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User's Manual - Lakewood Automation

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1. Approvals OS32C User s Manual 11 Description of Use and Features OS32C 12 User s Manual Chapter2 Operating States amp Output Modes Operating States 14 Operating Mode 16 Automatic Start 16 Start Interlock 16 Start Restart Interlock 16 Power Reserve Mode 16 Parameter Configuration 17 Safety Critical Parameters 17 Non Safety Critical Parameters 18 Safety Outputs 19 Auxiliary amp Warning Outputs 19 Reference Boundary Monitoring RBM 21 Zone Set Selection 22 Zone Set Input Selection 22 Zone Set Switching 24 OS32C User s Manual 13 Operating States amp Output Modes Operating States The following operating states exist for the OS32C system 1 OSSD ON State The two safety outputs are in the ON state and the machine run green indicator is lit The protected machine is allowed to operate The state diagnostic display indicates a state of monitoring zone set selection and a response time 2 OSSD OFF State An object exists in a safety zone and it is being detected The two safety outputs are in the OFF state and the machine stop red indicator and the intrusion indicators in the affected region s are lit The protected machine is not allowed to operate The status diagnostic display shows 3 Interlock State This state waits for a start input See p 16 for details The two safety outputs are in the OFF state the red STOP indicator and yellow interlock indicator ar
2. 2m cable for scanner configuration OS32C ECBL 02M 5m cable for scanner configuration OS32C ECBL 05M 15m cable for scanner configuration OS32C ECBL 15M Mounting Brackets Bottom Side Mounting Bracket OS32C BKT1 XY Axis Rotation Bracket must be used with OS32C BKT1 OS32C BKT2 Simple mounting bracket OS32C BKT3 Protective cover for window OS32C BKT4 OS32C mounting stand for use with OS32C SP1 1 OS32C MT OS32C hardware kit to mount BKT1 BKT2 BKT3 to OS32C MT 2 OS32C HDT Miscellaneous Window replacement kit OS32C WIN KT Printed user manual English paper OS32C MANUAL EN Printed user manual Japanese paper OS32C MANUAL JP Spare CD Configuration Tool user manual OS32C CD 1 When using a mounting stand use an OS32C with side location cable entry The OS32C with back location cable entry cannot be mounted Use with XY axis rotation bracket OS32C BKT2 2 Use this when mounting a bracket to the mounting stand OS32C 126 User s Manual Appendix Checkout and Test Procedure Log The following test procedure must be performed by qualified personnel eduring initial OS32C system installation eafter any maintenance adjustments or modifications to the OS32C or the machine it is guarding eat least every three months or more frequently depending on machine usage and employer guidelines Testing ensures that the OS32C system and machine control system work together to properly stop the machine Fai
3. 70mm object 4 detected 4 Safety Zone d i 70mm object Vv a gt not detected OS32C Fig 6 2 Field of View OS32C User s Manual 106 Chapter7 Appendix Troubleshooting 108 Troubleshooting 108 OS32C Status Check 111 Additional Error due to Reflective Background 114 Conditions of Background Influence 114 Using Other Safety Device in Combination 116 Sensor and I O Block Replacement 117 Window Replacement Procedure 118 OS32C Maintenance 119 Additional Zone Set Switching Strategies 120 Glossary 124 Accessories 126 Checkout and Test Procedure Log 127 Declaration of Conformity 128 Revision History 129 OS32C User s Manual 107 Appendix Troubleshooting Troubleshooting E Safety output OFF state while there is no intrusion by an object This may happen due to 1 Mutual interference This may happen if light from another scanner OS32C or other type of photoelectric sensor such as a safety light curtain is transmitted into the OS32C In such a case install the sensor so that its scanning plane does not receive light from the other sensor a When positioning the OS32C downward the OS32C may be affected by reflection from the floor surface Effect of A reflection may increase depending on the material of the screen Be sure to check surrounding environment before CHECK installing the OS32C For mounting see Chapter 4 Installation Source of interference Metal pole
4. max 4 5 7 NPN PNP transistor x 1 load current of 100mA max residual voltage of 2V max leak current of 1mA Warning Output Non Safety 3 max 4 5 7 Operation Mode Auto Start Start Interlock Start Restart Interlock External Device ON OV short input current of 50mA OFF Open Monitoring Input Start ON OV short input current of 20mA OFF Open Zone Select ON 24V short input current of 5mA OFF Open Standby ON 24V short input current of 5mA max OFF Open l Power Cable 18 pin mini connector pigtail Connection Type Communication Cable M12 4 pin connector Communication Ethernet 6 OS Supported Windows 2000 Windows XP Windows Vista RUN indicator Green STOP indicator Red Interlock Indicator Yellow Warning Auxiliary Output Indicators Indicator Orange Connection with PC 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 deg C Storage 25 to 70 deg C Ambient Humidity Operation amp Storage 95 RH max non condensing Ambient Operation Incandescent lamp Illumination on receiving surface 1500Ix max an angle of laser scanning plane and Illumination disturbance light must be 5 degrees or more Insulation resistance 20Mega ohm or higher 500VDC OS32C 10 User s Manual Description of Use and
5. Additional Error due to Reflective Background p 114 Zgc Safety factor for lack of clearance between under surface of AGV and ground E Fig 4 15 Zot Safe factor for reduction of brake force of the AGV through wear and usage E Configured zone w 100 i l ab Safety O ta factor gt Z n o 50 O Clearance between ground and under surface of AGV 0 50 100 150 Safety factor Z mm Fig 4 15 Safety Factor for Low Ground Clearance E Safety Distance Width Required for Safety Zone Sw Minimum safety distance of safety zone width mm Vw Width of AGV mm Z Additional safety factors maximum measurement error With the conditions above the minimum safety distance Sw of safety zone width is calculated as follows Sw Vw 2xZ OS32C User s Manual 81 Installation Z Z1 Z2 Zgc Lf Z OS32C s measurement error 100mm Z2 Additional error by reflective background 0 114 Zgc Safety factor for lack of clearance between under surface of AGV and ground E Fig 4 15 Zot Safe factor for reduction of brake force of the AGV through wear and usage _ Additional Error due to Reflective Background Configuration Example Use of an AGV Length of safety zone S Maximum stopping distance of AGV Sp ae Sue oa sting Width of AGV Vw Width of AGV Vw Width of safety zone Sw Fig 4 16 Installation on AGV E Specifications Sp 1600 mm Maximu
6. SAFETY TECHNOLOGY amp INNOVATION Safety Laser Scanner OS32C Series User s Manual OSTI P N 99863 0010 Rev A Manual No Z296 E1 01 Original instructions Introduction Thank you for purchasing the OS32C Safety Laser Scanner herein after referred to as the OS32C This is the instruction Manual describing the use of the OS32C Always take into account the following points when using the OS32C Make sure OS32C is handled by a Responsible Person who is well aware of and familiar with the machine to be installed The term Responsible Person used in this Instruction Manual means the person qualified authorized and responsible to secure safety in each process of the design installation operation maintenance services and disposition of the machine It is assumed that the OS32C will be used properly according to the installation environment performance and function of the machine A responsible Person should conduct a risk assessment of the machine and determine the suitability of this product before installation Read this Manual thoroughly and understand its contents Legislation and Standards 1 Application of an OS32C sensor by itself cannot receive the type approval provided by Article 44 2 of the Labor Safety and Health Law of Japan It is necessary to apply it as a system Therefore when using this product in Japan as a safety system for presses and shearing machines as prescribed in Article 42 of the Labo
7. Set Point as Reference Boundary Set Point as Non Reference Boundary Set All as Reference Boundary Set All as Non Reference Boundary Save Reference Boundary Setting Fig 3 46 Set Points as Reference Boundary Points Repeat as needed c To cancel RBM for the zone Right click on the display screen and select Set All as Non Reference Boundary and select Save Reference Boundary Setting Reference Boundary Setting o No point has been selected as Reference Boundary lt Zone will be reverted Would like to continue Fig 3 47 Cancel RBM Settings OS32C 60 User s Manual Basic Operation of Configuration Software 8 When done selecting the points for RBM right click on the display screen and select Save Reference Boundary Setting Select a Group of Points Set All as Reference Boundary Set All as Non Reference Boundary Fig 3 48 Save Reference Boundary Setting 9 Now that the Reference Boundary is set click OK at the prompt shown below Reference Boundary Setting a i i Reference Boundary setting saved NAP Review khe Reference Boundary Tolerance setting Fig 3 49 1 0 Specify the allowed tolerance for RBM Reference Boundary Monitoring Tolerance rone J afety Critical Parameters Measurement unt Ci Safety zone 5 Fig 3 50 RBM Tolerance 1 1 Send the created zone information to the OS32C for registration From the Configuration me
8. fone delay imsi 20 ei Operating made Start Interlock Fig 3 21 Multi zones 2 From the Configuration menu select Add Zone e 0532C Configuration Tool Yersion 0 8 2 File Edit View Configuration Reference Boundary Utilities x gah Edit Properties pE Edit Zone pre r P i Add Zone Sculpting Receive from Sensor Send to SensorfEnter CFG Mode Fig 3 22 Add Zone OS32C User s Manual 49 Basic Operation of Configuration Software 3 Confirm the zone shapes for the new zone Configuration Fone number 1 E b zone shape type Safety zone Circular segment Warning zone 1 Polygon Warning zone Circular segment Fig 3 23 Confirm Zone Shapes Delete a Zone 1 On the Defined Zones tab right click on the zone to be deleted 2 Select Delete Zone sislar Olea E Defined Zones ff Zone 1 Fle Zone 2 Defined Zones Configuration Information Properties Sensors Fig 3 24 Delete Zone OS32C 50 User s Manual Basic Operation of Configuration Software Zone Set Input Selection Once you have determined the number of zone sets required for your application you will need to determine the number of inputs you will use and the zone set select input states associated with each zone set Fig 3 25 illustrates the use of five inputs and how they apply to the five selected zones a The c
9. 6 1 The hazardous motion of the guarded equipment must stop immediately within the pre determined accepted stop times While in Automatic Start Mode the OS32C MUST remain in the machine stop state throughout the entire test To test the OS32C use a test object with a diameter ranging from 70mm to 80mm A test object does not come with the OS32C Guarded machine Note i In this example a semicircle is configured as 2m of safety zone i 4 and 3m of warning zone ey n s __ Warning Zone _ Fig 6 1 Testing Safety Zone Verify that all indicators and displays are operating properly and correspond to their defined functions of the OS32C Inspect the OS32C housing and the exit window for signs of damage or manipulation If the OS32C is used in a stationary guarding application ensure that the safety zone s are clearly marked on the floor For mobile applications make sure that the vehicle stops moving within the limits set in the initial configuration If the OS32C fails any of these tests lock out the guarded equipment and contact the factory supervisor immediately OS32C User s Manual 105 Checkout Detection Capability The OS32C has a minimum Object Resolution of 70mm This means that the OS32C will detect an object 70mm or larger in diameter that is completely within the field of view _ A igs Field of View x y 70mm object ae KA detected wooo y rae eo
10. Application Examples 5 Applying the OS32C to fixed stationary applications 5 Applying the OS32C on Automated Guided Vehicles AGV 7 Rating Performance 10 Chapter2 Operating States amp Output Modes 13 Operating States 14 Operating Mode 16 Automatic Start 16 Start Interlock 16 Start Restart Interlock 16 Power Reserve Mode 16 Parameter Configuration 17 Safety Critical Parameters 17 Non Safety Critical Parameters 18 Safety Outputs 19 Auxiliary amp Warning Outputs 19 Reference Boundary Monitoring RBM 21 Zone Set Selection 22 Zone Set Input Selection 22 Zone Set Switching 24 Chapters Basic Operation of Configuration Software 29 Getting Started 30 Installing Configuration Software 30 How to Start 31 OS32C User s Manual Xi Description of Screen 32 Menu 32 Tool Bars 34 Information Bar 34 Offline Mode 35 Connection to the OS32C 36 Connecting the PC and the OS32C 36 Forced DHCP mode 37 Changing the IP address of the PC Windows 2000 37 Changing the IP address of the PC Windows XP 37 Changing the IP address of the PC Windows Vista 39 Logging on to the OS32C 40 Detecting the OC32C on the network 40 Logging On 40 Logging OFF 41 Changing Password 41 Forgot the Password 42 Changing Ethernet Configuration of OS32C 43 Receiving OS32C Configuration Information 44 Configuring New OS32C Property and Monitoring Zone 44 Default Configuration Settings 44 Creating a New Configuration 45 Zone Se
11. For OS32C to meet IEC 61496 1 and UL508 its DC power supply unit must satisfy all of the following conditions eLine voltage rated within 24VDC 25 30 Complying with EMC directives industrial environments Double insulation or reinforced insulation between primary and secondary circuits eAutomatic return for overcurrent protection eOutput retention time of 20 ms or longer eSatisfying output characteristics requirements of Class 2 circuit or limited voltage current circuit define in UL508 ePower supply complying with regulations and standards of EMC and safety of electrical equipment in a country or a region where the OS32C is used Example In EU a power supply must comply with EMC directives for low voltage To prevent an electrical shock use double insulation or reinforced insulation from hazardous voltage such as AC230V Cable extension must be within a specified length Otherwise it may result in a failure of the safety functions The OS32C can be operated directly using 24VDC 25 30 Operation power of the OS32C must be supplied from dedicated power source The power source must comply with requirements of IEC 60204 1 and IEC 61496 1 OS32C User s Manual Wiring Additional Wiring Information Protection of Cable at Installation Care should be taken when installing the OS32C cable The cable must be properly routed and secured to ensure that damage does not occur Signal Connector Isolation The con
12. T 1T 1T tstart tmin tmaxToOft Start tstart Tdelay T tol start Tdelay Tiol switching Object detected Tresponse T sample earliest Object detected latest Fig 2 12 Object detection in Zone set B From the diagram there is a period of time Textend Between tmin and tendZoneA where the system may have switched to Zone set B already but it needs to protect Zone set A This is covered in the following section m How to Guarantee Protection of Original Zone Set Additional measures may be necessary to ensure that Zone set A maintains adequate monitoring up to tEndZoneA With tstart established relative to tbangerZoneB we must compare tEndZoneA and tmin Case 1 Zone set switching after the monitoring of zone set A is no longer required tEndZonea lt tmin When tendZoneA lt tmin NO further modifications are necessary Zone set A will be properly monitored for the duration that is needed Case 2 Zone set may be switched before the monitoring of zone set A is no longer required tEndZonea gt tmin When tendZoneA gt tmin Measures must be taken to ensure that Zone set A is protected even when the monitoring zone is switched to zone set B before tendzonea A simple measure is to modify safety distance S used when defining Zone set A such that it includes an additional component Zextra defined by the maximum approach speed K and a worst case extension time Textend to account for the time that Zone set A may not
13. guarded machine and the OS32C are correct 8 Start the machine While the machine is in motion intrude into the safety zone with the test object The machine should stop immediately Move the test object inside the perimeter of the safety zone The machine should remain stopped Caution Never insert the test object into the dangerous parts of the machine 9 Verify that the machine braking system is working properly If the machine does not stop fast enough adjust the braking system or increase the safety zone distance 10 Record the results of this procedure in the machine log OS32C User s Manual 127 128 Appendix Declaration of Conformity OMRON SCIENTIFIC TECHNOLOGIES INCORPORATED OMRON Scientific Technologies Incorporated at 6550 Dumbarton Circle Fremont CA 94555 3605 U S A hereby declares that the following series manufactured products listed below conform with the relevant Essential Health and Safety Requirements EHSRs of the European Machinery Directive 2006 42 EC with the relevant requirements of the Low Voltage Directive 2006 95 EC with the essential protection requirements of the Electromagnetic Compatibility EMC Directive 2004 108 EC and with the RoHS Directive 2002 95 EC the restriction of the use of certain hazardous substances in electrical and electronic equipment Laser Scanner OS32C Series The OS32C Series Devices are Electro Sensitive Protective Equipment E
14. ie 20 59 87 84 ir 547 45 yi 547 06 Fig 3 33 Edit Zones 5 When a scanner enters zone configuration mode the zone scanned by the OS32C is displayed If you do not want to display scanning zone information in the zone configuration mode select Options from the Utility menu and apc unselect Shows scan zone in edit mode 3 A monitoring zone can be edited by a Moving a point Click a point of the circular segment or polygon you want to move and drag it where you want to place it b Changing a zone shape From Edit menu select Convert Shape To Select the new shape c Sculpting I Sculpting amp Reference Boundary Monitoring p 58 d Changing the scan angle To change the scan detection angle of a zone 1 Select the zone to be changed E OS32C User s Manual 55 Basic Operation of Configuration Software 2 From the Configuration menu select Edit Zone 3 Adjust the scan angle by moving either of the outermost points of the zone In each of the figures below the two bottom most points can be used to adjust the scan angle of the zone The scan angel can be as small as 45 deg or as large as 270 deg Fig 3 35 Polygon Shape For normal zones polygon and sculpted shapes the user can add or remove points from the zone shapes a To add a point double click on the zone to add a point b To add a point by specifying a coordinate i Right click on the zone and select Creating
15. 144 243 User access level Password Jecseees Mo password required for Operator Continue Cancel Fig 3 12 Logging On OS32C User s Manual Basic Operation of Configuration Software 3 Select User access level and enter a password The initial password of the supervisor is Supeusr 4 Click Continue 5 When connected the IP address and User access level of the OS32C are displayed Log on to Sensor gt x i j You have logged on to the sensor at 192 168 1 1 beT Logon status Supervisor Fig 3 13 Logged On to Sensor Logging OFF From the Utilities menu select Log OFF and click OK Changing Password To limit access by an unauthorized user the password may be changed The user needs to log on to the OS32C with the supervisory access level to change the password The following steps describe this process 1 Log on to OS32C with the supervisory access level 2 From the Utilities menu select Change Password 3 Enter the current password 4 From Change Password select an access level you want to change 5 Enter the new password 6 Enter the new password again for confirmation 7 Click Change Password 8 A confirmation message is displayed Click Yes to change the password Change Password x Authorization password essees Change password for access level Supervisor J Cancel Fig 3 14 Change User Password 5 The password must contain at least 4 but n
16. 3 Safety output B Yellow Safety output A Red 3 Phase Motor Start Input use for releasing lockout 24 VDC Power This is for monitoring only and unrelated to a safety system 1 The External Devices ED1 amp ED2 are force guided relays e g G7Z G7SA or G7S 2 The Start Input must be a Normally Closed switch 3 If the External Device Monitoring is not used connect brown white wires to 0 V and then turn OFF the External Device Monitoring with the configuration software 4 For zone select switch setting see Zone Set Input Selection 5 5 Connecting to the Controller G9SA 301 ale x Q This wiring example is for category 3 CHECK OS32C User s Manual 101 Wiring OS32C 102 User s Manual Chapter6 Checkout Checkout and Test Procedures 104 Testing Safety Zone 105 Detection Capability 106 OS32C User s Manual 103 Checkout Checkout and Test Procedures The tests outlined in this Test Procedure See Checkout and Test Procedure Log in p 127 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
17. 3 Z t4 0 f1 1 0 Zoneset4 one 7 5 Active no of inputs 2 Zone set 6 Active no of inputs 2 Fig 2 6 Four Zone Set Application The above examples illustrate two different wiring schemes that use four inputs with two active required The example on the left is configured for a four zone set application The example on the right is configured for a six zone set application Number of Inputs Z1 z2 z3 z4 Z5 Detection zone sets Zone set 1 Zone set 2 Zone set 3 Zone set 4 Zone set 5 Zone set 6 Zone set 7 Zone set 8 Zone set 6 Invalid Active no of inputs 2 Multiple inputs can be assigned to the same zone set Fig 2 7 Eight Zone Set Application This example illustrates a wiring scheme that uses five inputs with two active required This is used for an eight zone set application OS32C User s Manual 23 Operating States amp Output Modes Zone Set Switching E Introduction to zone set switching As an example examine a system configured to use 4 inputs with 2 of them active according to the following table Zone Set Select Inputs Zi Z2 Z3 Z4 Zone Sets Hen iow Zone set select input Zne Set switching time I Select Inputs i Z1 i 7 Z3 Z4 i i Monitored i Fone Zone set 1 Zone set 2 i I Zone set switching time Fig 2 8 Zone Switching example If the external zone switching device momentarily exceeds the configured number of active
18. 620 ms to 60 52s 560 ms 660 ms to 60 56s 0 13 600 ms 700 ms to 60 6s 640 ms 740 ms to 60 64s 0 15 Configurable using the Restart Delay parameter Table 7 2 Status Diagnostic Display Indication OS32C User s Manual 113 Appendix Additional Error due to Reflective Background An additional measurement error may need to be added due to reflective backgrounds See Specifications of additional Errors by Background Conditions of Background Influence The OS32C s measurement precision can be affected by the background reflection of an object 1 High reflective background material or object is present in the scanning plane and within 1 2m beyond the safety zone e g acryl panel stainless steel reflective tape mirror 2 Low reflective background material or object is present in the scanning plane and within 1 2m beyond the safety zone e g paint finished equipment If any of the conditions listed above apply to your application an additional error factor Z2 should be added to the calculated safety zone size M Result of safety zone calculation from safety distance Z Additional safety factors maximum measurement error Z Z1 Z2 Z The OS382C s maximum measurement error 100mm Z2 Additional Error by Reflective Background Safety zone The OS32C s maximum measurement error Z 1 100mm Machine table Reflective background or object Distance to the background beyond the s
19. BKT4 User s Manual 87 OS32C 88 Installation E OS32C with Bottom Side Mounting Brackets 3 6 4 0 25 dia 116 7 4 60 79 2 3 12 9 10 19 2 2 SCAN PLANE MED i 37 9 1 49 50 0 1 97 toe ae E 4 2 0 17 93 7 3 69 BACK VIEW SIDE VIEW 155 9 6 14 106 0 4 17 F b 4 4 5 3 0 21 dia 102 4 4 03 144 4 5 69 66 4 2 62 DIMENSIONS mm Inches 54 5 2 15 23 3 0 92 BOTTOM VIEW Fig 4 25 External dimensional drawing of OS32C with OS32C BKT1 E OS32C with Bottom Side Mounting Brackets Assembly Drawing x4 HOLES FOR Y M5 MOUNTING SCREWS ey HARDWARE USER SUPPLIED j x3 HOLES FOR M6 MOUNTING SCREWS A FLAT HEAD 90 DEG Y x4 M5 x 16 HARDWARE USER SUPPLIED MOUNTING SCREWS AD x4 M5 Or WASHERS FLAT x4 STAND OFF INDENTATIONS BOTTOM SIDE MOUNTING BRACKET Fig 4 26 Assembly drawing of OS32C with OS32C BKT1 OS32C User s Manual Installation E OS32C with Bottom Side Mounting Brackets and Top Guard Kit 107 5 4 24 154 7 6 09 103 7 4 08 p 7 97 7 3 85 fd CN Sa 3 6 4 0 25 dia o AR E OU ST f I E 4 9 0 19 NORC 79 2 3 12 Ka RARA A WS SCAN PLANE ii ol E 24 5 0 97 m eof T eeel i tT 376 1 49 a3 hf nner ae eeoa aT 4 8 0 19 1 62 93 7 3 69 BACK VIEW SIDE VIEW 155 9 6 14 102 4 4 03 144 4 5 69 BOTTOM VIEW DIMENSIONS mm Inches Fig 4 27 Dimensional d
20. HOLES FOR E M5 MOUNTING SCREWS BRACKET 2 AND FLAT WASHERS k HARDWARE USER GS SUPPLIED x1 MS x 16 HARDWARE FOR MTG SCREW Y ADJUSTMENT x1 M5 INSTALL BEFORE WASHER SPLIT MOUNTING UNIT x1 M5 IF Y ADJUSTMENT WASHER FLAT IS REQUIRED x3 M5 x 10 EACH SIDE MTG SCREWS x3 M5 EACH SIDE WASHERS SPLIT x3 M5 EACH SIDE X ADJUSTMENT HARDWARE OS32C LASER SCANNER UNIT WA MENS FLAT WITH BOTTOM SIDE MOUNTING KIT In order to comply with Section 4 2 16 of IEC 61496 3 when the OS32C is mounted where the scanner position MODEL OS32C BKT1 could change e g as the result of an impact additional mechanical means such as serrated or toothed lock washers must be employed in the mounting hardware Fig 4 30 Assembly drawing of OS32C with OS32C BKT1 and OS32 BKT2 OS32C User s Manual Installation E OS32C with XY Axis Rotation Mounting Kit and Top Guard Dimensional Drawing 168 4 6 63 7 107 5 4 24 7 i 4 14 39 141 0 5 55 95 2 3 75 j SCAN PLANE Dy a a 1 81 93 5 3 68 28 ag a 1 11 0 19 a SIDE VIEW BACK VIEW FOR BACK MOUNTING l 15 0 eae 4 5 3 0 21 dia HARDWARE FOR Y ADJUSTMENT 163 0 6 42 102 4 4 03 2 R72 0 2 83 6 4 0 25 54 5 2 15 37 0 1 46 BACK VIEW FOR Y ANGULAR ADJUSTMENT BOTTOM VIEW DIMENSIONS mm Inches Fig 4 31 Dimensional drawing of OS32C with OS32C BKT1 and OS32C BKT2 an
21. Sensor 4 Confirm the change in Ethernet configuration Click NO to abort the change 5 The following window is displayed Read the message and decide if you want to continue to use the current IP address or start using the new address now Ethernet Configuration Ss Sensor s Ethernet Configuration changed sucessfully The new setting will not take effect until the next power cycle To remain the connection at current address Click Exit button To connect to the sensor at the new adress Wait for the sensor to resume the operation Click Connect button Fig 3 16 Ethernet Configuration Read from Sensor Write to Sensor Cycle power to the sensor to have the change to take effect OS32C User s Manual 43 Basic Operation of Configuration Software Receiving OS32C Configuration Information The configuration software receives and displays current configuration information immediately upon connection to the OS32C Configuration information can be received manually as well From Configuration menu click Receive from Sensor Configuration information is retrieved from the sensor Configuring New OS32C Property and Monitoring Zone To use the protective function of 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 O
22. Systems I O block serial Systems Firniware wersion 0 4 Minimum CFG Tool wersion O70 FPGA wersion 0 33 Compatible FPGA version 0 33 Chronometer himm 1457 56 Ethernet Configuration IP address 169 254 52 3 Subnet mask 255 255 255 0 Default gateway 192 168 1 5 DHCP Enable MAC address 00 0 51 00 11 00 Sensor name DST Fault Log Sensor block Fault eny 40 rge EDM_FAULT_SFTER_OSSD ACTIVATION Category Ox00 CRITICAL Chronometer himm 1438 29 System state RUM Temperature C 39 File name inputs c Unet 1234 Firmware version 0 4 FPA version 0 33 Sensor block serial Systems If block serial Systems Fault entry 39 rge EDM_FAULT_SFTER_OSSD ACTIVATION Category 0x00 CRITICAL Chronometer himm 1420 01 System state RUM Temperature PT 39 File name inputs c ne 1234 Fimm are wersion 0 4 FPA version 0 33 Sensor block serial Systems LO block serial4 Systemi Fig 3 53 Fault Log OS32C 64 User s Manual Basic Operation of Configuration Software Window Calibration If the scan window of the OS382C is replaced window calibration needs to be performed Do not execute window calibration except when the scan window is replaced The steps shown below describe this process The window calibration procedure resets the threshold values of window transmittance which is used for window contamination warning detection To execute this procedure the user must log on with the supervisory access
23. This application takes advantage of the multi zone functions of the OS32C This function allows an operator to enter and set up on one side the safe side shown as Zone A while the robot performs its tasks on the hazardous side shown as Zone B The warning zones are represented by the lighter colors The robot s position is determined via external devices that provide discrete inputs to the OS32C Fig 1 3 270 deg Area Guarding In this application the OS32C is the primary guarding device using a 270 degree horizontal protective field for area protection guarding The production process in this example does not allow for any frontal hard guarding obstructions in front of the work cell The warning fields Shown as Zone A amp Zone B of the OS32C provides manufacturing personnel with a preliminary warning to prevent them from accidentally stopping the manufacturing process In some cases an unintentional interruption can result in very high waste costs OS32C User s Manual 5 Description of Use and Features ANN vy wy y 7i a A ANN x N K 7 Z pai Fig 1 4 Internal Robot Cell Guarding In this application the OS32C is the secondary guarding device in conjunction with a safety light curtain The OS32C is responsible for detecting that the work area is clear before start up of the robot OCCUIS ANY Sia ai 4 hey lt Fig 1 5
24. Vertical Guarding Installation In this application the OS32C is the primary guarding device using a vertical protective field for point of operation guarding In some cases the machine s architecture or production flow may not permit the installation of a safety light curtain The OS32C meets all the requirements of IEC 61496 3 for vertical guarding installations and employs a reference boundary monitoring function OS32C User s Manual Description of Use and Features Fig 1 6 Dual Zone Vertical Guarding In this application the OS32C is the primary guarding device using a vertical protective field for entry presence detection The OS32C can guard the hazardous area based on the robot s position When the robot is in the left side the OS32C guards the left side and changes to the right side along with the robot This application takes advantage of the multi zone functions of the OS32C This function allows an operator to enter and set up on one side the safe side while the robot performs its tasks on the hazardous side The robot s position is determined via external devices that provide discrete inputs to the OS32C The OS32C meets all the requirements of IEC 61496 3 for vertical guarding installations and employs a reference boundary monitoring function Applying the OS32C on Automated Guided Vehicles AGV Unmanned automated vehicles require guarding devices to prevent accidental collisions The OS32C will scan the path of
25. circular segment or a polygon Undo Undo last action Redo Redo last action Add zone Add a new zone to the configuration Table 3 8 Information Bar 313 46 r 534 48 x 367 65 yi 367 95 lern Beam Es Safety Zone D warning Zone 1 E hwarning Zone 2 Supervisor 192 168 1 1 1 2 b 4 5 6 7 8 9 10 11 1 Shows mouse position in polar coordinates degrees 2 Shows mouse position in polar coordinates radius Shows mouse position in cartesian coordinates x axis Shows mouse position in cartesian coordinates y axis Shows unit of measure of mouse position Shows color of safety zone in the zone information screen 8 Shows color of warning zone 1 in the zone information screen Shows color of warning zone 2 in the zone information screen Shows beam number of the mouse position Shows current logon access level When connected to an OS32C displays the IP Address of the OS32C Table 3 9 OS32C 34 User s Manual Basic Operation of Configuration Software Offline Mode In offline mode a user can create configure and save a configuration to the PC as well as load and edit existing configurations on the PC To enter offline mode follow the steps shown below 1 After the configuration software is launched the window shown below is displayed Click Cancel The configuration software is launched in o
26. for the monitoring zone to be changed if the hazardous area changes Using diffused reflection of light back to the OS32C precludes the need for a traditional transmitter receiver pair Within the sensing range of the OS32C three fields can be monitored simultaneously One safety zone and two warning zones e One Safety Zone is used to detect personnel or other objects entering an area that has been determined to be a hazard Upon sensing that the object is within the Safety Zone the OS32C will send a stop signal to the control circuitry of the machine being guarded e Two Warning Zones can be defined with a longer distance than a safety zone allowing a configuration to detect objects that are closely approaching the hazardous area of the Safety Zone before the actual Safety Zone is encroached Applications for the OS32C include mobile applications on automatic guided vehicles AGV or transfer carts as well as stationary use such as within a robotic work cell in front of a press or around other hazardous machinery OS32C User s Manual Description of Use and Features Features e Can detect intrusions within the safety zone with a radius of 3m and two warning zones with a radius of 10m covering a maximum scan angle of 270 e When an object is detected within the safety zone individual sector indicators immediately turn on 8 red indicators indicating the object s position of intrusion e Seventy sets of safety zone and warni
27. indicators in the affected region is lit or flashing Table 2 1 Indication Patterns OS32C User s Manual RUN indicator STOP indicator Green LED Red LED Power On Self Test Operating States amp Output Modes Interlock indicator Yellow LED Warning output indicator Orange LED On Machine Stop Depends on configuration and object position Machine Run Normal Operation Machine Run Dust on scan window Depends on configuration and object position Flashing 1 Hz Interlock Standby Depnds on configuration and object position Off Fault Dust on scan window Flashing 1Hz Flashing 1 Hz Fault others Flashing 1Hz Off Configuration Table2 2 OS32C Operating States and Corresponding Outputs Flashing 4Hz Off OS32C User s Manual 15 Operating States amp Output Modes Operating Mode Automatic Start After power on OS32C automatically enters machine run ON state if no fault is detected during initialization and self tests and if no intrusion is detected within the safety zone An object entering the safety zone shall turn the OSSDs OFF Once the safety zone is clear the sensor will automatically enter the machine run ON state Start Interlock After power on OS32C automatically enters the interlock state if no fault is detected in its system Initialization and self tests and if no intrusion is detec
28. network CHECK 2 Configure the Ethernet settings of the PC and the OS32C so that they can communicate with each other There are two ways to do this Configure both the PC and the OS32C to DHCP mode Set both the PC and the scanner to DHCP mode both devices are set to obtain an IP address automatically If no DHCP server is present on the network it will take approximately 40 seconds to establish the connection after connecting the PC to the OS382C While the connection is being established the Local Area Connection icon on the system tray will look like this Fig 3 6 Connecting Icon The configuration tool will not be able to connect to the OS32C while this icon is displayed A Limited Connection icon will be displayed after the connection icon on the system tray disappears The configuration tool will now be able to connect to the OS32C Fig 3 7 Limited Connectivity OF Configure both the PC and the OS32C to different fixed IP addresses on the same network OS32C User s Manual Basic Operation of Configuration Software A PC can be connected to the OS32C by configuring the PC to a different fixed IP address within the same network as the IP address of the OS32C Keep in mind that every time a change is made to the scanner a reset of the scanner will be required A which means the connection session between PC and scanner will have to be re established zs CHECK Consider the am
29. number of scans may be increased when operating the OS382C in a dirty environment to avoid nuisance trips caused by floating particulate matter Application Example Example of Response Time Stationary clean environment 80ms Mobile 80ms 240ms Stationary Dirty environment More than 240ms Table 2 3 Response Time Examples 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 the hazardous area is reached resulting in severe injuries E Zone Set Selection The OS32C is capable of monitoring up to seventy zone sets where a zone set is defined as one safety zone with a maximum range of 3m and two warning zones with a maximum range of 10m These zone sets can be controlled via programmable selectable inputs The installer has the ability of deciding how many and which inputs to use with the configuration software For more information on Zone Set Switching see page 24 OS32C User s Manual 17 Operating States amp Output Modes E Zone Set Select Inout Combinations When multiple zones are selected the zone set select input combination table must be configured These settings will be determined by the number of zones needed and available inputs E Zone Transition Delay When multiple zones are used the transi
30. outputs Reference boundary N Fig 2 3 Reference Boundary Monitoring User s Manual 21 OS32C Operating States amp Output Modes Zone Set Selection Zone Set Input Selection When configured for multiple zones there are a total of 8 inputs available for zone set selection for the OS32C it is not necessary to use them all The minimum requirement for safe operation is 2 total inputs The user must also configure the total number of inputs the number of input terminals to be used and active inputs the number of inputs to be activated needed to select a zone set During operation the scanner will always monitor for that specific configuration of inputs to be active Once the number of inputs and active inputs is configured the user is able to define and assign the detection zone sets to each combination of inputs The number of unique active combinations available depends on the number of total inputs and the number of active inputs Table 2 4 shows the maximum number of zone sets possible for the various configurations It is not necessary to have a zone assigned to every possible combination Unassigned combinations are assumed to be invalid as No of Total Inputs n 8 7 6 5 a Total No 1 r i of Active 9 10 6 mu 3 ee D E EARTE 5 56 21 6 6 28 7 Maximum number of zones 7 7 8 Table 2 4 Maximum number of combinations depending on total number of inputs and total number o
31. referenced ASME ANSI B56 5 1993 EN 1493 eEN 1525 eIEC EN 61496 3 OS32C User s Manual 83 Installation External Dimensional Drawings E OS32C with Back Location Cable Entry OS32C BP ETHERNET CONNECTOR WITH M12 CAP PLUG CABLE NOT SHOWN 158 3 6 24 DUST 1 DETECTION SENSOR HEAD ISOMETRIC VIEW 140 4 5 53 100 0 3 94 104 5 4 12 ME x08 32 8 1 29 DEPTH 9 0 0 35 MAX x4 57 0 2 25 Ha ae 67 0 2 64 i Reo SCAN PLANE 27 7 1 09 Las 2 01 50 0 1 97 SIDE VIEW 121 0 4 77 i MTG HOLES m BACK VIEW 142 7 5 62 102 9 4 05 2 0 3 0 10 0 20 0 or 30 0 Meters ETHERNET CONNECTOR WITH M12 CAP PLUG 60778 0040 CABLE NOT SHOWN BACKPLATE 930 0 1 18 OD O CABLE ASSY 60781 OXXX FOR OSC2C BP CONTROLLER 88 1 3 47 CABLE ASSY 3 A 71 5 2 82 71 3 2 81 MIN Made In Malaysia 0S32C CBL xxPT T aonn 270 10 63 ETHERNET 1_ ey BOTTOM VIEW Fig 4 17 OS32C with Back Cable Entry Dimensional Drawing E OS32C with Side Location Cable Entry OS32C SP1 90 4 3 56 70 8 2 79 104 5 4 12 67 0 2 64 41 4 1 63 SCAN PLANE MTG HOLES ante ora 121 0 4 77 MTG eee SIDE VIEW CABLE NOT SHOWN 39 0 1 54 ETHERNET CONNECTOR WITH M12 CAP PLUG CABLE NOT SHOWN I 18 2
32. 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 the hazardous area is reached resulting in severe injuries 6 Dirty window Check if the scan window or dust detection surface on the base of the window If the status diagnostic display shows error code 80 the scan window should be cleaned with a soft cloth E Slow response of the safety output turning ON This may happen due to unexpected turning OFF of the safety outputs for the reasons described above E Constant Safety Output OFF 1 Dirty window If the status diagnostic display shows error code 80 and if the error cannot be reset by cleaning of the scan window replacement of the scan window may be needed A Do not put any sealant on the optics cover If the scan window of the OS32C is replaced a window calibration needs to be performed by the configuration software See Chapter 3 Window Calibration T CHECK 2 Safety zone layout change Verify that no objects are intruding in the configured safety zone If the OS32C is detecting something the intrusion indicator will turn ON The configuration software can also be used to monitor the scanning information of the OS32C E f the configuration software cannot receive configuration from the OS382C 1 The communication cable is not properly connected Che
33. source natural light or halogen light Screen Front View Top View Fig 4 4 Separation using a screen 5 Use of a screen may increase the effect of reflection depending on its material Select one with matte black finish that is resistant to reflection CHECK User s Manual 71 OS32C Installation Distance from Wall The safety or warning zones must be configured so that they maintain a distance of 100mm from the wall or tooling fixture If sculpting is performed the distance is automatically configured with a stand off distance of 100mm from walls Wall 100mm or longer Fig 4 5 Distance from Wall OS32C User s Manual Installation Stationary Installation and Configuration Installation for Stationary Area Scanning E Position The OS32C must always be installed in a position that the safety zone can cover the danger area being scanned Area which cannot be scanned e g behind obstacles must be secured by taking appropriate additional measures e g barriers The reset switch for clearing interlock must be positioned in such a way that the entire monitoring zone is in view and the operating element cannot be reached from inside the monitored zone E Installation Height Detection Level The installation mounting height of the OS32C is very important and the following considerations should be taken into account to determine the mounting height The OS32C must be m
34. 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 An OS32C system should only be installed verified and maintained by a qualified person A qualifed person is defined as an individual who understands is trained on and demonstrates competence with the construction operation or maintenance of the machinery and the hazards involved ANSI PMMI B155 1 2006 Checkout and Test Procedures Refer to p 127 in Appendix for step by step instruction and checkout inspection log Once the OS32C has been mounted configured and properly connected to the machine control system qualified personnel must perform the Checkout Procedure detailed in the test procedures A copy of the checkout results should be kept with the records for the guarded machine s maintenance records OS32C 104 User s Manual Checkout Testing Safety Zone If the OS32C is operating in automatic start mode make sure that the machine stops and not restart when the test object is in the safety zone Check its operation by approach of a test object into a safety zone It is recommended that this test be performed after a shift change or 24 hours of operation To test the OS32C s detection capability guide the test object along the perimeter of the safety detection zone as shown in Fig
35. to the diagnostics function Properly perform the wiring after confirming the signal names of all the terminals Do not operate the control system until 8 5 seconds or more after turning ON the power of the OS32C eBe sure to route the OS32C cable separate from high potential power lines or through an exclusive conduit eWhen using a commercially available switching regulator power supply make sure to ground the FG terminal frame ground terminal E Cleaning Do not use thinner benzene or acetone for cleaning They will adversely affect the product s resin parts and paint on the case OS32C Vill User s Manual E Object detection The OS32C has a resolution of 70mm it can detect objects with a diameter of 70mm or larger It cannot detect transparent or translucent objects or objects with reflective surfaces of less than 1 8 User s Manual iX OS32C How to Read This Manual Explanation of Symbols wu Indicates the description of an essential function such as operation or advice on how to properly use A this product CE Indicates the page number for related content OS32C User s Manual Contents Legislation and Standards I READ AND UNDERSTAND THIS DOCUMENT ii Safety Precautions iV Precautions for Safe Use viii Precautions for Correct Use viii How to Read This Manual Explanation of Symbols X Chapter1 Description of Use and Features 1 Theory of Operation 2 Features 3 System Components 4
36. will be detected within the normal Zone Switching Time described below OS32C User s Manual V vi 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 IS Configured without consideration of TmaxReaction object detection within the new safety zone after switching and turning OFF of the safety outputs may be delayed Wiring Connections Do not connect the OS32C to a power supply with more than 24VDC 25 30 Do not supply AC power to the OS32C this may result in electrical shock For the OS32C to meet IEC 61496 1 and UL 508 its DC power supply unit must satisfy all of the following conditions eWithin rated line voltage 24 VDC 25 30 Complying with EMC directives industrial environments Double insulation or reinforced insulation between primary and secondary circuits eAutomatic return for overcurrent protection eOutput retention time of 20 ms or longer eSatisfying output characteristics requirements of Class 2 circuit or limited voltage current circuit defined in UL508 Power supply complying with regulations and standards of EMC and safety of electrical equipment in a country or a region where OS32C i
37. x 1 4 WASHER FLAT x4 if Cj NOTE ARROW TOWARDS FRONT WINDOW FULL ASSY a GASKET Fig 7 6 Window Replacement OS32C User s Manual N Bo Appendix Window replacement of the OS382C can be accomplished without factory support Follow the procedure below Remove power from the OS32C Remove all the cables connected to the OS32C Using a clean cotton cloth gently wipe off any dirt or dust from the front of the unit that may inadvertently enter the internal space of the OS32C while the window is removed Do not use standard compressed shop air to blow off dust from inside the unit Remove the four screws and washers on the sides of the window Remove the existing window by using a small flat head screwdriver to gently pry up the window s edge Verify that the gasket is properly seated onto the new window Gently press around the gasket surface with your thumb To remove airbone particles from the inside of the unit only use low pressure compressed air that is suitable for optics and sensitive electronics Install the new window Make sure the arrow on top of the new window points towards the front of the scanner Care should be taken to ensure that the inside of the window is clean and free of fingerprints While applying even pressure to the top of the window evenly tighten the four screws with flat washers in an alternating pattern E Fig 7 6 It is recommended that the screws be tightened to a
38. 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 described below Let s consider an example Zone set A to Zone set B switching where A represents any origin zone set number and B represents any destination zone set number When switching zone sets there are three installation dependent parameters 1 Zone Set Switching Timing When switching from Zone set A there is a point in time when protection of that zone set is no longer required this point will be defined as tendZonea When transitioning to Zone set B there is a point in time when the OSSDs must turn OFF if an object is present in Zone set B this point will be defined as tDangerzoneg In order to ensure tDangerZoneB iS met monitoring of Zone set B must start at least one response time Tresponse prior to tDangerZoneB The time at which monitoring of Zone set B must start will be defined as tstartzoneB where tStartZoneB tDangerZoneB Tresponse OS32C User s Manual Operating States amp Output Modes 2 Zone Set Select Input Switch Timing The worst case time it can take for switching zone set select inputs This time starts on the transition o
39. 0 72 H 2 0 3 0 10 0 20 0 or 30 0 Meters 142 7 5 62 88 2 3 47 71 5 2 82 Fig 4 18 OS32C with Side Cable Entry Dimensional Drawing OS32C User s Manual Installation E OS32C with Top Guard Kit Dimensional Drawing 150 4 5 93 107 5 4 24 E Pr 93 4 8 68 ooo 4 5 6 0 22 dia a 3 0 0 12 Oo a Wi 112 4 4 43 E TOP VIEW 63 0 2 48 ea 41 4 1 63 PLANE DEA SFAR CIK 27 7 1 09 aioe E eee O HL 6 0 0 24 121 0 4 77 145 7 5 74 BACK VIEW DIMENSIONS mm Inches SIDE VIEW Fig 4 19 Dimensional drawing of OS32C with Top Guard Kit OS32C BKT4 E OS32C with Top Guard Kit Assembly Drawing x4 MOUNTING SCREWS HARDWARE USER SUPPLIED M5 x 0 8 MOUNTING SCREWS Fig 4 20 Assembly drawing of OS32C with Top Guard Kit OS32C BKT4 OS32C User s Manual 85 Installation E OS32C with Simple Mounting Bracket Assembly Drawing gma 4 08 67 0 2 64 SCAN PLANE rf ail 2 eem X4 12 0 0 47 169 0 6 66 155 7 6 13 BACK VIEW SIDE VIEW 52 8 2 08 185 0 7 29 BOTTOM VIEW Fig 4 21 Assembly drawing of OS32C with simple mounting bracket OS32C BKT3 E OS32C with Simple Mounting Bracket Dimensional Drawing X4 SLOTS M5 SCREWS SPLIT AND FLAT WASHERS HARDWARE USER SUPPLIED SX X4 M5 x 12 e MOUNTING SCREWS X4 M5 WASHERS FLAT io SIMPLE MOUNTING BRACKET In order to compl
40. 24VDC White OVDC Brown Standby input Violet Zone Select 1 Orange White Zone Select 2 Orange Black 424VDC Zone Select 3 Gray Zone Select 4 Pink Zone Select 5 White Black Zone Control a om Zone Select 6 Tan Z Zone Select 8 Blue White Start Black Auxiliary output Blue Warning output Red Black EDM Brown White Safety output B Yellow Safety output A Red Auxiliary Control Stop Brake Control OS32C Configuration External Device Monitoring Disabled Automatic Start Fig 5 4 Connecting to AGV Controls Q This wiring example is for category 3 In addition the circuit configuration of the stop deceleration control must meet the A requirements of category 3 CHECK OS32C 100 User s Manual Wiring Connecting to the controller G9SA 301 ED1 ED2 Forced guided relay ED3 Solid state contactor G3u M S1 S2 Zone Select Switch S3 Reset Switch S4 Standby Switch E1 PLC Programmable Controller Fig Category 3 Performance Level d IS013849 1 Functional Earth Green 24VDC White OVDC Brown Standby input Violet Zone Select 1 Orange White Zone Select 2 Orange Balck Zone Select 3 Gray Zone Select 4 Pink Zone Select 5 White Black Zone Select 6 Tan Zone Select 7 Orange Zone Select 8 Blue White Start Black Auxiliary output Blue Warning output Red Black EDM Brown White
41. 2C for registration Entire Sends all setup items to OS32C for registration Configuration Table 3 4 Reference Boundary Monitoring Disable Setting Disable reference boundary monitoring for the selected zone Set Point as Reference Boundary Set selected point s as reference boundary monitoring points Set Point as Non reference Un set the selected point s as reference boundary monitoring point s Boundary Set All as Reference Boundary Set all points in the zone for reference boundary monitoring Set All as Non reference Boundary Set none of the points in the zone for reference boundary monitoring Set Zone Tolerance Set the reference boundary monitoring tolerance for a zone Save Reference Boundary Setting Apply reference boundary monitoring settings to the zone Table 3 5 Utilities Discover Sensors Find sensors on the network Log On Used to log on to the OS32C Log Off Used to log off from the OS32C Change Sensor Name Change the name of the OS32C Sensor Ethernet Configuration Change the IP address of the OS32C Change Password Used to change the password Read Encrypted Password Shows the encrypted password in case of lost password Read Fault Log Sensor Displays the fault log of the sensor block I O Block Display the fault log of the I O block System Information Display the system and ethernet configuration of the OS32C Window Calibration Used after the window is replaced Sy
42. 3 The RBM function allows users to select certain areas on the detection zone safety or warning boundary and program them to detect continuous presence This function is intended to prevent unauthorized changes in the physical position of the OS32C scanner For a reference boundary area to be valid the selected group of consecutive beams must span a distance of 7Omm equivalent to the OS32C s resolution The selected areas can also be specifically tuned user defined for accuracy detection tolerance e When RBM is enabled for the safety zone the area beams that has been activated will cause a transition to a machine stop state when a distance change is sensed e When RBM is enabled for a warning zone the area beams that has been activated will cause a transition of the corresponding auxiliary output when a distance change is sensed Z For complete directions on setting up reference boundary monitoring see page 58 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 The tolerance zone for RBM must NOT exceed 100mm The OS32C response time must not exceed 120ms as the OS32C must detect objects moving at 1 6 meters per second If the detection zone is infringed or if the detection zone boundaries are changed the scanner shall turn off the two OSSD
43. 32C 54 User s Manual Basic Operation of Configuration Software Editing Monitor Zones This section describes how to edit and register the changes made to the zone configurations to the OS32C 1 From Configuration menu click Edit Zones 2 From Zone Set of the tool bar select a zone set to edit Then select a zone to edit from Foreground In this example Zone 2 and a Warning zone 2 are selected s 0532C Configuration Tool ersion 0 8 2 File Edit view Configuration Reference Boundary Utilities O BS E B of Foreground Warning zone 2 Zone Zone 2 bt 3 OR Sh ela Safety Critical Parameters External Device Monitoring Disable Response time ms 80 Monitoring zone Multiple zone Zone delay ms 20 id Operating mode Automatic Start gt Non Safety Critical Parameters Restart delay rms 100 z Auxiliary output mode Folow OSSD Auxiliary output type PNP v Auxiliary output polarity active ON Warning output mode Follow OSSD v Warning output type PNP x Warning output polarity lactveON xl Power reserve mode Disable x Segment display Enable xi ISI option Enable ISI mode Folow safety zone Default Properties Defined Zones Zone Inputs Sensors Configuration Information E Safety zone E Warning zone 1 l Warning zone 2 Supervisor im Beam 173
44. ENSIONS mm Inches 250 8 9 87 Fig 4 33 Mounting Stand Kit OS32C MT MOUNTING STAND w FOR STAND MOUNTING x3 HOLES HARDWARE SHOWN INSTALLED IN x2 PLACES ONLY 6 Oo JA yy A A M Qy MODEL OS32C HDT HARDWARE KIT OPTIONAL CAN BE USER SUPPLIED M6 x 20 FLAT HEAD 90 DEG SCREW FLAT amp SPLIT WASHERS AND NUT MODEL OS32C BKT2 MOUNTING KIT MODEL OS32C BKT1 MOUNTING KIT Fig 4 34 Mounting Stand Assembly OS32C MT 5 When using a mounting stand use an OS32C with side cable entry The OS32C with back cable entry cannot be used CHECK OS32C 92 User s Manual Installation E Tightening Torque Refer to table below for tightening torque Bolt Diameter Tightening Torque M3 5 1 4 Nem M5 3 4 Nem M6 3 6 Nem M8 3 6 Nem Table 4 1 E Power Cable Unit mm 56 L 90 7 S 0 eeo P O Oo oU E Vinyl insulated round cable diameter max 10mm Black 15 core conductor section area 0 3 mm insulator diameter max 1 5 mm Standard length L See NAME PLATE SIZES ARE AS BELOW Model Number Length in m OS32C CBL 03M OS32C CBL 10M OS32C CBL 20M O 32C CBL 30M Fig 4 35 External dimensional drawing of power cable Ethernet Cable L CABLE LENGTH RJ45 Vinyl insulated round cable diameter max 6 5mm Light blue 4 core conductor section area 0 34mm2 insulator diameter max 1 57mm Standard length L See SIZES ARE AS BE
45. Features Dielectric withstand voltage 350VAC 50 60Hz 1 minute Enclosure Rating IP65 IEC60529 Sensor Head Die cast aluminum Enclosure Optics Cover Polycarbonate I O Block Die cast aluminum Dimensions WxHxD 133 0 x 104 5 x 142 7mm except cable Impact Resistance 98m s2 1000 times for each of X Y and Z directions IEC60068 2 29 Vibration 10 55Hz 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 T Cat 5 cable Certificated by TUV Rheinland UL Major Standards IEC61496 1 3 Type 3 IS013849 1 2006 Category 3 UL508 UL1998 An additional measurement error may need to be added due to reflective backgrounds See p 114 for details For power source specification see Power Supply Unit in p 96 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 5 0mA Start input 20mA Standby input 5mA Zone X input 5mA x 8 eight zone set select inputs Output voltage is Input voltage 2 0VDC Total consumption current of 2 OSSDs auxiliary output and warning output must not exceed 700mA An ethernet cable with an M12 4 pin connector is required Output polarity NPN PNP is configurable via the configuration tool Table1 2 OS32C Specifications
46. Highly Reflective Wall Fig 7 1 2 Incorrect monitoring zone configuration A safety zone may have been configured too close to any objects Since the maximum measurement error of the OS32C is 100mm the safety zone must be configured at least 100mm away from any objects An additional measurement error may need to be added due to reflective backgrounds I Additional Error due to Reflective Background p 114 3 Incorrect zone delay setting The OS32C will turn OFF if the zone set select input pattern does not fit to any of the patterns configured with the configuration tool within the configured zone delay time Set the zone delay time to adjust to the specified zone set select input pattern within the given zone delay time I Zone Set Switching p 24 4 Bright light Stroboscopic light Ambient light including high density factory lighting and strobe flash may directly affect the OS32C An angle of 5 degrees must be maintained from the laser scanning plane ee Mounting Considerations p 70 OS32C 108 User s Manual Appendix 5 Dirty environment Dirty environment for instance fog smoke steam or other small flying particles may cause the incorrect switching of a Machine Stop state The influence of the incorrect switching may be decreased if the response time can be increased To avoid the operation failure keep the monitoring area clean IE Installation p 69 If the response time is changed re calculation of the
47. ISO13849 1 2006 Functional Safety of SIL 2 IEC61508 Electrical Electronic Programmable Electronic Safety related Systems Detection Capability Non transparent with a diameter of 70mm 1 8 reflectivity or greater Monitoring Zone Monitoring Zone Set Count Safety Zone 2 Warning Zones 70 sets max Operating Range Up to a radius of 3m for Safety Zone 10m for Warning Zones Maximum Measurement Error 100mm 1 Detection Angle 270 Angular Resolution 0 4 degree Laser Beam Diameter 6mm at optics cover 14mm typical at 3m Response time from ON gt OFF From 80ms 2 scans to 680ms up to 17 scans R Ti ARROUS R AS Response time from OFF gt ON Configurable See Table 7 2 on page 113 Zone Switching Time From 20 to 320 ms Line voltage 24VDC 25 30 ripple p p 2 5V max 2 Normal operation 5Wmax 4W typical without output load 3 F OWErSONSUmMpugN Standby mode 3 75W without output load Emission Source Infrared Laser Diode 905nm Wavelength Class 1 IEC EN60825 1 2007 Laser Protection Class Class 1 JIS 6802 2005 Class I CFR21 1040 10 1040 11 PNP transistor x 2 load current of 250mA max residual voltage of 2V max load capacitance of 2 2 uf max leak current of 1mA max 3 4 5 Safety Output OSSD i NPN PNP transistor x 1 load current of 100mA max residual voltage of 2V max leak current of 1mA Auxiliary Output Non Safety
48. LOW Model Number Length in m OS32C ECBL 02M OS32C ECBL 05M OS32C ECBL 15M Fig 4 36 External dimensional drawing of ethernet cable OS32C User s Manual 93 Installation XS5 OMRON Smartclick Connection E Connecting the XS5 Plug and Socket 1 Align the projection on the plug with the polarity key on the socket then insert the plug all the way in Polarity key Protrusion on cover aligns with polarity key meee Fig 4 37 Aligning to polarity key 2 Hold the knurled grip then insert the plug into the socket a Fig 4 38 Inserting into the socket 3 Turn the knurled grips of the plug clockwise approximately 45 degrees A click will indicate that the Connectors are locked The locking condition can also be confirmed by the alignment marks on the plug and socket Alignment marks Fig 4 39 Aligning the XS5 Plug OS32C 94 User s Manual Chapter5 Wiring Power Supply Unit 96 Additional Wiring Information 97 Input Output Signal 98 Example of Safety Circuit 99 Basic Connection with Single OS32C unit 99 Connecting to AGV Controls 100 Connecting to the Controller G9SA 301 101 OS32C User s Manual 95 96 Wiring Power Supply Unit Do not connect the OS32C voltage lines to DC power supplies with more than 30V or less than 16 8 V In addition the OS32C should not be connected to AC voltages Either of the above will result in electrical shock or product malfunction
49. NFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED STORED INSTALLED AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION ABUSE MISUSE OR INAPPROPRIATE MODIFICATION OR REPAIR SUITABILITY FOR USE OMRON STI 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 At the customer s request OMRON STI will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products This information by itself is not sufficient for a complete determination of the Suitability of the products in combination with the end product machine system or other application or use The following are some examples of applications for which particular attention must be given This is not intended to be an exhaustive list of all possible uses of the products nor is it intended to imply that the uses listed may be suitable for the products e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this document e Nuclear energy control systems combustion systems railroad systems aviation systems medical equipment amusement machines vehicles and installations subject to separate industry or government regulations e Systems machines and equipment that could present a risk to life or property Please know and observe al
50. OS32C Scanners Distance from Wall Stationary Installation and Configuration Installation for Stationary Area Scanning Configuration Configuration Example Installation on a Machine 1 Configuration Example Installation on a Machine 2 Mobile Installation and Configuration Applying OS32C on Automated Guided Vehicles AGV Configuration for Automated Guided Vehicles AGV Configuration Example Use of an AGV AGV Standards External Dimensional Drawings Mounting Stand Ethernet Cable XS5 OMRON Smartclick Connection 70 70 72 73 73 74 19 11 79 19 81 82 83 84 92 93 94 OS32C User s Manual 69 Installation Mounting Considerations N CAUTION 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 The following considerations should be taken into account when determining the mounting location for the OS32C It is possible for ambient light to interfere with normal operation of the OS32C Ambient light interference DOES NOT lead to a loss of safety it may however cause false nuisance stops of the guarded equipment some installations may require that the OS32C be mounted in direct exposure to ambient light In these situations you must assure that the separat
51. PE IEC61496 1 Type 3 AOPDDR IEC61496 3 T V Rheinland type approval Type 3 ESPE IEC61496 1 Type 3 AOPDDR IEC61496 3 OS32C User s Manual i READ AND UNDERSTAND THIS DOCUMENT Please read and understand this document before using the products Please consult your OMRON STI representative if you have any questions or comments WARRANTY OMRON STI s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by OMRON STI OMRON STI MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NON INFRINGEMENT MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE OMRON STI DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED LIMITATIONS OF LIABILITY OMRON STI SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL 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 OMRON STI for any act exceed the individual price of the product on which liability is asserted INNO EVENT SHALL OMRON STI BE RESPONSIBLE FOR WARRANTY REPAIR OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON STPS ANALYSIS CO
52. Protocol The default Wide area network protocol that provides communication across diverse interconnected networks W Show icon in notification area when connected IY Notify me when this connection has limited or no connectivity Fig 3 8 Local Area Connection Properties 5 To set the PC to DHCP mode select Obtain an IP Address automatically To set the PC to a fixed IP address select Use the following IP address and specify the desired IP address Internet Protocol TCP IP Properties General You can gel IF settings assigned automatically if your network supports this capability Othermise you need to ask your network administrator for the appropriate F settings Obtain an IP address automatically f Use the following IP address IP address Poe ebb te ae Subnet mask 255 255 255 El Default gateway f Gbtain ONS server address automatically f Use the following DNS server addresses Preferred DHS server F Alternate ONS server Advanced Cancel Fig 3 9 TCP IP Properties 6 When selecting Obtain DNS server address automatically an alternate configuration can be set To set a fixed IP address for the alternate configuration select Use the following IP address from the OS32C User s Manual CONG OCI1RQN Basic Operation of Configuration Software Alternate Configuration tab Set an IP address correctly according to the network enviro
53. S32C If the safety distance is not appropriate for the application the machine may not stop before the hazardous area Is reached resulting in severe injuries This section describes how to configure a new monitoring zone or change the operating properties of the OS32C using the configuration software Default Configuration Settings Safety Critical Parameters External Device Monitoring Disable Response time ms 80 Monitoring zone Zone 1 Zone delay ms Operating mode Non Safety Critical Parameters Restart delay ms 20 Automatic Start 400 Auxiliary output mode Follow OSSD Auxiliary output type PNP Auxiliary output polarity Active ON Warning output mode Warning output type Warning output polarity Power reserve mode Follow OSSD Active ON Disable Seven segment display Enable ISI option Enable ISI mode Follow safety Safety Zone Shape Circular segment Radius cm 100 Scan angle degrees 2 0 Warning zone 1 Shape Radius cm OS32C User s Manual Circular segment Basic Operation of Configuration Software Scan angle degrees 270 Warning zone 2 Shape Circular segment Radius cm 300 Scan angle degrees 270 Table 3 10 Defalt Settings Creating a New Configuration To change the configuration of the OS32C a user must log on to the OS32C with the supervisory access lev
54. SPE Active Optoelectric Protective Device responsive to Diffuse Reflections AOPDDR Type 3 designed to detect persons as part of a safety related system The OS32C Series products have been type examined per EC Type Examination Certificate issued by notified body TUV Rheinland Industrie Service GmbH Alboinstr 56 12103 Berlin Germany Certification Body for Machinery NB No 0035 The following Standards were used to form the basis for the requirements and tests EN 61496 1 2004 A1 2008 Safety of machinery Electro Sensitive Protective Equipment Part 1 General requirements and tests IEC 61496 3 2008 Safety of machinery Electro Sensitive Protective Equipment Part 3 Particular requirements for Active Optoelectric Protective Device responsive to Diffuse Reflections AOPDDR EN ISO 13849 1 2008 Safety of machinery Safety related parts of control systems Part 1 General principle for design IEC 61508 Parts 1 7 1998 2000 Functional Safety Of Electrical Electronic Programmable electronic Safety Related Systems EN 62061 2005 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems Martin D Krikorian Omron Europe B V Quality Director Wegalaan 67 69 OMRON Scientific Technologies Inc 2132 JD Hoofddorp Fremont CA 94555 3605 U S A Netherlands April 6 2010 Tel 31 0 23 568 13 00 Tel 31 0 23 568 13 00 OS32C Use
55. See Table 7 3 Machine table Width of Danger danger zone zone SS Z 7 E PSS SSS SS l l l l l Safety zone i distance M k Safety zone that needs setup by the configuration software Fence Top View Cover to prevent intrusion to dead zone F S SFdistance lt gt l Fig 4 7 Installation on a Machine E Specifications K 1600mm s Movement or approach speed mm s T ti te ti 0 08s Response time of OS32C s tz 0 2s Stop time including response time of machine s C 1200mm 0 4xH C 850mm safety factor mm H 300mm Distance of detected level from reference level mm Z Z1 Z2 Z 100mm OS32C s measurement error mm Z2 Omm Additional error by reflective background mm OS32C User s Manual 75 76 Installation E Calculation Example of Safety Distance S S KxT C Z 1600 mm s x 0 08 s 0 2 s 1200 mm 0 4 x 300 mm 100 mm 448 mm 1080 mm 100 mm 1628 mm There are several different ways to install the OS32C as shown in Fig 4 8 Each length of SFdistance the potential dead space indicated in Fig 4 7 between the OS32C and the danger zone is different 90 4mm 111 4mm 103 4mm OS32C only OS32C with OS32C BKT1 OS32C with OS32C BKT1 amp OS32C BKT2 OS32C with OS32C BKT3 Fig 4 8 Dimensions of SFdistance Take additional precautions to prevent intru
56. TT Save Sculpting Data Select a zone to assign the sculpting data to Safety zone v Zone 1 bd Sculpting is running Select the next action Save or Edit zone Start RBM Sculpting Cancel a eet 322 39 rs 446 97 Ix 354 08 yi 272 78 lm Beam 330 la Safety zone Bi warning zone 1 B Warning zone 2 Supervisor Fig 3 40 Sculpting Mode 3 To redo the configuration exit sculpting mode by clicking the Cancel button on the Save Sculpting Data window and re entering sculpting mode Save Sculpting Data Select a zone to assign the sculpting data to Safety zone Zone 1 Sculpting is running Select the next action 4 Save or Edit zone Start RBM Sculpting Cancel Fig 3 41 Save Sculpting Data Window 4 If sculpting data displayed on the screen is correct select the zone to which the configured sculpting data is to be assigned by using the pull down menus in the Save Sculpting Data window Click the Save or Edit Zone button OS32C User s Manual Basic Operation of Configuration Software 5 To enable Reference Bounding Monitoring RBM select the desired zone for RBM and then click the Start RBM Sculpting button 6 The scanner will then take approximately 50 seconds to measure the boundary It is important not to change the boundary during this time since the scanner will be re scanning the area and taking an average of the distances Learning the Bou
57. a point by coordinate Undo Add Point Creating 4 point by coordinate Editing by coordinate Select a Group of Points Convert Shape To Fig 3 36 Create a Point by Coordinate ii Specify the x y coordinates for the location of the new point Creating a point by coordinate Create point at oe Yi 77 4 F 100 8 E Measurement unit cm Fig 3 37 Specify x y coordinates OS32C 56 User s Manual Basic Operation of Configuration Software iii Click OK c To change the location of a point by specifying a coordinate i Right click on the zone and select Editing by coordinate Undo Add Point Creating a point by coordinate Editing by coordinate Select a Group of Points Convert Shape To Fig 3 38 Edit a Point by Coordinate ii Select the point to be modified by selecting the point number from the pull down menu The selected point will be circled Editing by coordinate x Point number Current X 9 3 Ta 41 0 l6 Change to 24 7 ia 34 0 E Measurement unit cm Fig 3 39 Specify x y Coordinate iii Specify the new desired x y coordinates for the selected point iv Click OK d To remove points i From the Edit menu select Select a Group of Points This menu can also be accessed by right clicking on the zone ii Use the mouse to select the desired point s iii From the Edit menu select Delete Selected Points 4 When zone edit is finished click E
58. achine stop 80 70 Window contamination indication guarded machine stop Incorrect number of active zone set select inputs guarded machine stop Invalid or undefined zone set select input combination but correct number of active zone set select inputs guarded machine stop The window is dirty or scratched clean or replace as necessary Check zone set select input wiring zone configuration selection zone set select input switching time and zone delay configuration Check zone set select input wiring zone configuration selection zone set select input switching time and zone delay configuration I Table 7 2 Safety output fault Safety output A is short circuited to 24V Safety output B is short circuited to 24V Safety output A is short circuited to OV Safety output B is short circuited to OV Check output connection and wiring External device monitoring fault EDM external device monitoring fault External device monitoring fault before OSSD turning ON External device monitoring fault after OSSD turning ON Check output external device monitoring connection and wiring Check the NC contact status of the external device is changing state before the OSSDs turning ON Check the NC contact status of the external device is changing state after the OSSDs turning ON External device monitoring fault during OS32C power on Check the OS32Cs output configuration connect
59. afety zone Barrier Taea paa a Additional error by reflective background Z2 f See Table 7 3 Top View JT Safety zone to be configured by the configuration software Fig 7 2 OS32C 114 User s Manual Appendix Use the following steps to calculate the additional error Z2 from the safety zone distance M Take OS32C s measurement error Zi and the additional error Z2 into account to setup safety zone with the configuration software E Procedure 1 Use Table 7 3 to calculate the additional error Z2 for the safety zone distance M Measure a distance to a reflective background or object assuming M Z1i Z2 as the edge of the safety zone If the dimension above satisfies the condition 1 or 2 add Z1 and Z2 to the value for the safety zone range If neither condition is satisfied add Z1 without adding Z2 200 Additional error by background influence Z2 180 4 160 4 140 4 120 4 100 4 80 5 60 4 40 4 20 4 Additional error by background influence Z2 mm 0 1500 2000 2500 3000 3500 Safety zone distance M mm 0 500 1000 High reflective background or object i amp Low reflective background or object Table 7 3 Additional error by background influence User s Manual 115 OS32C Appendix Using Other Safety Device in Combination If the OS32C is used for presence detection only instead of intrusion detection it is n
60. be monitored Zextra K Textend K tEndZoneA tmin Expanding monitoring zone using this additional parameter Zextra enables the OS32C to detect an object in advance that may enter the actual monitoring zone of zone set A during zone set switching In other words expanding the monitoring zone means that the timing of tEnazonea is shifted to tmin OS32C User s Manual 27 Operating States amp Output Modes a Zone set B J a Zone set A Extension Zone set A Fig 2 13 Zone A extension The extension of the safety distance around the entire protection zone will guarantee the safe operation of the scanner However most installations may benefit from using the smallest possible monitoring zone perimeter to maximize usable work space For other measures refer to Additional Zone Set Switching Strategies on page 120 OS32C User s Manual Chapter3 Basic Operation of Configuration Software Getting Started 30 Installing Configuration Software 30 How to Start 31 Description of Screen 32 Menu 32 Tool Bars 34 Information Bar 34 Offline Mode 35 Connection to the OS32C 36 Connecting the PC and the OS32C 36 Forced DHCP mode 37 Changing the IP address of the PC Windows 2000 37 Changing the IP address of the PC Windows XP 37 Changing the IP address of the PC Windows Vista 39 Logging on to the OS32C 40 Detecting the OC32C on the network 40 Logging On 40 Logging OFF 41 Changing Passwo
61. ck connections of the communication cable and the ethernet cable 2 An OS32C has been set to a fixed IP address and the user loses the address The user will need to set both the PC and the scanner to DHCP mode so that they can communicate with each other before the user can set the scanner to a new fixed IP address I See page 37 to force the scanner into DHCP mode User s Manual 109 OS32C Appendix E Configuration Tool was unable to find sensors on the network 1 Check power and ethernet cables 2 Check the IP address settings of the PC and the scanner Make sure both are on the same network LZ See Chapter 3 Connecting the PC and the OS32C E Communication Time Out 1 Check power and ethernet cables 2 Check the IP address settings of the PC and the scanner Make sure both are on the same network LZ See Chapter 3 Connecting the PC and the OS32C OS32C 110 User s Manual OS32C Status Check The OS32C has the status diagnostic display on the front which indicates configuration error status of the OS32C E Diagnostic Codes Status Normal Operation Safety output fault Diagnostic Code Description Power up indication Appendix Corrective Action blinking at a slow rate 01 02 Normal operation guarded machine stop Standby mode guarded machine stop The rate of blinking depends on the mode Interlock state waiting for start input Configuration mode guarded m
62. ctive Background Conditions of Background Influence Using Other Safety Device in Combination Sensor and I O Block Replacement scan Window Replacement Procedure Window Replacement Procedure OS32C Maintenance Additional Zone Set Switching Strategies Glossary Accessories Checkout and Test Procedure Log 108 108 111 114 114 116 117 118 118 119 120 124 126 127 OS32C User s Manual xiii Declaration of Conformity 128 Revision History 129 l OS32C XIV User s Manual Chapter1 Description of Use and Features Theory of Operation Features System Components Application Examples Applying the OS32C to fixed stationary applications Applying the OS32C on Automated Guided Vehicles AGV Rating Performance 1 ON OF OF BR WO PY OS32C User s Manual Description of Use and Features Theory of Operation The OS32C safety laser scanner is an optical safety sensor that uses diffuse reflection of a pulsed laser light to determine the location of objects entering a predefined monitoring zone Internally a spinning mirror assembly scans a monitoring zone by sending a pulse of light which reflects off the first object in its path The distance from the sensor to the object is determined by measuring the time that the light requires to return from the sensed object This method of sensing allows for standard simple or irregular shapes to be used as the predetermined sensed monitoring zones It also allows
63. d Not used with a current that is higher than the OSSD rating 250 mA sourcing e The main unit must be properly mounted with the proper mounting hardware e Do not drop the product serious damage will occur e Comply with all the laws regulations and standards of the country region where the product is used e 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 E 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 eAreas with high humidity where condensation is likely to occur eAreas where corrosive gases are present eAreas exposed to vibration or shock levels higher than in the specification provisions eAreas where the product may come into contact with water eAreas where the product may get wet with oil eAreas where smoke and or water vapor exists on the laser scanning plane 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 E Wiring and installation eMake sure to perform wiring while the power supply is OFF Otherwise the OS32C may fail to operate due
64. d to enter the 4 digit Visual Sensor Identification code when making changes to the scanner Visual senson Identification Fig 3 29 Directly connected l A confirmation message is displayed for the changed item Verify the message and click Yes to confirm A message shown below is displayed for confirmation of zone configuration edits Clicking Refresh Scan Zone displays new scanning zone information of the OS32C on the screen Click Yes to confirm the configured zone If a configured zone has not changed this message will not appear Safety Critical Parameter a Safety Zone 1 Confirm that the safety zone data is correct Refresh Scan Zone i Fig 3 30 Confirming Zone Configuration 9 After transmission is finished the window shown below is displayed Click Yes to confirm If you do not want to register the configuration click No Write Configuration l x All changes were sent to the sensor ay would you like to register your changes Selecting Mo will discard all changes Fig 3 31 Write Configuration User s Manual 53 OS32C Basic Operation of Configuration Software 1 0 The screen shown below is displayed while the OS32C resets Please wait Configuration is being updated Where wil be a delay for resetting the sensor Fig 3 32 Reset The configuration is now complete wv A If writing cannot be done wiring may be wrong Refer to page 95 to correct wiring zs CHECK OS
65. d 2 warning zones Monitoring Zone Set There are 70 selections for this property A user can select a zone set in the zone set configuration window Non Safety Critical Parameters These are settings that are not related to the safe installation of the OS32C Auxiliary output warning output restart delay and standby mode Offline Mode A user can create edit and save a configuration to a PC without connecting to the OS32C The loading and editing of existing configurations on the PC can be done offline as well Operator Access Level This access level cannot change the OS32C settings Only verification and monitoring of the existing configuration information is available Password input is not required OSSD Output Signal Switching This provides ON output when no object is interrupting the sensor in the safety zone It is used for Device safety applications Reference Boundary Monitoring When activated the scanner will monitor the boundary of a given detection zone safety or warning The detection zone will be considered violated if the boundary range requirements are not within a certain tolerance Response Time The maximum time between the actuation of the sensor function and the switching of the safety outputs of the OS32C The response time ranges from 80ms 2 scans to 680ms 17 scans in increments of 40ms Safety Critical Parameters These are the settings that configure the safe installation of the OS32C Exter
66. d OS32C BKT4 E OS32C with XY Axis Rotation Mounting Kit and Top Guard Assembly Drawing X4 HOLES FOR M5 MOUNTING FOR Y ANGULAR ADJUSTMENT SCREWS AND FLAT WASHERS X3 SLOTS HARDWARE USER SUPPLIED Bonn DCA cee FOR BOTTOM MOUNTING X4 HOLES Q FOR M5 MOUNTING SCREWS HARDWARE USER SUPPLIED OG AND FLAT WASHERS BRACKET 2 HARDWARE USER A SUPPLIED O E qzR OG X1 M5x16 HARDWARE FOR O MTG SCREW Y ADJUSTMENT X1 M5 INSTALL BEFORE WASHER SPLIT MOUNTING UNIT X1 M5 IF Y ADJUSTMENT WASHER FLAT IS REQUIRED X3 M5 x 10 EACH SIDE MTG SCREWS X3 M5 EACH SIDE HARDWARE WASHERS SPLIT FOR X3 M5 EACH SIDE X ADJUSTMENT WASHERS FLAT OS32C LASER SCANNER UNIT WITH BOTTOM SIDE MOUNTING KIT MODEL 0S32C BKT1 order to comply with Section 4 2 16 of IFO 61496 3 WITH TOP GUARD KIT MODEL OS32C BKT4 when the OS32C is mounted where the scanner position could change e g as the result of an impact additional mechanical means such as serrated or toothed lock washers must be employed in the mounting hardware Fig 4 32 Assembly drawing of OS32C with OS32C BKT1 and OS32C BKT2 and OS32C BKT4 OS32C User s Manual 9 Installation s Mounting Stand 203 2 8 00 gt e 8 i 1609 6 24 00 1 S a aa A SR 2 fi 637 2 25 09 Cth 209 6 8 25 317 3 18 56 came comes pooh e 111 714 40 H Y7 165 1 6 50 190 5 7 50 ta apse pas VIEW A DIM
67. dit Zones from Configuration menu and verify if the checkbox is being unselected Now zone configuration is complete Send the configured zone information to the OS32C for registration From Configuration menu click Send to Sensor Enter CFG Mode All Changes Configure by following instructions on a displayed message 6 Reset the OS32C by following the prompts Configuration is now complete gat Q Safety and warning zones must be configured so that they maintain a distance of 100mm from the wall or fixtures z CHECK OS32C User s Manual 57 Basic Operation of Configuration Software Sculpting amp Reference Boundary Monitoring The scanning zone information from the OS32C can be used for zone configuration The desired safety zone can be traced within the scanning range of the OS32C Zone configuration based on this data is called sculpting To configure a zone with sculpting follow the steps shown below 1 From the Configuration menu select Sculpting The sculpting data displayed on the screen is based on the scanning information sent from the OS32C Move an object such as a test piece around the perimeter of the zone under configuration The position where the object is detected closest to the OS32C is used as the sculpting data 0532C Configuration Tool ersic iol x File Edit View Configuration Reference Boundary Utilities 9 SSB Foreground warning zone 2 gt Zone Zone1 EEA
68. e lit The protected machine is not allowed to operate The status diagnostic display shows 01 4 Lockout State A failure is being detected and the guarded machine is being stopped The two safety outputs are in the OFF state the machine stop red indicator is lit and yellow interlock indicator is flashing The protected machine is not allowed to operate The status diagnostic display shows the error code that caused the lockout The OS32C system will remain in the lockout state until the problem is corrected and a start input is applied or power on the unit is cycled E Indication Patterns RUN indicator When OSSD is ON Green LED When OSSD is OFF STOP indicator When OSSD is OFF Mea LED When OSSD is ON Interlock Indicator Interlock State Yellow LED Flashing Lockout State 1Hz Configuration State 4Hz Off Other than the above Warning output indicator When any warning zone is intruded Orange LED Flashing When dust or contamination is detected on the scan window 1 Hz Off Other than the above Status Diagnostic Display o0 LE See OS32C Status Check on page 111 Individual Sector Indicators On When an object is in any safety or warning zone 1 2 Red LED Flashing When dust or contamination is detected on the scan window 1 Off Zones are clear and window is clean 1 The functionality of the intrusion indicators is configurable via the configuration tool 2 The intrusion
69. ed 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 occurrs resulting in serious injuries Installation The main unit must be securely mounted and its cable connectors must be tightly attached 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 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 in this document at installatio
70. el 1 From File menu select New Enter a description for the configuration up to 127 characters Configuration Configuration Description 127 character s left Configuration Description Fig 3 17 Configuration Description OS32C User s Manual 45 Basic Operation of Configuration Software 3 New configuration screen is displayed Configuration o Safety Critical Parameters External Device Monitoring Disable Response time ims 80 bd Monitoring zone Single zone fone delay imsi jo H Operating mode Automatic Stat l on Safety Critical Parameters Restart delay imsi 100 Suxiliary output mode Follow OSSD T Auxiliary output type PHF Y Auxiliary output polarity active GN Warning output mode Folow DOSSO r Warning output type PHF Y Warming output polarity active IN Power reserve mode Disable ka 7 5egment display Enable ISI option Enable ISI mode Folow safety zone Default Configuration properties Fig 3 18 New Configuration Parameters e Safety Critical Parameters 1 External Device Monitoring EDM When enabled the OS32C can monitor the N C contacts of the external control relays These relays are controlled by the OSSD safety outputs 2 Response Time Configures a time period for OS32C safety output from ON to OFF The available range is from 80ms to 680ms in increments of 40ms 3 Monitoring Zo
71. erZoneB IN this Case tDangerZonec The second switch Zone set C to Zone set B should be setup so that tenaZonea which is relative to the first switch is guaranteed to be earlier than tmin relative to tstat of this second switch OS32C User s Manual 123 Appendix Glossary Automatic Start An object entering the safety zone turns the OSSDs OFF Once the safety zone is clear the sensor will automatically enter the safety output ON state Auxiliary Output This is a non safety output It may be configured to provide safety output information or lockout information Edit Monitoring Zones When enabled the edit zones mode will allow the current configurations of the safety and warning zones to be modified The monitoring zones are graphically displayed for editing This feature can only be used with an access log on level of supervisor user or higher External Device Monitoring The function to detect a fault such as the welding of the NC contacts of the machine s primary control element Interlock OSSD OFF status is maintained until safety is ensured and the start input is applied Lockout A failure is detected and the guarded machine is stopped The OS32C system will remain in the lockout state until the problem is corrected and a start input is applied Monitor Mode In this mode the continuously measured data from the OS32C is displayed on the screen in real time Monitoring Zone The cumulative area of the safety an
72. es are shown ERRORS AND OMISSIONS The information in this document has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical proof reading or omission errors PROGRAMMABLE PRODUCTS OMRON STI shall not be responsible for the user s programming of a programmable product or any consequence there of PATENTS Elements of the electronics and optics essential to meet the specifications and performance standards of Omron STI controls are covered by one or more of the following U S Patents Numbers 6 665 621 6 753 776 6 493 653 6 587 811 Additional patents pending COPYRIGHT AND COPY PERMISSION This document shall not be copied for sales or promotions without permission This document is protected by copyright and is intended solely for use in conjunction with the product Please notify us before copying or reproducing this document in any manner for any other purpose If copying or transmitting this document to another please copy or transmit it in its entirety OS32C User s Manual 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 indictions and symbols are u
73. ess level cannot make changes to OS32C configurations Only verification and monitoring of existing configuration is available e Supervisory Access Level Supervisor To log on to the configuration software with this access level a password is required This access level allows a user to check change and monitor OS32C configuration information Detecting the OC32C on the network To connect to the OC32C using the configuration software the user needs to find the IP address of the OS32C on the network Select Discover Sensors from the Utilities menu Since the configuration software is connected to the OS32C via Ethernet Windows Security Alert is displayed when Windows firewall is activated Select Unblock The alert will not be displayed once it is unblocked Windows Security Alert x o To help protect pour computer Windows Firewall has blocked some features of this program Do you want to keep blocking this program D Name 0532C_CFGTool Publisher Unknown Keep Blocking Unblock Ask Me Later Windows Firewall has blocked this program from accepting connections from the Internet or a network IF you recognize the program or trust the publisher you car unblock it When should unblock a program Fig 3 11 Windows Security Alert Logging On 1 From Utilities menu select Log On 2 The Log On screen is displayed Select an IP address of the OS32C to be connected Log on to sensor at IP address 169 254
74. ety zone K Movement or approach speed in mm s constant K 1600 mm s T Delay between interruption of the safety zone and standstill of the machine in seconds consisting of the sum of t and tz t1 Response time of the OS32C t2 Rundown time of the machine mechanical rundown reaction time of control system C Additional supplemental distance in millimeters E Example of safety distance calculation K 1600 mm s approach speed constant T t1 t2 0 58s Overall response time t1 0 08 seconds OS32C response time adjustable t2 0 5 seconds Max time required to full stop of the machine C 850mm S Kx T C 1600 x 0 58 850 1778 mm OS32C 78 User s Manual Installation Mobile Installation and Configuration Applying OS32C on Automated Guided Vehicles AGV AGVs equipped with an OS32C should only be used on private or company property and not allowed to operate on public streets The OS32C must only be used in AGV applications where the vehicle is equipped with an electric motor In addition to the following guidelines it is important that you follow the AGV manufacturer s recommendations E Positioning Height The OS32C must be mounted so that it provides a horizontal safety scan plane in the path of the AGV The height of the scan plane must not exceed 200mm It is recommended that the installation height of the scan plane be 150mm so that objects with a height of 150mm can be detected After installation
75. ety Critical Parameters External Device Monitoring Disable xl Response time rns Monitoring zone Zone delay ms Operating mode Automatic Start Non Safety Critical Parameters Restart delay ms 100 Auxiliary output mode Follow OSSD Auxiliary output type PNP v Auxiliary output polarity Active ON Warning output mode Folow ossD Warning output type PNP z Warning output polarity active ON Power reserve mode Disable X 7 Segment display Enable ISI option Enable z ISI mode Folow safety zone Default Properties Defined Zones Configuration Information ly 595 16 lem Beam 325 B Safety zone _ E Warning zone 1 ia Warning zone 2 Off Line ix 58 06 95 57 r 597 99 Fig 3 20 Confirming Configuration wv Safety and warning zones must be configured so that they are at least 100mm away from the wall ww z CHECK OS32C 48 User s Manual Basic Operation of Configuration Software Zone Set Selection and Configuration Once the number of zone sets is defined the configuration tool is used to program the OS32C Zone sets can be added one at a time Add a Zone 1 Before adding a new zone make sure Multiple Zone has been selected for the Monitoring Zone parameter atety Critical Parameters External Device Monitoring Enable Response time rns 50 Monitoring zone
76. f active inputs The examples below are some of the possible configurations that can be accomplished for many applications Here z1 and z2 are used as abbreviations of zone set select input 1 and 2 24VDC l 24VDC Input configurations z2 lt a u Detection zone sets Zone set 1 08320 ose A Zone set 2 Active no of inputs 1 Fig 2 4 Two Zone Set Application The examples above illustrate two different wiring schemes that use two inputs with one active required This is used for a two zone set application OS32C User s Manual Operating States amp Output Modes 424VDC 24VDC Number of Inputs z1 z2 z3 Detection zone sets Number of Inputs Z1 z2 Z3 z4 z5 Detection zone sets tf hio Zone set 1 1 i Oo 1 Zone set 2 0 MEE Zone set 3 Active no of inputs 2 Zone set 1 Zone set 2 Zone set 3 Active no of inputs 2 Fig 2 5 Three Zone Set Application The examples above illustrate a wiring scheme that uses three inputs with two active required This is used for a three zone set application Note that the selection of inputs is programmable the user has the ability to select which inputs to use These configurations are technically the same but different inputs are selected as active 24VDC Number of Inputs Z1 Z2 Z3 Z4 Detection zone sets 24VDC Number of Inputs z1 z2 z3 z4 Detection zone sets Zone set 1 ajoji 20 1 Zone set 1 Zone set 2 HeH Zone set 2 Zone set 3 Zone set
77. ffline mode Network ee Configuration Tool will discover all sensors that are attached to the network Make sure that sensors are connected to network and power on Press Cancel if you choose to work off line you will not be able to communicate with sensors in this mode Local IP address 192 168 1 2 Continue Cancel Fig 3 5 Offine Configuration User s Manual 35 OS32C 36 Basic Operation of Configuration Software Connection to the OS32C This section describes how to connect a PC with the configuration software and the OS32C The configuration software is connected to the OS32C via Ethernet An Ethernet cable with an M12 4 pin connector is required I See page 93 for more details The default Ethernet configuration of the OS32C is DHCP mode configuration to automatically obtain an IP address When connecting a PC to the OS32C different types of connections are available depending on the user s environment See the following examples according to your connection environment Connecting the PC and the OS32C 1 Physically connect the OS32C to the PC eFor a direct connection use an Ethernet cable to connect the OS32C directly to the Ethernet port of the PC or eUse an Ethernet cable to connect the OS32C to the local area network of the PC 5 On a network that limits the connection by MAC address authentication etc modify the settings to allow the OS32C A7 to connect to the
78. g in severe injury to the operator To use this product for a category 3 safety system both of the two safety outputs must be used to build the safety system controls circuit Configuring the safety control system with only one safety output may result in serious injuries due to output circuit failure The OS32C provides two PNP safety outputs each capable of sourcing 250 mA 24 VDC These two outputs can be connected to the machine s primary control element or may be used to connect to a control device The safety outputs will turn on when the safety zone is clear and the guarded machine can operate The OS 32C will turn off its safety outputs when it detects an intrusion in the safety zone and the guarded machine stops In addition the OS32C will test the safety outputs by switching the outputs off for lt 600us every 5 min See Fig 2 1 below 5 minutes OSSD A fo eare oo Jp H lt 600ps OSSD B r qq l lt 600us 2 5minutes i g Fig 2 1 OSSD Test Pulses Auxiliary amp Warning Outputs The OS32C has a non safety auxiliary output and a non safety warning output max 100mMA 24VDC Both the output type PNP NPN and polarity Active ON Active OFF can be configured These outputs can be configured to operate in one of the following modes e Follow OSSD indication output will turn ON when the machine stops e Indicate FAULT output will turn ON when a fault has occurred e Warning Zone 1
79. guage English US W Show scan zone in edit mode M Auto monitoring zone switching M Show warning zone 1 M Show warning zone 2 tart the graphical display using cordinate system C Cartesian Polar soe e Fig 3 58 Changing Configuration Software Options 3 Edit an item you want to change 4 After configuration is finished click Apply A screen shown below is displayed Click OK Configuration Tool j Lal i Jj Selected options are sawed Fig 3 59 Apply Option Changes OS32C User s Manual 67 Basic Operation of Configuration Software Caution on Safety Zone Configuration Due to the scanner s minimum object resolution criteria it is possible to configure zones that are not considered valid These zone configurations may contain a protrusion or intrusion that is narrower than 7Omm in width within the field of view This type of invalid zone configuration can only occur within a distance of 4 meters from the scanner Narrow protruding areas less than 70mm wide are NOT valid zone perimeters A scanner configured with such a safety zone would see a presence within this area if in monitor mode but would not initiate a machine stop The following pictures shows a possible zone configuration that contains a protrusion that is narrower then 70mm in width since this protrusion is less than 70mm in width it will not detect a 70mm object Refer to Fig 3 60 s 0532C Configuration Tool ers
80. infringed output will turn ON when an intrusion is detected in warning zone 1 e Warning Zone 2 infringed output will turn ON when an intrusion is detected in warning zone 2 e Window Contamination Warning output will turn ON when contamination of the scan window reaches a certain level OS32C User s Manual 19 Operating States amp Output Modes Output Mode Active ON Active OFF Disabled Output always OFF Output always OFF Safety Output Information Mode Same as OSSDs output ON when safety Opposite of OSSDs output OFF when zone is clear safety zone is clear Lockout Information Mode Output ON when fault occurs Output OFF when fault occurs Warning Zone 1 Information Mode Output ON when zone 1 infringed Output OFF when zone 1 infringed Warning Zone 2 Information Mode Output ON when zone 2 infringed Output OFF when zone 2 infringed Window Contamination Warning Mode Output ON when window contaminated Output OFF when window contamined NOTE If the unit enters a fault state all outputs will be OFF except in Lockout Information Mode Fig 2 2 Output Polarity OS32C 20 User s Manual Operating States amp Output Modes Reference Boundary Monitoring RBM The OS82C has the ability to reference and monitor the presence of pre determined areas beams within the boundary being guarded i e walls doorways etc Reference boundary monitoring RBM is normally used in vertical guarding installations see Fig 2
81. ing Zone set B Is tmax When you take into account the scanner s response time required to actually detect an object present in Zone set B the longest time to turning off the OSSDs relative to tstat can be shown as tmaxToOft tmax Tresponse The critical timing guarantee to be met when changing zone sets Is tDangerZoneB The input switching circuitry should begin switching the zone set select inputs prior to tDangerZoneB to ensure Zone B is activated early enough to detect an object previously present in the zone set The amount of time prior to tDangerZoneB to Start switching can be derived from tmaxTooit by equating it to tbangerZoneB tstart tDangerZoneB Tresponse T delay Ttol Tsample This means the switching circuitry must be configured to begin switching the inputs TmaxReaction before tDangerZoneB to ensure safe monitoring of Zone set B where TmaxReaction Tresponse T delay Ttol Tsample If tstart is Configured without consideration of TmaxReaction object detection within the new safety zone after switching and turning OFF of the safety outputs may be delayed OS32C User s Manual Operating States amp Output Modes teEndZoneA tDangerZoneB Da a ebeoaeaaae amp ma amm ab amm o amm amm o amm o amb o amm o a cr ZonesetA l r Zone set A 7 OR E l i Zone setB one se ep aD lt as as op os oe ae Wes SS ED Gp O D O D O GZ CHED 0O Gaz time l l extend
82. ion 0 8 2 File Edt View Configuration Reference Boundary Utilities OeAe amp Foreground safety zone Zone Zone 3 7 rt 3 Oa ANEA EEA Bl 114 66 1416 87 x 173 93 y 378 85 em_ Beam 277 P Safety zone J Warning zone 1 J Warning zone 2 Supervisor Fig 3 60 Detection Zone in Protruding Part Narrow intruding areas less than 70mm wide are NOT valid zone perimeters A scanner configured with such a safety zone would see a presence within this area if in monitor mode but would not initiate a machine stop The following pictures shows a possible zone configuration that contains an intrusion that is narrower than 70mm in width In this case the scanner has two fields of view and the object must be entirely in the left or right field of view to be detected therefore this narrow intrusion of less than 70mm in width is not a valid zone Refer to Fig 3 61 0532C Configuration Tool ersion 0 8 2 KE ol x File Edt Yiew Configuration Reference Boundary Utilities o i Z A Se Foreground Safety zone Zone Zone 3 j ue ma es g si 35 sa 2 E 141 88 i r 278 67 7 x 219 24 ly 172 02 al icm Beam 209 a Safety zone E warning zone Hi H warning zone 2 Supervisor Fig 3 61 Detection Zone in Intruding Parts OS32C 68 User s Manual Chapter4 Installation Mounting Considerations Configuring Multiple
83. ion between the scan plane of the OS32C and the light source be greater than 5 Fig 4 1 Angle between scan plane and light source Configuring Multiple OS32C Scanners The possibility exists that two OS32C may interfere with each other To avoid this when using multiple OS32C in the same location please review the following mounting recommendations Adjust the scanners to offset the scanning plane by tilting the OS32Cs Adjust the scanners to offset the scanning plane by mounting the OS32Cs at different heights Adjust the scanners to different scanning planes and additional sampling scans response time on the OS32Cs eInstall a barrier to block the direct path of possible signal crossing Detection Plane Boe s Se ty Bas 5 or more 5 or more Fig 4 2 Offset Scanning Level by Tilting OS32C 70 User s Manual Installation Detection Plane 5 or more Detection Plane wee 5 or more TF Fig 4 3 Offset Parallel Scanning Levels by Different Installation Height E fil 5 When installing the OS32Cs side by side it is more effective to set their mounting heights differently When adjusting Q the OS32C tilted it may be more effective to adjust the OS32C downward depending on the condition of the outside light
84. ions and wiring OS32C User s Manual 111 Appendix Status Other fault Diagnostic Code 50 Description Affected by noise or disturbance light Or internal fault Mutual interference Possible electrical noise interference or internal fault Corrective Action Check the environment if any noise or disturbance light is coming in Or consult factory LE Mounting Considerations p 70 Check the environment for electrical noise sources or repair the unit Or consult factory The unit was possibly jarred or bumped Invalid configuration in unit Check the environment if any jarring or bumping occurs Reconfigure unit or double check current configuration Incorrect number of active zone set select inputs hard fault code after diagnostic code 70 above persists for more than 10 minutes Check zone set select input wiring and zone configuration selection Invalid or undefined zone set select input combination but correct number of active zone set select inputs hard fault code after diagnostic code 71 persists for more than 10 minutes Standby input or zone set select inputs voltage too high Scanner chassis connected to power 24 VDC Check zone set select input wiring and zone configuration selection Check zone set select inputs or standby input wired at more than system power 24 VDC Scanner chassis should be grounded to 0 VDC Table 7 1 Diagn
85. ires the following e Pentium 4 class 1 5GHz CPU or equivalent e Windows 2000 Windows XP or Windows Vista e 512MB of RAM e 10MB of available hard disk space e Monitor with resolution of 1024 x 768 pixels or better Install the software based on the following steps 1 Terminate all applications running Insert CD ROM of the configuration software to your CD drive 3 Double click the CD ROM icon in My Computer to run Setup exe 4 Follow instructions of the installer program A program icon appears where you specified during installation oe To install the configuration software on Windows 2000 Windows XP Professional or Windows Vista a user account of supervisory access level Administrators is required CHECK OS32C User s Manual Basic Operation of Configuration Software How to Start select Start All Programs OS32C Configuration Tool and OS32C Configuration Tool if you have not changed the program folder name 0532C Configuration Tool ersion 0 8 2 File Edit view Configuration Reference Boundary Utilities Oe 5l 8l Foreground Safety zone Zone Zone 1 j D 4 wt PE ie 3 3 as sal E Safety Critical Parameters External Device Monitoring Disable gt Response time ms Monitoring zone Zone delay ms Operating mode automatic Start Non Safety Critical Parameters Restart delay rms 100 Auxiliary output mode Follo
86. ity active OM Power reserve mode Disable bi 7 5egment display Enable x ISI option Enable ISI mode Follow safety zone Default Properties i Sensors Defined Zones Configuration Information Fig 3 26 Edit Properties 3 Edit the item to be changed 4 After finishing the edits from Configuration menu click Send to Sensor Enter CFG Mode All Changes he screen shown below is displayed Click Yes to confirm Send configuration to sensor The operation requested will result in the deactivation of the protected equipmentand the O532C will enter the configuration mode r would you like to proceed Fig 3 27 Save Configuration to Sensor OS32C 52 User s Manual Basic Operation of Configuration Software 6 When the configuration tool detects multiple scanners on a network the user will be prompted to enter a 4 digit code from the seven segment display of the scanner being configured The order in which each two digit pair is entered does not matter isual Sensor Identification Enter the 4 digit code fram the sensor s display Order of each two digit pair is not important Press OK to continue The process must be completed within 30 seconds Fig 3 28 Visual Scanner Identification When the configuration tool detects only one scanner on the network the user will be prompted to confirm that the computer is connected to only one scanner When this happens the user will not nee
87. l prohibitions of use applicable to the products NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS AND THAT THE OMRON STI PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM OS32C User s Manual PERFORMANCE DATA The performance data in this document is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of OMRON STI s test conditions and the users must correlate it to actual application requirements Actual performance is subject to the OMRON STI Warranty and Limitations of Liability CHANGE IN SPECIFICATIONS Product specifications and accessories may be changed at any time based on improvements and other reasons It is our practice to change model numbers when published ratings or features are changed or when significant construction changes are made However some specifications of the product may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your OMRON STI representative at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when toleranc
88. level 1 From Utilities menu select Window Calibration A screen shown below is displayed Click Yes to confirm Window Calibration The operation requested will result in the deactivation of the protected equipmentand the O532C will enter the configuration mode e Would you like to proceed Fig 3 54 Window Calibration 3 When window calibration starts the window shown below is displayed Window Calibration Discard Fig 3 55 Calibration Starts 4 When calibration is successfully completed the window shown below is displayed Click Save to confirm Window Calibration 3 Fig 3 56 Calibration Success Confirm that the window calibration data has changed and wait for the OS32C to reset Calibration is complete OS32C User s Manual 65 Basic Operation of Configuration Software The window shown below may be displayed even after replacing the scan window due to dust or finger prints on the scan window or dust detection surface during replacement Clean the inside and outside of the scan window and surface of the dust detection surface using a soft cloth Window Calibration Fig 3 57 Calibration Value too Low OS32C User s Manual Basic Operation of Configuration Software Changing Options of Configuration Software This section describes how to change options of the configuration software 1 From Utilities menu click Options The Options screen is displayed Lan
89. ll turn ON to indicate the sector s where an intrusion has occured in a safety or warning zone depends on the ISI mode see below 11 1ISI mode Select Follow safety zone to have the ISls light up to indicate the sectors where an intrusion has occurred in the safety zone Select Follow warning zone to have the ISls light up to indicate the sector s where an intrusion has occured in a warning zone 4 After configuration of parameters is finished click Next Configuration Zone number zone shape type Safety zone Circular segment Y Warning zone 1 Circular segment Warning zone Circular segment Cancel Add zone Fig 3 19 Zone Shape Zone Shape Select either polygon or circular segment Selecting a polygon automatically creates a shape with six segments This shape can be changed after finishing the wizard 5 Click Next If Multiple zones is selected proceed to select zone shapes for the other zone s OS32C User s Manual 47 Basic Operation of Configuration Software 6 The screen shown below is displayed In this example a polygon was selected for the safety zone a polygon was selected for warning zone 1 and a circular segment was selected for warning zone 2 0532C Configuration Tool ersion 0 8 2 File Edit View Configuration Reference Boundary Uilities OSS 8 4_ Forsround safety zone z Zone Zone1 z ist ti 56 oe ve 2 ela Saf
90. lure to properly test the equipment could result in serious injury to personnel 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 Machine Identification Date Technician Signature Condition Comments 1 Disable the guarded machine Apply power to the OS32C system 2 Verify that the guarded machine is suitable for use with the OS32C system See Introduction for more information 3 Visually inspect the machine to ensure that all access to the danger point is through the OS32C safety zone If access to any danger point is possible without being detected by OS32C additional protective measures must be taken such as barriers Verify that all other guarding devices and barriers are installed and operating properly 4 Verify that the maximum safety zone distance of the OS32C system is equal to or greater than the calculated safety zone distance from the danger point Make sure that the operator cannot stand between the safety zone and the danger zone See Chapter 4 for calculation of the safety distance 5 Verify that the scanner can only be reset from a position outside and with a view of the monitoring zone 6 Check for signs of external damage to the OS32C system the guarded machine the electrical cables and wiring 7 Verify that the connections between the control system of the
91. ly If there is any damage to the window replace them 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 tests outlined in this Test Procedure See Checkout and Test Procedure Log in p 127 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 n
92. m stopping distance of AGV Vw 1100 mm Width of AGV Z 100 mm OS32C s measurement error Z2 0 mm Additional error by reflective background no reflective background Zgc 50 mm Safety factor for lack of clearance between under surface of AGV and ground Zot 100 mm Safe factor for reduction of brake force of the AGV through wear and usage Installation position Centered E Calculation Example of Safety Distance Safety Zone Depth S Spe Z SP Z1 Z2 Zgc Lot 1600 mm 100 mm 0 mm 50 mm 100 mm 1850 mm Calculation Example of Safety Distance Safety Zone Width Sw Vw 2xZ VW 2x Z1 Z2 Loc Lf 1100 mm 2 x 100 mm 0 mm 50 mm 100 mm 1600 mm OS32C 82 User s Manual Installation E Additional Error Z2 due to Reflective Backgrounds If one of the conditions listed below applies to your application an additional error factor Z2 should be added to the safety zone 1 High reflective background material or object is present in the scanning plane and within 1 2m beyond the safety zone e g acrylic panel stainless steel reflective tape mirror 2 Low reflective background material or object is present in the scanning plane and within 1 2m beyond the safety zone e g paint finished equipment I Additional Error due to Reflective Background p 114 AGV Standards Safety and Machine standards vary from country to country and machine to machine The following related standards may be
93. mm s constant K 1600 mm s T Delay between interruption of the safety zone and standstill of the machine in seconds consisting of the sum of t1 t2 and ts t Response time of the OS32C t2 Rundown time of the machine mechanical rundown reaction time of control system ts additional time delay for use when multiple zones are used t3 10 ms C Safety constant with C 1200 mm 0 4 x H C 850 where H Distance of detection level from reference level in mm Z Additional safety factors maximum measurement error Z Z1 Z2 Z1 The OS32C s maximum measurement error 100mm Z2 Additional error by reflective background La Additional Error due to Reflective Background 0 114 m Documentation of Configuration Parameters The person responsible for the set up must record the configuration parameters print out and sign the report Connect the printer to the PC Select the menu File Print Configuration in the configuration software The report is printed out Sign and date the report and file it in a Known location which is always accessible OS32C 74 User s Manual Installation Configuration Example Installation on a Machine 1 An example of the installation of OS32C without undercut on the machine is shown below fH 300 mm Machine table Side View l The OS32C measurement error Z1 100mm Additional error Z2 by reflective background In this example Z2 is 0 due to no surrounding wall
94. mporary mode power cycle the OS32C to return the scanner to its fixed IP address S zs CHECK Changing the IP address of the PC Windows 2000 1 Log on to the computer as the Administrator 2 Click the Start button click Settings then click Control Panel 3 Double click Network and Dial up Connections 4 Right click the local area connection to be changed then click Properties 3 In the Components checked are used by this connection box select Internet Protocol TCP IP then click Properties 6 To set the PC to DHCP mode select Obtain an IP Address automatically To set the PC to a fixed IP address select Use the following IP address and specify the desired IP address Changing the IP address of the PC Windows XP 1 From the Control Panel open Network Connections Right click the Local Area Connection and select Properties Scroll down and select Internet Protocol TCP IP OS32C User s Manual 37 Basic Operation of Configuration Software 4 With Internet Protocol TCP IP highlighted click Properties L Local Area Connection 2 Properties General Advanced Connect using Ba NETGEAR F 4i1 POMCIA Mobile Ac Configure Thie connection uses the following items i AEGIS Protocol IEEE 802 1 3 4 3 0 i AEGIS Protocol IEEE 02 14 v2 2 1 0 i nternet Protocol TEFAF Install Uninstall Description Transmission Control Protocal lnternet
95. ms or more 4 20 ms gt 4 20 ms gt 4 20 ms gt 4 20 ms Tswitches Fig 2 10 Zone Delay configuration If an insufficient Zone Delay is used for the actual worst case zone set select input switching time of the installation an unintended zone set may be temporarily enabled resulting in temporarily monitoring the wrong zone Also it must be ensured that after a zone switch there is a minimum hold time before the next zone switch can take place That time is 2 Tsample OS32C User s Manual 25 Operating States amp Output Modes The Zone Input Switch Tolerance Ttoi is the tolerance on when the zone switching circuitry is actually able to start the switching of the inputs Besides Tto and delay there is an additional delay of up to Tsample before the change on the zone set select inputs is recognized Therefore assuming switching of the inputs starts at tstat the system is guaranteed to switch zones between tmin tstart Tdelay Tto ANd tmax tstart Tdelay Ttol Tsample omens TRU a eee T sample Tstart tmin tmax Start tstart Tdelay Tiol tstart Taelay Tiol T sample switching Zone set switches Zone set switches earliest latest Fig 2 11 Zone set select input switching and zone set switch m How To Configure Input Switch Circuitry Timing Relative to tstat the longest time it will take to begin monitor
96. n after maintenance adjustment repair or modification to the machine controls tooling or the OS32C system See page 127 Perform only the test and repair procedures outlined in this 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 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 lf 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
97. n the first input change and ends to the transition on the last input change this will be defined as Tswitches 3 Zone Set Select Input Switch Tolerance It is required that the zone set select input switching circuitry begin switching the zone set inputs at a precise time relative to when the zone set transition is desired to occur The tolerance of timing when input state is actually switched generated by input switching circuitry will be defined using Tto The simplest monitoring zone set switching timing in an installation is tendZonea lt tstartZoneB In this case the interval between tendZonea and tendZoneA does not require any monitoring thus switching from zone set A to zone set B Is straightforward But when tendZoneA tstartZoneB OF tEndZoneA gt tStartZoneB both zone set A and zone set B may need to be monitored simultaneously In such case refer to How to Guarantee Protection of Original Zone Set tEndZoneA tstartZoneB t DangerZoneB tt Zone set response Po Zone seta WSS B gt Zone set B gt time p Monitoring zone set Fig 2 9 Switch from Zone set A to Zone set B The Zone Set Input Switch Timing must be configured to consider delay time of input switching circuitry and ensure proper monitoring and safety The configuration parameter Zone Set Switching Delay Tdelay needs a value larger than Tswitches in increments of 20 ms Tsample In the following example Tdelay IS Configured to 80
98. n this application the OS32C is the primary guarding device The drawing illustrates a common AGV guarding configuration where 4 zone sets are used to safely navigate the vehicle around a factory floor The four zone sets consist of two for forward motion high speed low speed one for left turn and one for right turn The active safety zone set is selected by the AGV s controls which are configured for maximum efficiency OS32C User s Manual Description of Use and Features Fig 1 10 Automated Guided Vehicles AGV Two Scanners Three Sided In this application two OS32Cs are used as the primary guarding devices using 270 degree protective fields They are positioned at the front corners this scheme allows for two scanners to guard three sides of the AGV This configuration is appropriate for AGVs that can maneuver in three directions forward and side to side Fig 1 11 Automated Guided Vehicles AGV Two Scanners Four Sided In this application two OS32Cs are used as the primary guarding devices using 270 degree protective fields They are positioned at opposite corners This scheme allows for two scanners to guard four sides of the AGV This configuration is appropriate for AGVs that can maneuver in four directions forward reverse and side to side OS32C User s Manual Description of Use and Features Rating Performance Sensor Type Type 3 Safety Laser Scanner Safety Category Category 3 Performance Level d
99. nal device monitoring response time operating mode zone set selection zone set select input combos zone transition delay and reference boundary monitoring Safety Zone A user defined protection area to which intrusion of an object stops the guarded machine When an object enters this area the safety outputs of OS382C turns OFF within a predefined response time This zone is a safety critical property Sculpting Within a scanning range of OS32C a position where closest to OS32C can be automatically configured as a zone A distance subtracting 100mm from that to an object is configured Start If start interlock or restart interlock is configured applying the start input releases the interlock state It can be also used to release lockout Start Interlock After OS32C is started the interlock state is maintained Once the interlock is released by the start input an object entering the safety zone shall turn OSSD OFF Once the safety zone is clear the sensor will automatically enter the safety output ON state Start Restart Interlock After the OS32C is started the interlock state is maintained After the interlock is released by the start input an object entering the safety zone shall turn OSSD OFF and the interlock state is maintained Supervisor Access Level To log on to the configuration software with this access level a password is required This access level allows a user to edit OS32C configuration information and send i
100. nce Boundary Utilities eS B amp i Foreground warming zone 2 Zone Zone 2 gt a T f e MOETE ATTICA EEA 25 789 r 647 25 x 582 81 iy 281 53 em Beam 250 a Safety zone Bi warning zone 1 fl Warning zone 2 Supervisor Fig 3 52 System Monitoring The outmost border indicates a scanning zone of the OS32C on the diagram above A zone marked in pink indicates the intruded area in the warning zone 1 a zone marked in yellow indicates the intruded area in the warning zone 2 while a zone marked in red indicates the intruded area in the safety zone The zone selected in Foreground is displayed as purple line In this example Zone 2 and Warning zone 2 are selected Under the monitor mode the OS32C state is displayed on the main tool bar OS32C User s Manual 63 Basic Operation of Configuration Software Read Fault Log There are separate fault logs for the sensor block and for the IO block Each fault log contains the most recent 100 faults that have occurred Fault entries are shown with the most recent faults first so fault entry 1 is the oldest fault To retrieve a fault log From the Utilities menu select Read Fault Log 2 Select sensor block or IO Block 3 Print or save the error log to a text file Omron Scientific Technologies Inc S220 Configuration Tool Version 0 8 0 Wednesday January 27 2010 02 50 10 PM System Information Sensor block serial
101. nch CHECK 1 Remove power from the OS32C Remove the four screws and washers that secure the sensor block to the I O block 3 Replace the old sensor block or I O block with the new one 4 Replace the four screws with flat and lock washers in an alternating patterns It is recommended that the screws be tightened to a torque of 1 5 2 0 Nem 13 28 17 1 inelb OS32C User s Manual 117 118 Appendix Scan Window Replacement Procedure Window Replacement Procedure 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 this manual Doing so may result in a failure of the safety functions If there is any damage to the scan window such as a crack replace it as soon as possible Otherwise it may result in a failure of the protective mechanism 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 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 E Window Replacement Kit OS382C WIN KT Kit contents Scan Window 1 a Gasket pre installed in window S Required Tool 2mm Allen wrench Screw for window M3 4 CHECK Flat Washer A 1 SCREW x4 3 M3
102. ndary i E The sensor is performing required tasks in background Fig 3 42 Learning the Boundary Learning the Boundary k i The sensor has finished required tasks If you have finished the reference boundary setting select Save Reference Boundary Setting from Reference Boundary menu Fig 3 43 Learning the Boundary Complete T Select the points to be used for RBM a To select all the points in the zone for RBM eRight click on the display screen and select Set All as Reference Boundary Select a Group of Points Set All as Reference Boundary Sec as Reference boundary Set All as Non Reference Boundary Save Reference Boundary Setting Fig 3 44 Set All as Reference Boundary User s Manual 59 OS32C Basic Operation of Configuration Software b To select a group of points to be used for RBM Right click on the display screen and select Select a Group of Points Select a Group of Points Set All as Reference Boundary Set All as Non Reference Boundary Save Reference Boundary Setting Fig 3 45 Select Group of Points Select a group of consecutive points so that the distance between the first point and the last point is at least 70mm the OS32C s resolution Use the coordinates in the status bar at the bottom of the screen to help determine the distance between points Right click on the display screen again and select Set Point as Reference Boundary Select a Group of Points
103. ne To configure only one zone set select Single zone To configure more than one zone select Multiple zone 4 Zone Delay Select the desired Zone Delay The available range is 20ms to 320ms in increments of 20ms 5 Operating Mode A user can select from Automatic Start Start Interlock or Start Restart Interlock e Non Safety Critical Parameters 1 Restart Delay Select the desired OFF to ON delay when wiring the OS32C in Automatic Start Available range is 100ms to 60s in increments of 100ms OS32C User s Manual Basic Operation of Configuration Software 2 Auxiliary Output Mode Select either Follow OSSD Indicate FAULT Warning Zone 1 infringed Warning Zone 2 infringed or Window contaminated 3 Auxiliary output type Select PNP or NPN 4 Auxiliary output polarity Select Active ON or Active OFF 5 Warning Output Mode Select either Follow OSSD Indicate FAULT Warning Zone 1 infringed Warning Zone 2 infringed or Window contaminated 6 Warning output type Select PNP or NPN 7 Warning output polarity Select Active ON or Active OFF 8 Power reserve mode Select either Disabled or Standby mode 9 Seven segment display Select Enable or Disable The seven segment display can be disabled to save power Note even if the seven segment display is disabled the 4 digit code for programming a scanner will still be displayed 10 ISI option Select Enable or Disable When enabled the ISIs wi
104. nectors used during installation must provide sufficient signal separation in order to prevent a short circuit condition of the input power and system signals Functional Earth The OS32C system requires a functional earth connection Do not connect Functional Earth to a positive ground system If it is connected to positive ground the guarded machine to be controlled may NOT stop resulting in severe operator injury OS32C User s Manual 97 Wiring Input Output Signal The tables below reference the connections on the OS32C They are identified by the pin number input type and input name Fig 5 1 Power Control 18 Pin Mini Type Connector The table below cross references the Power Control connector pin out and to the mating cable conductor color and signal description 1 Orange White Zone Select 1 2 Orange Black Zone Select 2 3 Gray Zone Select 3 4 Pink Zone Select 4 5 Black Start 6 Violet Standby input 18 Pins Mini Type Connector ova 10 Yellow OSSD B 11 Blue White Zone Select 8 12 White 24V 13 White Black Zone Select 5 a E e C Brown White Tan Zone Select 6 Orange Zone Select 7 Green Functional earth Fig 5 2 Ethernet Port adi Name 2 RX 3 TX Table5 2 PC Interface Connections M 12 4 Pin Female OS32C 98 User s Manual Wiring Example of Safety Circuit Basic connection with single OS32C unit Category 3 Pe
105. ng zone combinations are available supporting complicated changes of working environments e The configuration software allows easy to use monitoring zone configuration e A safety relay can be directly monitored by the external device monitoring function e The physical mounting position of the safety laser scanner can be monitored by the reference boundary monitoring function e Compact design allows for low clearance installations OS32C User s Manual Description of Use and Features System Components Component RUN indicator green Interlock Indicator yellow Status Diagnostic Display Warning Output Indicator orange STOP indicator red Dust Ring Individual Sector Indicators Function Will turn ON when safety zone is clear and OSSDs are ON Will turn ON when in interlock state blink under lockout and blink in case of a failure The scanner s status configuration operation or failure is displayed Will turn ON when the warning output is ON Will turn ON when safety zone is blocked OSSD are OFF or under interlock state Dust detection cover with reflective surface for dust accumulation detection Will turn ON when an intrusion is detected in the safety zone 8 sectors total Each sector 33 75 Scan Window I O Block The window where the laser light i
106. nger area identified in this diagram is only for example the actual shape of the danger area will vary based on the installation CHECK Zone set B Zone set A Fig 7 7 Danger area during zone set switching There are 3 options for ensuring the Danger Area is adequately guarded during the transition described in the following examples OS32C 120 User s Manual Appendix Example 1 Extend Zone Set A Safety Distance relative to the danger area during zone set switching In this option the extra safety distance Zextra is also used to extend Zone set A but in this case it is only considered relative to the danger area during zone set switching not the entire monitoring area protected by Zone set A The resulting zone will adequately protect the danger area during zone set switching even in the event of zone set switching having completed at tmin Zone set B Zone set A Extension around danger Zone set A Resulting zones Zone set B Extended Zone set A Fig 7 8 Zone set A extension on limited danger area example 1 OS32C User s Manual 121 122 Appendix Example 2 Extend Zone Set B to protect the danger area during zone set switching in Zone Set A In this option no change is made to Zone set A Instead the definition of Zone set B is extended to protect the danger area during zone set switching in zone set A For this expansion only the normal safety distance to define
107. nment If you do not set the IP address select Automatic private IP address Internet Protocol TCP IP Properties ae General Alternate Configuration IF this computer i used on more than one network enter the alternate IP settings below Automatic private IP address User configured IP address Subnet mask Default gateway Preferred ONS server Alternate DAS server Preferred WINS server Altermate WINS server Fig 3 10 Alternate Configuration 192 168 1 98 255 255 255 0 192 168 1 5 Changing the IP address of the PC Windows Vista Click the Start button then click Control Panel Click Network and Internet Click Network and Sharing Center Click Manage network connections Right click on the connection to be changed and select Properties If prompted for an administrator password enter the password and confirm Select the Networking tab Select Internet Protocol Version 4 TCP IPv4 and then click Properties To set the PC to DHCP mode select Obtain and IP Address automatically To set the PC to a fixed IP address select Use the following IP address and specify the desired IP address OS32C User s Manual 39 Basic Operation of Configuration Software Logging on to the OS32C There are 2 types of access levels e Operator Access Level Operator To log on to the configuration software with this access level a password is not required This acc
108. nu click Send to Sensor Enter CFG Mode All Changes Configure by following the instructions displayed OS32C User s Manual 61 Basic Operation of Configuration Software i 0532C Configuration Tool ersion 0 8 2 File Edit wiew Configuration Reference Boundary Ltilities Edit Properties Edit Zone Add Zone Sculpting Receive from Sensor Send to SensorfEnter CFG Mode All Changes Selected Items Entire Configuration Sfr E Fig 3 51 Send to Sensor 1 2 Follow the prompt to reset the OS32C Now configuration is complete 5 Safety and warning zones must be configured so that they maintain a distance of 100mm from the wall or fixtures While executing the Sculpting command a warning zone cannot be set with the range exceeding 10 meters Use Edit e Zones or Convert Shape To command to modify the shape of the warning zone OS32C 62 User s Manual Basic Operation of Configuration Software Monitor Mode The configuration software can display scanning zone information of the OS32C in real time without stopping the machine The monitor mode can be used by logging on to the OS32C with either operator access level or Supervisory access level To start the monitor mode select System Monitoring from the Utilities menu To terminate follow the same step and deselect System Monitoring 0532C Configuration Tool ersion 0 8 2 z s k aA oj x File Edt View Configuration Refere
109. o more than 7 alphanumeric characters The password is case sensitive ww CHECK OS32C User s Manual 4 Basic Operation of Configuration Software Forgot the Password If the password has been losi forgotten follow the steps shown below to acquire the password This procedure must be executed under the operator access level 1 Log on with the Operator access level 2 From the Utilities menu select Read Encrypted Password 3 Select Supervisor and click Read Password 4 The encrypted password is displayed on the screen 5 Contact OMRON STI s sales representative with this character string OS32C 42 User s Manual Changing Ethernet Configuration of OS32C 1 From the Utilities menu select Ethernet Configuration 2 To configure the OS32C to DHCP mode select Obtain an IP Address automatically To configure the Basic Operation of Configuration Software OS32C to a fixed IP address select Use the following IP address to specify an IP address Set an IP address correctly according to the network environment Target Sensor IP address 192 1 1 74 LOO E i SSSSS eee I EE MAC address 00 0c 51 00 11 00 TCPHIP Configuration Obtain an IP address automatically Use the following address IP address 192 168 1 1 Subnet mask 255 SS neo D Default gateway 192 5 166 x S Fig 3 15 Ethernet IP Address 3 Click Write to
110. ombination of required inputs can be customized by the installer This configuration uses the recommended Default combinations zs CHECK Number of active inputs 1 T Used inputs 2h ee Ue fae AEE a a a ca Ones Fone input combos 6 GND oo 24VDC 4 Not use Default combos Properties zone Inputs Defined Zones Configuration Information Fig 3 25 Zone Set Select User s Manual 51 OS32C Basic Operation of Configuration Software Editing Properties This section describes how to edit the properties of the OS32C such as response time and operating mode 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 1 From Configuration menu click Edit Properties 2 A configuration properties screen is displayed Satety Critical Parameters External Device Monitoring Disable Response time ims 80 ii Monitoring zone Zonei fone delay imsi z A Operating mode Automatic Start x on Safety Critical Parameters Restart delay ms 100 T Auxiliary output mode Follow OSSD bi Auxiliary output type PRP Auxiliary output polarity Active ON Warning output mode Follow OSSD i Waring output type PRP Warning output polar
111. on software Top View Undercut U kH l S SFdistance ael Fig 4 9 Installation on a machine with cover Put a cover on the OS32C as shown in Fig 4 9 to cover the dead zone and prevent entry to the Undercut U and SFdistance The calculation example of safety distance S and SFdistance are the same as Configuration Example Installation on a Machine 1 Configuration Example Entry Access Protection An application example for perpendicular approach to the scanning plane is shown below entry access protection for a vertical plane protection zone eIntrusion body detection protection User s Manual 77 OS32C Installation Reference Boundary Monitoring RBM must be applied when the OS32C is used for Entry Access Protection guarding as specified in IEC61496 3 2008 Refer to page 19 for more information on RBM eTo ensure adequate detection a response time of 80 mS is required If the response time exceeds 80mS a 70 mm object with a speed of 1 6 m s may not be detected under certain circumstances eAdditional counter measures for protection must be provided if there is a space between the protection zone and the machine hazard point The OS32C can not be used in applications for hand and arm detection Protective Field Contour of the floor as reference Fig 4 10 Perpendicular Approach Installation S KxT C S Minimum safety distance in mm measured from the danger area to the outer contour of the saf
112. ostic Code References OS32C 112 User s Manual Window not detected or entire dust detection surface is dirty or blocked Internal temperature fault Check that the window is properly mounted and clean the dust detection surface The scanner internal temperature exceeds the operating limit Add more ventilation Appendix E Status Diagnostic Display The state diagnostic display indicates a state of the set selection and the response time when of the OSSDs For example code 24 indicates zone set 2 with a response time of 160ms 5 The response times longer than 400ms are represented by Zero S v LF CHECK Left 2nd Digit Monitoring Zone of OS32C Digital Indication Zone Set 1 1 Zone Set 2 Zone Set 3 Zone Set 4 Zone Set 5 Zone Set 6 Zone Set 7 Zone Set 8 Zone Set 9 Zone Set 11 Zone Set 13 Zone Set 15 Zone Set 16 or higher 2 3 4 5 6 7 8 9 b d F Right 1st Digit Response Time ms Response Time ms OSSDs output Auxiliary and Warning Output A ao rN ITE Digital Indication Scan Count So eas Configurable ORO SE Configurable 120 ms 220 ms to 60 12s 160 ms 260 ms to 60 16s 3 3 200 ms 300 ms to 60 2s 240 ms 340 ms to 60 24s 5 5 280 ms 380 ms to 60 28s 320 ms 420 ms to 60 32s 7 7 360 ms 460 ms to 60 36s 400 ms 500 ms to 60 4s 19 9 440 ms 540 ms to 60 44s 480 ms 580 ms to 60 48s 0 11 520 ms
113. ot necessary to take the additional error Z2 into account Figures 7 3 and 7 4 show examples using OS32C for presence detection only 5 Configure the safety zone with a distance of 100mm or more taking only OS32C s measurement error Z 100mm AJ into account CHECK Actual configured zone Required distance from the wall 100mm The OS32C s maximum Danger zone measurement error Z 100mm Reflective background or object Safety light curtain e g F8SJ MS4800 Fig 7 3 Installing Safety Light Curtain on Entrance Reflective background or object Required distance from the wall 100mm Danger zone The OS32C s maximum measurement error Z 100mm Actual configured zone Safety door switch Door Reflective background or object Fig 7 4 Installing Door on Entrance OS32C 116 User s Manual Appendix Sensor and I O Block Replacement N CAUTION 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 When either the sensor block or the I O block is replaced the Checkout and Test Procedure on page 125 must be performed NO oa ss 3 2 g SENSOR HEAD ASSY 60 SCREW x4 M4 x a ee QU WASHER FLAT x4 4 WASHER LOCK x4 Fig 7 5 Sensor Block Replacement All N Required Tool 3mm Allen wre
114. ot run the machine Immediately tag or lock out the machine to prevent its use and notify the appropriate supervisor 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 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 OS32C User s Manual Vil Precautions for Safe Use Make sure to follow all the safety precautions that are necessary to ensure safe use of the product e Thoroughly read this installation manual and understand the installation operation checks and maintenance procedures before using the product e Loads must satisfy both of the following conditions Not short circuite
115. ount of time required for a reset of the OS32C when deciding which Ethernet settings to use for the PC and the OS382C When both PC and OS32C are set to DHCP mode the time required for resetting the scanner and re establishing the ethernet connection between the two devices can be up to 55 seconds When both PC and OS32C are configured with fixed IP addresses the time required for resetting the scanner and re establishing the ethernet connection can be up to 15 seconds e When a device with the same IP address as the OS32C exists a connection failure may occur Be careful not to have any duplicate IP addresses when connecting multiple OS32Cs to the network Forced DHCP mode The OS32C can be temporarily forced into DHCP mode upon startup regardless of the Ethernet configuration settings of the OS32C 1 Connect a PC directly to the scanner 2 Power cycle the OS32C and then press and hold the Start button upon startup 3 If the Start input is detected upon startup the LEDs start blinking this particular blinking does not happen with a normal startup 4 Once the blinking starts release the Start button before 5 seconds have elapsed If the release occurs before 5 seconds the OS32C enters forced DHCP mode 5 Disconnect and reconnect the Ethernet cable to start automatic IP address acquisition 6 Using the forced DHCP mode connects the PC with the DHCP mode and OS32C with the fixed IP address setting 5 As forced DHCP mode is a te
116. ounted in such a way to prevent access to the hazardous area personnel should not be able to crawl under stand behind or climb over the protective field According to EN999 for an installation height exceeding 300mm the possibility of creeping under the protective field must be taken into account Always mount the OS32C so that it is protected from moisture and dirt Mount the scanner so that the indicators are visible Avoid locations where the OS32C is exposed to excessive shock and vibration Scanning level Fig 4 6 Installation Height User s Manual 73 OS32C Installation Configuration When using the OS32C to detect the hazardous area the Start Restart Interlock mode should be selected the regulations applying to the machine must also be complied with E Safety Distance Required Depth of Safety Zone Always configure the safety zone in such a way that the machine comes to a standstill in a time less than that taken to reach the danger point of the machine after infringing interrupting the safety zone The standard ISO 13855 2005 EN 999 1998 must be used to calculate the minimum safety distance according to ISO 13855 2005 EN 999 1998 the minimum safety distance S from the danger zone area to the outer edge of the safety zone is calculated as follows S KxT C Z where S Minimum safety distance in mm measured from the danger area to the outer contour of the safety zone K Movement or approach speed in
117. r s Manual Appendix Revision History A manual revision code appears as a suffix to the manual number at the bottom of the front and back covers Manual No Z296 E1 01 Revision code of this manual April 2010 First edition OS32C User s Manual 129 OMRON CORPORATION Industrial Automation Company Safety Devices Division Shiokoji Horikawa Shimogyo ku Kyoto 600 8530 Japan Tel 81 75 344 7093 Fax 81 75 344 8197 Regional Headquarters OMRON EUROPE B V Representative in EU Wegalaan 67 69 2132 JD Hoofddorp The Netherlands Tel 31 2356 81 300 Fax 31 2356 81 388 OMRON SCIENTIFIC TECHNOLOGIES INC 6550 Dumbarton Circle Fremont CA 94555 3605 U S A Tel 1 510 608 3400 Fax 1 510 744 1442 OMRON ASIA PACIFIC PTE LTD No 438A Alexandra Road 05 05 08 Lobby 2 Alexandra Technopark Singapore 119967 Tel 65 6835 3011 Fax 65 6835 2711 OMRON CHINA CO LTD Room 2211 Bank of China Tower 200 Yin Cheng Zhong Road PuDong New Area Shanghai 200120 China Tel 86 21 5037 2222 Fax 86 21 5037 2200 Authorized Distributor Z296 E1 01 Note Specifications subject to change without notice
118. r Safety and Health Law the complete system must receive the type approval 2 1 This product is electro sensitive protective equipment ESPE in accordance with European Union EU Machinery Directive Index Annex IV B Safety Components Item 1 2 This product complies with the following legislation and standards 1 EU legislation Machinery Directive 98 37 EC 2006 42 EC EMC Directive 2004 108 EC 2 European standards EN61496 1 2004 Type3 ESPE EN61496 3 2001 Type3 AOPDDR EN61508 SIL 2 3 International standards IEC61496 1 2004 Type3 ESPE IEC61496 3 2008 Type3 AOPDDR IEC61508 SIL 2 ISO13849 1 2006 4 North American Standards per UL File E241445 US and C UL approvals CNN NIPM NIPM7 e ANSI UL 508 Industrial Control Equipment e IEC 61496 1 Type 3 ESPE e IEC 61496 3 Type 3 AOPDDR e UL 1998 Software in Programmable Components e IEC 61508 Functional Safety of Electrical Electronic Programmable Electronic Safety Related Systems e IEC 61508 3 Functional Safety of Electrical Electronic Programmable Electronic Safety Related Systems Part 3 Software Requirements e CAN CSA C22 2 No 14 Industrial Control Equipment e CAN CSA C22 2 No 0 8 Safety Functions Incorporating Electronic Technology 5 JIS standards JIS B 9704 1 2006 JIS B 9704 3 2004 Type3 ESPE 3 This product received the following approvals from T V Rheinland of the EU EC Type Examination in accordance with the EU Machinery Directive Type 3 ES
119. rawing of OS32C with OS382C BKT1 and OS32C BKT4 OS32C with Bottom Side Mounting Brackets and Top Guard Kit Assembly Drawing X4 HOLES FOR A M5 MOUNTING SCREWS oe HARDWARE USER SUPPLIED a amp X3 HOLES FOR s gt M6 MOUNTING SCREWS ve S FLAT HEAD 90 DEG Y X4 M5 X 16 HARDWARE USER SUPPLIED MOUNTING CREWE SCREW DIRECTION LINE AN X4 M5 WASHERS FLAT X4 STAND OFF INDENTATIONS MODEL OS32C BKT1 BOTTOM SIDE BRACKET 1 MOUNTING KIT MODEL OS32C BKT4 TOE GUARD TOP GUARD KIT DIMENSIONS mm Inches Fig 4 28 Assembly drawing of OS32C with OS32C BKT1 and OS382C BKT4 OS32C User s Manual 89 90 Installation E OS32C with XY Axis Rotation Mounting Kit Dimensional Drawing 111 4 4 39 55 9 2 20 50 0 1 97 93 5 3 68 46 0 1 81 ie 150 5 5 93 SIDE VIEW BACK VIEW 163 7 6 45 FOR BACK MOUNTING 4 5 3 0 21 dia 119 7 4 72 gt 163 0 6 42 HARDWARE FOR 102 4 4 03 Y ADJUSTMENT 42 2 1 66 2 R72 0 2 83 BACK view 4 0 25 37 0 1 46 DIMENSIONS mm Inches FOR Y ANGULAR ADJUSTMENT Fig 4 29 Dimensional drawing of OS32C with OS32C BKT1 and OS32C BKT2 OS32C with XY Axis Rotation Mounting Kit Assembly Drawing x4 HOLES FOR M5 MOUNTING FOR Y ANGULAR ADJUSTMENT SCREWS AND FLAT WASHERS X3 SLOTS HARDWARE USER SUPPLIED USE M6 HEX HEAD SCREWS FOR BOTTOM MOUNTING HARDWARE USER SUPPLIED De x4
120. rd 41 Forgot the Password 42 Changing Ethernet Configuration of OS32C 43 Receiving OS32C Configuration Information 44 Configuring New OS32C Property and Monitoring Zone 44 Default Configuration Settings 44 Creating a New Configuration 45 Zone Set Selection and Configuration 49 Add a Zone 49 Delete a Zone 50 Zone Set Input Selection 51 Editing Properties 52 Editing Monitor Zones 55 Sculpting amp Reference Boundary Monitoring 58 Monitor Mode 63 Read Fault Log 64 Window Calibration 65 Changing Options of Configuration Software 67 Caution on Safety Zone Configuration 68 E OS32C User s Manual 29 30 Basic Operation of Configuration Software Getting Started The configuration and installation of an OS32C is a simple process Here are the basic steps needed to get started Refer to the appropriate section of Chapter 3 for more information on any of these steps e Install the configuration tool e Connect the OS32C to the same network as the computer e Start the configuration tool e Discover scanners on the network e Log on to the OS32C Select Access Level Enter password e Create new configuration Safety critical parameters EDM response time operating mode zone sets etc Non safety critical parameters auxiliary output warning output power consumption mode etc Zone configuration e Send configuration to the OS32C Installing Configuration Software Installation of the configuration software for the OS32C requ
121. required clearance when installing the OS382C in a recessed location needs to be considered depending on the mounting method Also take additional precautions to prevent intrusion into the dead zone 77 9mm _98 3mm OS32C only OS32C with BKT1 OS32C with OS32C BK1 OS32C with OS32C BKT3 and OS32C BKT2 Fig 4 14 Dimensions of DFdistance OS32C User s Manual Installation Configuration for Automated Guided Vehicles AGV E Safety Distance Safety zone depth required for safety zone For calculating the minimum safety distance for AGV the standard IEC 61496 3 can be used The safety distance S for use with an AGV should be calculated using the following formula S Minimum safety distance in mm measured from the danger area to the outer contour of the safety zone Sp Maximum stopping distance for AGV mm Z Additional safety factors maximum measurement error With the conditions above the minimum safety distance S is calculated as follows S Sp Z SP Vmax X T Sbrake Z Z1 Z2 Zgc Li Vmax Maximum speed of AGV in mm s T Response time consisting of sum of t1 t2 and ts t1 Response time of OS32C t2 Response time of AGV ts additional time delay for use when multiple zones are used t3 10 ms Sbrake Braking distance of AGV in mm based on manufacturer s document Z OS32C s measurement error 100mm Z2 Additional error by reflective background I
122. rformance Level d ISO13849 1 E1 Functional Earth Green OV 24V 24VDC White OVDC Brown Standby input Violet L Zone Select 1 Orange White 4 ae Zone Select 2 Orange Black 4 S2 Zone Select 3 Gray 4 S2 Zone Select 4 Pink 4 So Zone Select 5 White Black 4 S2 Zone Select 6 Tan 4 S2 Zone Select 7 Orange 4 S2 Zone Select 8 Blue White 4 S2 Start Black 3 Auxiliary output Blue Warning output Red Black EDM Brown White Safety output B Yellow Safety output A Red LES a E OS32C Configuration S1 Start Input External Device Monitoring S2 Zone Select Switch Enabled S3 Standby Switch Start Restart Interlock ED1 ED2 Forced guided relay M1 3 Phase Motor E1 24 VDC Power 1 The External Devices ED1 and ED2 are force guided relays e g G7Z G7SA or G7S 2 If the External Device Monitoring is not used connect brown white wires to OV and then turn OFF the External Device Monitoring with the configuration software 3 The Start Input must be a Normally Closed switch 4 For zone select switch setting see Zone Set Input Selection Fig 5 3 Basic Connection with Single OS32C unit ale gt 0 2 S This wiring example is for category 3 lt CHECK User s Manual 99 OS32C Wiring Connecting to the AGV Controls Category 3 Performance Level d 1SO13849 1 AGV Controls Functional Earth Green Power 24VDC
123. s emitted and received Connector module Center of rotation Indicates the location of the axis around which the laser irradiates from Sensor Sensor head field replaceable 1 The communication and power connections can also be mounted on the left side of the I O block Table 1 1 System Components and Indicators _ mi OS32C User s Manual For details on indicators refer to Indication Patterns on page 14 For details on Status Diagnostic Display refer to OS32C Status Check on page 111 Description of Use and Features Application Examples The OS32C may be used for personnel safeguarding Typical applications include work cell area guarding and collision prevention of AGV Automated Guided Vehicles The OS32C is a versatile Safety Laser Scanner capable of guarding many types of applications The application examples in this chapter are for informational and instructional purposes only and not intended to represent complete guarding solutions Care must be taken to ensure that all aspects of a machine or work cell are reviewed and appropriate guarding techniques are employed Applying the OS32C to fixed stationary applications Wn E s ee Fig 1 2 Dual Zone Area Guarding In this application the OS32C is the primary guarding device using a horizontal protective field for area protection The OS32C will guard one side of the area based on the robot s position
124. s used Example In EU a power supply must comply with EMC directives for low voltage To prevent electrical shock use double insulation or reinforced insulation from hazardous voltage such as 230 VAC Cable extensions must be within the specified lengths otherwise it may result in a failure of the safety functions To use this product for a category 3 safety system both safety outputs must be connected to the safety system Configuring a safety system with only one safety output may result in serious injuries due to output circuit fault and a failure of the machine to stop Protection of Cable at Installation Care should be taken when installing the OS32C cable The cable must be properly routed and secured to ensure that damage does not occur Functional Earth The OS32C system requires a functional earth connection Do not connect Functional Earth to a positive ground system If it is connected to positive ground the guarded machine to be controlled may NOT stop resulting in severe operator injury Signal Connector Isolation The connectors used during installation must provide sufficient signal separation in order to prevent a short circuit condition of the input power and system signals OS32C User s Manual Others 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 this manual Doing so may result in a failure of this device to function correct
125. sed Indicates a potentially hazardous situation which if not avoided will result in minor or moderate injury or VAN WARNING 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 moderate injury or VAN CAUTION there may be property damage Meanings of Alert Symbols Indicates prohibited actions Alert Statements in this Manual WARNING An O S32C 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 qualifed person is defined as an individual who understands is trained on and demonstrates competence with the construction operation or maintenance of the machinery and the hazards involved ANSI PMMI B155 1 2006 OS32C User s Manual The machine requirements The guard
126. sion to the dead zone after determining how to mount the OS32C E Additional Error Z2 due to Reflective Background 1 High reflective background material or object is present in the scanning plane and within 1 2m beyond the safety zone e g acrylic panel stainless steel reflective tape mirror 2 Low reflective background material or object is present in the scanning plane and within 1 2m beyond the safety zone e g paint finished equipment If any of the conditions listed above apply to your application an additional error factor Z2 should be added to the safety zone I Additional Error due to Reflective Background p 114 OS32C User s Manual Installation Configuration Example Installation on a Machine 2 An example of installing a cover on the machine with undercut to mount the OS32C is shown below The OS32C needs to be installed so that the operator cannot stand between the safety zone and danger zone Set a cover or undercut on the machine as shown in Fig 4 9 so that the operator cannot stand on the dead zone Recessed mounting on the machine eliminates the dead zone as shown in the left figure Machine table Side View Machine table The OS32C measurement error Z1 100mm Additional error Z2 by reflective background In this example Z2 is O due to no surrounding wall See Table 7 3 Width of danger zone Safety zone distance M Safety zone that needs setup by the configurati
127. stem Monitoring Shows current OS32C scanning zone information on the zone information screen in real time Change configuration software options Table 3 6 OS32C User s Manual 33 Basic Operation of Configuration Software Tool Bars Cc Aa Foreground O fone W OoOo o do fd 1 2 3 4 5 6 Create a new configuration Used to create new configuration of OS32C Open configuration from file Opens a configuration information file saved on PC Print configuration Prints OS32C configuration information 5 System Monitoring Shows current scanning zone information on the zone information screen in real time 6 Sculpting Enable disable sculpting mode Table 3 7 E a re Aa E 8 SO an AEE D 2 a n amp o do a az Save configuration to file Saves created configuration information on PC Toggle measurement unit Toggles unit of measure inches or cm Zoom in Magnifies the zone information screen Zoom out Minimizes the zone information screen Zoom window Magnifies a specific area of the zone information screen View center Shows the zone information screen with the OS32C in the center View all Shows the zone information screen with minimum zoom Toggle view panning Enables Disables view panning Allow a user to click on the displayed zone and move their mouse to adjust their view of the zone Convert shape to Convert zone being edited to either a
128. t Convert zone being edited to a circular segment Polygon Convert zone being edited to a polygon Table 3 2 View ee Main Tool Bar Shows or hides the Main Tool Bar Edit Tool Bar Shows or hides the Edit Tool Bar Status Bar Shows or hides the status bar View Center Shows the zone information screen with OS32C in the center Zoom In Magnifies the zone information screen Zoom Out Minimizes the zone information screen Zoom Window Magnifies a specified range of the zone information screen Show Hide Warning Zone 1 Shows or hides warning zone 1 in the zone information screen Polar Coordinate View the monitoring zone using the polar coordinate system Cartesian Coordinate View the monitoring zone using the cartesian coordinate system Show Hide Grid Shows or hides grid Show Hide Scale Shows or hides the scaling Toggle Measurement Unit Switches unit of measure cm or inch Table 3 3 OS32C 32 User s Manual Basic Operation of Configuration Software Configuration Edit Properties Shows the configuration properties screen Edit Zone Switches to the monitoring zone configuration mode Add Zone Add a new zone to the configuration Sculpting Enable Disable sculpting mode Receive from Sensor Receives current configuration information from the OS32C Send to Sensor All Changes Sends only the changed item s to OS32C for registration Enter CFG Mode Selected Items Sends only the specified item s to OS3
129. t Selection and Configuration 49 Add a Zone 49 Delete a Zone 50 Zone Set Input Selection 51 Editing Properties 52 Editing Monitor Zones 55 Sculpting amp Reference Boundary Monitoring 58 Monitor Mode 63 Read Fault Log 64 Window Calibration 65 Changing Options of Configuration Software 67 Caution on Safety Zone Configuration 68 Chapter4 Installation 69 Mounting Considerations 70 Configuring Multiple OS32C Scanners 70 Distance from Wall 72 Stationary Installation and Configuration 73 Installation for Stationary Area Scanning 73 OS32C xii User s Manual Configuration Configuration Example Installation on a Machine 1 Configuration Example Installation on a Machine 2 Configuration Example Entry Access Protection Mobile Installation and Configuration Applying OS382C on Automated Guided Vehicles AGV Configuration for Automated Guided Vehicles AGV Configuration Example Use of an AGV AGV Standards External Dimensional Drawings Ethernet Cable XS5 OMRON Smartclick Connection Chapter5 Wiring 74 19 T 11 79 79 81 82 83 84 93 94 95 Power Supply Unit Additional Wiring Information Input Output Signal Example of Safety Circuit Chapter Checkout 96 97 98 99 103 Checkout and Test Procedures Checkout and Test Procedures Testing Safety Zone Detection Capability Chapter7 Appendix 104 104 105 106 107 Troubleshooting Troubleshooting OS32C Status Check Additional Error due to Refle
130. t to a normally open contact see Chapter 5 for wiring diagram To activate standby mode The closure of a normally open contact needs to connect the standby input line to 24VDC OS32C 16 User s Manual Operating States amp Output Modes Parameter Configuration The configuration properties consist of two sections Safety Critical Parameters and Non Safety Critical parameters Safety Critical Parameters E External Device Monitoring EDM External device monitoring is an important safety function It verifies that the external control elements are responding correctly The OS32C can operate with this feature enabled or disabled To use external device monitoring the OS32C requires that a Normally Closed contact from each Control Element be fed back in for monitoring If these contacts do not respond as expected the OS32C will enter the lockout state and turn off the safety outputs In the safety output ON state the OS32C expects to see the external device monitoring input open In the safety output OFF state the OS32C expects to see the external device monitoring input closed The external device monitoring inputs must change state within 300ms after a change of the OS32C s safety outputs or lockout will occur E Response Time The response time of the OS32C Is proportional to the number of scans The safety outputs will change from on to off within a preset response time The response time can be set from 80ms to 680ms The
131. t to the OS32C Warning Zone When an object enters the warning zone warning zone infringed will be reported This zone allows for a larger scanning area than the safety zone and can be used to activate a warning function This zone is a non safety critical property OS32C 124 User s Manual Appendix Window Contamination Warning This output can be assigned to the warning output and will turn ON when contamination of the scan window reaches a certain level Window Calibration This is required for replacement of the window Window calibration resets the threshold value of window transmittance This threshold value is used for Window contamination warning Zone Set Select Up to 70 zone sets can be switched according to the wiring for zone set selection Refer to Zone Set Selection on page 19 OS32C User s Manual 125 Appendix Accessories Description Model Complete OS32C Systems OS32C laser scanner with cable access from the back OS32C BP OS32C laser scanner with cable access from the left side OS32C SP1 Spare OS32C Sensor Block Ca OS32C spare sensor without I O block OS32C SN Spare OS32C I O Blocks Spare I O block with cable access from the back OS32C CBBP Spare I O block with cable access from the left side OS32C CBSP1 Power Cables 10m cable for power and I O OS32C CBL 10M 20m cable for power and I O OS32C CBL 20M 30m cable for power and I O OS32C CBL 30M Ethernet Cables
132. ted within the safety zone To release the interlock state a start input must be applied for 200ms or longer Once the interlock state is released and OS32C enters the machine run ON state an object entering the safety zone will turn the OSSDs OFF Once the safety zone is clear the sensor will automatically enter the safety output ON state Start Restart Interlock After power on OS32C automatically enters the interlock state if no fault is detected in its system Initialization and self tests and if no intrusion is detected within the safety zone To release the interlock state a start input must be applied for 200ms or longer Once the OS32C has started and enters the machine run ON state an object entering the safety zone will turn the OSSDs OFF Once the safety zone is clear the sensor will enter the interlock state Power Reserve Mode Power reserve mode allows the OS32C to enter a state of reduced power consumption This is a very useful mode when the OS32C is installed on a battery powered AGV This mode can be configured for Standby Mode OSSDs AUX and WARNING outputs will be off Individual Sector indicators will be deactivated Diagnostic display will display which blinks once every 2 seconds Wake up time time it takes for the OS32C to return to normal mode is less than 0 5s To use Standby mode Enable Standby mode under the Power Reserve property and send this change to the scanner Wire the standby inpu
133. the AGV and will send a stop signal to the vehicle if it detects an object or person The OS32C is more adjustable and reliable than conventional pressure sensitive bumpers The OS32C s flexibility allows three types of monitoring I See Fig 1 7 E Warning Zone 1 Detection The warning output will send a signal to the AGV when Warning Zone 1 is infringed Thiswill trigger the vehicle to sound an alarm allowing a person to move away from the vehicle s path E Warning Zone 2 Detection The auxiliary output will send a signal to the AGV when Warning Zone 2 is infringed This will trigger the vehicle to slow down allowing a person to move away from the vehicle s path E Safety Zone Detection The two safety outputs will send an E stop to the AGV when the Safety Zone is infringed This will signal the vehicle to come to a complete stop Safety Zone Detection Warning Zone 2 Detection Warning Zone 1 Detection Fig 1 7 AGV Navigation OS32C User s Manual T Description of Use and Features Fig 1 8 Automated Guided Vehicles Bi directional AGV In this application two OS32Cs are the primary guarding devices The two warning fields of the OS32C are used to give personnel extra warning allowing them to move out of the AGV path This is essential in achieving maximum travel efficiency Left Turn Zone Right Turn Zone Slow Zone Fast Zone Fig 1 9 Automated Guided Vehicles Multiple Zones AGV I
134. the entire hazardous area must be tested to verify detection of the 150mm object Fig 4 11 Installation on Automated Guided Vehicle E Protruding Front End Mounting When the application requires installation on the vehicle s front end it is necessary to eliminate dead zones These inactive zones can be minimized by recessed installation of the OS32C On vehicles capable of speeds greater than 0 3m sec within 3 seconds the dead zone must be minimized to prevent the operator from standing in the non detection zone Additional guarding safety measures must be taken i e hard guarding or pressure sensitive bumper Safety Zone Dead Zone Fig 4 12 Projecting Installation at Front of Vehicle E OS32C User s Manual 79 Installation E Recessed Front End Mounting Although a recessed installation reduces the size of the dead zone in some cases this technique creates dead angles If the OS32C is mounted too deep within the vehicle the OS32C will not be able to properly scan the hazardous area These areas are referred to as Dead Angles as shown in Fig 4 13 On vehicles capable of speeds greater than 0 3m sec within 3 seconds additional safety measures must be taken Dead Zone z Dead Zone m A Safety Zone Dead Zone oe Fig 4 13 Installation with Bodywork of AGV E Installation of OS382C There are several different ways to mount the OS32C as shown in Fig 4 14 The DFdistance the minimum
135. tion time must be accounted for in the safety distance calculation This delay is 10 ms This would show up as an additional component ts of T in the Safety Distance calculation on page 81 The tsdelay does not apply in applications without multiple zones Non Safety Critical Parameters E Auxiliary Output Mode There are five possible auxiliary output settings safety output information mode lockout information mode warning zone 1 infringed mode warning zone 2 infringed mode and window contamination warning mode E Warning Output Mode There are five possible warning output settings safety output information mode lockout information mode warning zone 1 infringed mode warning zone 2 infringed mode and window contamination warning mode m Restart Delay Machine Stop to Machine Run Time Adjustment This parameter is configurable when the OS32C has been configured to operate in Automatic Start Mode I Please see page 113 for more information E Power Reserve Mode I See Power Reserve Mode on page 16 OS32C 18 User s Manual Operating States amp Output Modes Safety Outputs This product is designed for use on a 24 VDC negative ground protective earth electrical system only Never connect the OS32C to a positive ground protective earth system With a positive ground protective earth wiring scheme certain simultaneous shorts of both safety outputs may not be detected and the guarded machine may not stop resultin
136. torque of 0 56Nem 5 0 in Ib 5 Excess pressure on the edges of the window may result in cracking of the material S T CHECK Recalibrate the sensor to the new window IA Window Calibration p 65 OS32C Maintenance The OS32C will require periodic cleaning of the scan window and dust detection surface on the base of the window The interval of the cleanings will depend on the environment in which the OS32C is used It is recommended that the window be cleaned using a common glass plastic cleaner The window should be sprayed and wiped down with a soft cloth to prevent damage to the surface OS32C User s Manual 119 Appendix Additional Zone Set Switching Strategies The following information provides additional strategies to specify protection zones that guarantee protection of zone set A when zone set may switch before monitoring of zone set A is no longer required when switching from zone set A to zone set B tEndZoneA These examples focus on the dangerous area that exists during zone set transitions limiting the extended protection zone Zextra to only the areas that need it as opposed to a general extension as described in section 2 The following diagram uses the same example zone set layout as in the example in section 2 Fig 2 13 Based on transition related timing parameters previously discussed this diagram identifies the actual remaining danger area during zone set switching during Textena s 1 AJ The da
137. w OSSD Auxiliary output type PNP ine Auxiliary output polarity active ON gt Warning output mode Folow ossD gt Warning output type PNP X Warning output polarity active ON Power reserve mode Disable v 7 Segment display Enable ISI option Enable ISI mode Follow safety zone gt Default Properties Defined Zones Configuration Information 321 799 r 631 66 k 496 30 y 390 74 em Beam 660 P Safety zone warning zone 1 ff Warning zone 2 Off Line Ife P Fig 3 1 OS32C Configuration Tool OS32C User s Manual 31 Basic Operation of Configuration Software Description of Screen The configuration software consists of the following Menu File Used to create new configuration of OS32C Opens a configuration information file saved on PC Save Saves created configuration information on PC or overwrites the existing configuration file if it was edited Save As Saves created configuration information on PC Print Configuration Prints OS32C configuration information Print Screen Snapshot Prints the zone information screen only with current window zoom Table 3 1 Edit Undo last action Redo Redo last action Delete Selected Points Delete selected point s Applies to polygon shaped zone Select a Group of Points Select a group of points Applies to polygon shaped zone Convert Shape to Circular Segmen
138. y with Section 4 2 16 of IEC 61496 3 when the OS32C is mounted where the scanner position could change e g as the result of an impact additional mechanical OS32C LASER SCANNER UNIT means such as serrated or toothed lock washers must be employed in the mounting MODEL OS32C BP SHOWN hardware Fig 4 22 Dimensional drawing of OS32C with simple mounting bracket OS32C BKT3 OS32C 86 User s Manual Installation OS32C with Simple Mounting Bracket and Top Guard Kit Dimensional Drawing PRESS DOWN TO LOWEST POSITION TOP GUARD MUST MAKE FIRM CONTACT WITH 1 0 BLOCK hes SCAN PLANE 112 7 4 44 26 8 1 05 13 3 0 52 X4 12 0 0 47 SIDE VIEW BACK VIEW BOTTOM VIEW Fig 4 23 Dimensional drawing of OS32C with OS32C BKT3 and OS32C BKT4 OS32C with Simple Mounting Bracket and Top Guard Kit Assembly Drawing X4 SLOTS M5 SCREWS SPLIT AND FLAT WASHERS AY HARDWARE USER SUPPLIED a S a X On X4 M5 x 16 MOUNTING SCREWS X4 M5 WASHERS FLAT eae X2 SIMPLE MOUNTING BRACKET ee TOP GUARD In order to comply with Section 4 2 16 of IEC 61496 3 when the OS32C is mounted where the scanner position could change e g as the result of an impact additional mechanical OS32C LASER SCANNER UNIT means such as serrated or toothed lock washers must be employed in the mounting MODEL OS32C BP SHOWN hardware Fig 4 24 Assembly drawing of OS32C with OS32C BKT3 and OS32C
139. zone set A should be considered This solution may not be practical if Zone set A and Zone set B are basically independent but in cases where Zone set A and Zone set B naturally overlap and or the danger is due to a device that simply moves from Zone set A to Zone set B this option may be used Zone set B l Zone set B Extension around danger Zone set A Resulting zones Extended Zone set B Zone set A Fig 7 9 Zone set B extension on limited danger area example 2 OS32C User s Manual Appendix Example 3 Create a third zone specifically for relaying the transition A third zone set in the following diagram Zone set C is defined that is the combination of both Zone set A and Zone set B Using this mechanism the zone set change is achieved by first changing from Zone set A to Zone set C which effectively begins monitoring Zone set B while continuing to monitor Zone set A and then changing from Zone set C to Zone set B This allows the timing of the two different zone set switches to be more flexible and easier to design Zone set B Zone set C Zone set A Danger Area during zone set switching NOT APPLICABLE Resulting zones Zone set B Zone set A New Zone set C Fig 7 10 The third zone set that relays switching example 3 The first switch Zone set A to Zone set C should be setup to meet the same criteria defined previously for specifying tstat relative to tDang

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