supply system type SELV or PELV.

  • Page 26: Connection Examples

    The device is already equipped with internal overvoltage and overcurrent suppression devices. The use of other external components is not recommended. Connection examples Figure 19: Orion1 Extended connection See connection 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 27 Figure 21: Incorrect connection of OSSD outputs Figure 22: Time chart of the OSSD outputs 2TLC172290M0201 Rev.D...

  • Page 28: 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 29: Correct Alignment Procedure

    Once the optimal alignment has been reached, the device is returned to normal function by turning the device off and on. Note! The OSSD outputs are off in alignment mode. Correct alignment procedure The alignment is performed after having completed the mechanical installation and the electrical connections as described above.
  • Page 30 Once the AOPD has been aligned and correctly fastened, the signal on the display is useful both to check the alignment and to show a change in the environmental conditions (presence of dust, light disturbance and so on). 2TLC172290M0201 Rev.D...

  • Page 31: Function Setting

    Function setting The configuration of the functions and the parameters of the AOPD can be performed with the help of push-buttons and LED display (available on both receivers and transmitters). A display consisting of 8 LEDs and 3 protected push-buttons is used for the basic configura- tion.

  • Page 32: Function List

    Function list Orion1 Extended has two main operating modes: Blanking and Muting. LEDs 5 to 8 have different functions in Muting mode and Blanking mode. Note! The default configuration is indicated in bold characters. Note! The last 3 LEDs don’t change status when changing from Muting mode to Blanking mode (and vice versa).

  • Page 33: Function List On The Receiver In Blanking Mode (Led 3 Off)

    8.3.2 Function list on the receiver in Blanking mode (LED 3 OFF) LED Status LEVEL Function Setting number Coding Code 1 Code 2 No Code Muting/Blanking selection Muting Blanking Enabled Disabled Reset function Auto Manual Floating blanking selection Floating blanking disa- bled Floating blanking 1 beam...

  • Page 34: Function List On The Transmitter

    8.3.3 Function list on the transmitter LED Status Function num- Setting CODE Coding Code 1 Code 2 No Code Range selection Long Short The default configuration (at delivery) is indicated in bold characters. 2TLC172290M0201 Rev.D...

  • Page 35: Functions

    Functions Reset function The interruption of a beam by an opaque object causes the OSSD outputs to switch off. The AOPD can be reset to the OSSD ON state in two different ways. Automatic reset is the default setting. The Reset function can be configured, see chapter 9.1.3.

  • Page 36: Manual Reset

    9.1.2 Manual Reset When activated, the AOPD returns to OSSD ON once the RESET button has been pushed, pro- vided that the object has been removed from the detection zone. The RESET push-button must be kept pressed for at least 500 ms but less than 5 s, otherwise the AOPD goes in Error mode.

  • Page 37: Configuration Of The Reset Function

    9.1.3 Configuration of the Reset function Configuration of the Reset function LEVEL Auto LED 5 ON Red Manual LED 5 OFF Test function The Test function is activated by pressing an external NO contact (TEST push-button, pin 2 of the M12-5 pole connector on the transmitter) for at least 0.5 s. The Test stops the emission, the receiver sees all beams being interrupted and the OSSD outputs switch off within the response time.

  • Page 38: Edm

    Figure 32: Time chart of the Acknowledge function The AOPD has a function for monitoring the actuation of external devices (EDM). This function can be activated or deactivated, see chapter 9.4.3. 9.4.1 EDM activated When the EDM function is activated, connect the EDM input (pin 6 of M12-12 pole connector on the receiver) to +24 VDC through the normally closed contacts of the devices to be monitored.

  • Page 39: Edm Deactivated

    Figure 34: 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. ≤ 350 ms: the external NC contacts must open within this time after the OSSD outputs have switched on.

  • Page 40: Configuration Of The Edm Function

    9.4.3 Configuration of the EDM function This function allows the user to activate or deactivate the monitoring of the external switching devices. Configuration of the EDM function LEVEL Activated LED 4 ON Yellow Deactivated LED 4 OFF To increase the level of safety, the AOPD checks that the EDM input is floating at start-up when the EDM function is deactivated.

  • Page 41: Configuration Of The Range Selection Function

    9.5.1 Configuration of the Range selection function Configuration of the Reduction of range function on the transmitter CODE Long LED 3 ON Yellow Short LED 3 OFF Muting The Muting function allows automatic bypassing of the safety function on the whole or part of the protected height in order to carry out specific operations without stopping the machine.

  • Page 42: Enabling Of The Muting Function

    The Muting function is enabled by default (at delivery). It can be dynamically enabled and dis- abled during the operation of Orion1 Extended. When disabled, no valid muting request on the MUTING inputs is accepted and the safety function is never bypassed.

  • Page 43: Muting Direction

    The output of the muting sensors (A1, B1, A2 and B2) should be high when the object is detected. The muting sensors can be optical sensors, mechanical sensors, proximity sensors, etc. 9.6.4 Muting direction The AOPD can be used with: •...
  • Page 44 • The length of the “box”. • The distance at which the sensors A1/A2 or B1/B2 must be mounted. (D depends on L, see below.) • The speed of the “box”. • d1 = The maximum distance between the muting sensors. (d1 depends on V, see below.) •...
  • Page 45 T and X-muting T12max Tdelay As soon as A or B goes low End of muting Muting timeout 10 min or infinite see chapter 8.6.5 9.6.4.2 L-muting 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 46 Time chart of L-muting Figure 42: L-muting T12max Tdelay End of muting After 2 × T12 after deactivation of MUTING1 10 min or infinite Muting timeout, see chapter 9.6.5 T12 is the actual activation time between MUTING1 and MUTING2. 9.6.4.3 Configuration of the Muting direction Configuration of the Muting Direction LEVEL...

  • Page 47: Muting Timeout

    9.6.5 Muting timeout The muting timeout defines the maximum duration of the Muting function, after the timeout the muting ends. This time can be set. The user can select a timeout of 10 minutes or infinite; “infinite” means that the muting could never end: the Muting function is activated as long as the muting conditions persist.

  • Page 48: 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 49 9.7.1.1 Override – Level trigger The Override function is activated when both contacts are closed AND at least one muting sensor is activated. OVERRIDE STATUS is an output signal that is high when the OVERRIDE inputs are active and the override conditions true. Figure 45: Time chart of the Override function with level trigger 9.7.1.2 Override –Edge trigger...

  • Page 50: Override Timeout

    Figure 46: Time chart of the Override function with edge trigger Warning! Edge trigger of the override is not compliant with EN 61496-1. 9.7.1.3 Configuration of the Override trigger Configuration of the Override trigger LEVEL Level LED 8 ON Green Edge LED 8 OFF 9.7.2...

  • Page 51: Override Reset

    Figure 47: Time chart of the Override function 9.7.3 Override reset The ACKNOWLEDGE/RESET/ALIGN input (pin 3 of the M12-12 pole connector on the receiver) should be connected to +24 VDC through a normally open contact. Figure 48: Connection of the override reset When override ends, the OSSD outputs switch off and a reset is required to switch them on.

  • Page 52: Blanking

    Figure 49: Time chart of the override reset Blanking The Blanking function allows the OSSD outputs of the AOPD to remain on and the machine to work, even if a pre-determined number of beams within the detection zone is being inter- rupted.

  • Page 53: Activation Of The Blanking Function

    9.8.1 Activation of the Blanking function Muting/Blanking selection LEVEL Muting LED 3 ON YELLOW Blanking LED 3 OFF 9.8.2 Fixed blanking Fixed blanking allows a fixed portion of the detection zone (i.e. a fixed set of beams) to be occupied, while all the other beams operate normally. In Fixed blanking, the beams of the blanked zone have to remain interrupted, otherwise the OSSD outputs of the AOPD switch off.

  • Page 54: Floating Blanking

    9.8.2.2 Fixed blanking – Tolerance When the Tolerance function is active, the object can move 1 beam above or below the blanking zone. If the object moves more than 1 beam out of the blanking zone, the AOPD enters Error mode (Blanking error). The Tolerance function is useful when there is a risk that the object slightly moves from its initial position.

  • Page 55: Cascade

    9.8.3.1 Reduced resolution Reduced resolution is a particular kind of floating blanking where more than one object can interrupt each a specific number of beams with the AOPD remaining in OSSD ON state. 4 adjacent beams can be interrupted by the object while the AOPD remains in OSSD ON state. The object may interrupt 0, 1, 2, 3 or 4 beams while the AOPD remains in OSSD ON state.

  • Page 56: Coding Function

    A safe auto-recognition procedure is implemented at start up. It automatically detects the topology of the cascade connection and correctly addressed units. To allow auto-recognition, the supplied termination caps must be mounted on the tail connector of the last cascade unit, on both transmitter and receiver units.
  • Page 57 Figure 51: Code 1 and code 2 The type of coding chosen can be visualized on the display when the beams are interrupted: Normal operation mode – Display on the receiver when a beam is interrupted LEVEL No Code LED 5 and 6 OFF Code 1 LED 5 ON Red, LED 6 OFF Code 2...
  • Page 58 9.10.2.1 Configuration of the codes Two codes are available, code 1 and code 2. An AOPD with no code can be disturbed by any other AOPD. Configuration of the codes ̶ Transmitter and receiver LEVEL CODE No Code LED 2 OFF Code 1 LED 2 ON Red Code 2...

  • Page 59: Diagnostic Functions

    Acknowledge. Switch the AOPD off and on. If the Critical error error persists, contact ABB. It is not possible to acknowledge a critical error. The device must be switched off and on. If the error persists, contact ABB. 2TLC172290M0201 Rev.D...

  • Page 60: Receiver

    10.1.2 Receiver LEVEL LED configuration AOPD mode Status Action See chapter Not aligned “Alignment procedure” See chapter “Alignment FIRST aligned procedure” See chapter Alignment LAST aligned “Alignment procedure” Minimum See chapter alignment signal “Alignment level procedure” Maximum See chapter alignment signal “Alignment level procedure”...
  • Page 61 LED configuration AOPD mode Status Action Valid Blanking (OSSDs ON) Blanking zones not respected. Invalid blanking Normal (OSSDs OFF) Reconfigure blanking operation (teach-in). Blanking only Check the effective resolution of the AOPD BCM tolerance and if the tolerance active function should be activated.
  • Page 62 Power supply wiring of the power supply error Connection. If the error persists, contact ABB. It is not possible to acknowledge a critical error. The device must be switched off and on. If the error persists, contact ABB. 2TLC172290M0201 Rev.D...

  • Page 63: Periodical Checks

    Periodical checks The following is a list of recommended checks and maintenance operations that should be periodically carried-out by qualified personnel. Check that: • AOPD remains in OSSD OFF state during beam interruption along the entire detection zone, using the suitable “Test piece” according to the Figure 16 scheme (chapter “Checks after first installation”.) •...

  • Page 64: Device Maintenance

    Device maintenance Orion1 Extended light curtains 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 65: Model Overview

    Model Overview Response Response Protected Number time time Resolution Model Article number height no code with code (mm) (mm) beams (ms) (ms) Orion1-4-14-030-E 2TLA022301R0100 Orion1-4-14-045-E 2TLA022301R0200 Orion1-4-14-060-E 2TLA022301R0300 Orion1-4-14-075-E 2TLA022301R0400 Orion1-4-14-090-E 2TLA022301R0500 Orion1-4-14-105-E 2TLA022301R0600 1050 Orion1-4-14-120-E 2TLA022301R0700 1200 Orion1-4-14-135-E 2TLA022301R0800...
  • Page 66 Slave response sponse time no time no code time with code time with code code Model (ms) (ms) (ms) (ms) slave master code slave code master Orion1-4-14-030-E 13.7 13.7 19.1 19.1 Orion1-4-14-045-E 15.4 15.4 23.6 23.6 Orion1-4-14-060-E 17.2 17.2 28.1 28.1 Orion1-4-14-075-E 18.9...

  • Page 67: Dimensions

    Dimensions 14.1 Profiles Figure 52: Dimensions of the profiles All dimensions are in mm. Model (mm) L (mm) Orion1-4-xx-030-E 306.3 Orion1-4-xx-045-E 456.3 Orion1-4-xx-060-E 606.3 Orion1-4-xx-075-E 756.3 Orion1-4-xx-090-E 906.3 Orion1-4-xx-105-E 1056.3 Orion1-4-xx-120-E 1050 1206.3 Orion1-4-xx-135-E 1200 1356.3 Orion1-4-xx-150-E 1350 1506.3 Orion1-4-xx-165-E 1500 1656.3...

  • Page 68: Angled Fixing Bracket

    14.2 Angled fixing bracket Figure 53: Dimensions of the of the angled fixing bracket 14.3 Fixing bracket with profile Figure 54: Angled fixing bracket 2TLC172290M0201 Rev.D...

  • Page 69: Tool For Bcm Configuration

    Connection cables 14.5.1 Transmitter cable Figure 56: Transmitter cable This cable must always be used with an Orion1 Extended transmitter. It has an 18 pole connector on one side and a M12-5 pole male connector on the other side. Model Description...

  • Page 70: Receiver Blanking Cable

    Receiver blanking cable Figure 57: Receiver blanking cable This cable must be used with an Orion1 Extended receiver configured in Blanking mode. It has an 18 pole connector on one side and a M12-12 pole male connector on the other side.

  • Page 71: Receiver Muting Cable

    Receiver muting cable Figure 58: Receiver muting cable This cable must always be used with an Orion1 Extended receiver configured in Muting mode. It has an 18 pole connector on one side and two M12 male connectors on the other side, one M12-5 pole and one M12-12 pole.

  • Page 72: 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) ± Unit current draw (TX) 3 W max...
  • Page 73 Housing material Painted aluminum (yellow RAL 1003) Front house material PMMA Caps material PBT Valox 508 (pantone 072C) Cover material PC LEXAN Weight 1.35 Kg per linear m for single unit Functional safety data Prob. of Dangerous Failure/Hour = 2.64·10 (1/h) Life span (years) T1 = 20...

  • Page 74: Declarations Of Conformity

    Declarations of conformity EC Declaration of conformity 2TLC172290M0201 Rev.D...
  • Page 75 UK Declaration of conformity 2TLC172290M0201 Rev.D...

This manual is also suitable for:

Orion1-4-14-060-eOrion1-4-30-060-e

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