TGR-T2 series USER`S MANUAL
Contents
1. P T N _ 2 T T o 9 Safety output 2 0 I U oO LE x 4 gt The supply of photocells must be taken S5 TYPE S5 TYPE from the same Transmitter Receiver coo i I5 supply of TGR Inc OE ae S m Si T2 unit Transmitter Receiver le E 11 12 TGR T2 Please note especially what follows models can be connected in all the possible combinations for maximum of two pairs of sensors with at least one pair connected In the following paragraph you can find the codes of the available models which can be used in the wished configuration The transformer which is necessary to power the system must conform to standard EN 60742 double insulation or with equal insulation for instance VDE 0551 It is necessary to protect the control unit with an outer fuse having a nominal interruption current equal to 1 A The TEST and START pushbuttons must be positioned in such a way that the operator can see the protected area when he restarts or carries out a test or override operation The LMS must be positioned in a place where it can be seen from any operative point Read the paragraph relating to the muting function and its use for the positioning of the activation sensors of this function Both safety contacts OUT1 and OUT2 must be connected If the m2. 8 oe contact of B TGR T2 terminals D minimum distance so that the muting sensors keep active the request it depends on the parcel length D L In the previous figures an installation example of a protection arranged on a conveyor is drawn The protection photocells S are connected to di necessary maximum distance so that the muting request the TGR T2 control unit and are temporaneously cut out at the package is accepted it depends on the parcel speed passage by means of the muting A1 A2 B1 and B2 activation dmax cm v m s 3 s 100 sensors This distance must not allow to activate both sensors Sensors A and B are optical mechanical proximity etc sensors with and the muting with the accidental passage of a person closed contact in the presence of the object to be detected To allow the muting function only for the first photocells it s necessary to set the unit with the dip switch number 3 in ON To allow the muting function for both the photocells the dip switch number 3 must be setted OFF 17 18 User s manual e The TEST and START pushbuttons must be positioned in such a way that the operator can see the protected area when he carries out start test or override operations e The LMS active muting signalling must be positioned in place where it can be seen from any operative point e f the muting sensors installed very near the protect
3. TO THE LED FLASHING ARE FREE THE BEAMS ARE INTERRUPTED THE LEDS CAN ONLY BE OFF 22 TGR T2 9 cg cg User s manual FINAL CHECKS Check that the area protected by the beams is free from any obstacle check the correct triggering of the safety relay opening by interrupting the protection rays red LED switched on controlled machine stopped CAUTION If the red LED switches on and off check the correct mechanical assembly NOTE This check must be repeated each time you move or mechanically re align the photocells 10 ROUTINE MAINTENANCE OPERATIONS Here is a list of checks recommended to the user to be carried out periodically by skilled workers Check that the unit locks by inserting an object detecting the single elements of each photocell By opening the test contact check that the safety relays are opened red LED switched on and machine under test stopped Make sure that the access to the machine dangerous areas is not possible from any non protected area and that the minimum distance from the beam dangerous parts is not lower than the one calculated with reference to the formula reported at paragraph 4 1 e Check that it is not possible for a person to stop between the beams and the dangerous parts of the machine Make sure that there is no outer damage to the unit and or the outer electrical connections Make sure that the response time including the unit and the machine ones does no
4. following operations e TEST button if pressed during normal operation it checks if all the system comprising the barrier and the machinery is efficient Pressing the button opening the contact basically simulates the interruption of one or more safety rays and it is possible to check that the machinery stops in the time and way set If perssed after a failure detection of the unit see the table of error code reset the system e START button It is used to start the system which has been just powered in case you are in a condition of manual reset and to start it again when it has locked after a relay triggering if you are in a condition of manual reset or after an error which can be reset see table relating to the error codes Two types of different operating modes are also available 1 Automatic restoring that is to say after the triggering caused by the detection of an object The barrier starts to work again normally when the object is removed 2 Manual reset by means of the START button so that the return to the normal operating mode takes place only after the object has been removed and the button has been pressed During the unit working no operation set by means of the user interface involves functions which can influence the system safety TGR T2 User s manual 4 PRECAUTIONS AND INSTALLATION CRITERIA The safety products used must be suitable for the required application and other influences must be also take
5. 5 serie Number of photocells two pairs max Wire range size AWG 16 24 Solid Stranded Wire type 60 75 C copper Cu conductor only Torque on terminals 0 9 N m Indicators 5 green LEDs 1 red LED Resolution with static test rod 55 5 510 5 15mm 530 5 20mm Resolution with dynamic test rod 55 5 510 5 S30 5 53mm measured with velocity of 1 6 m s Response time lt 30 ms Working temperature 10 a 55 Moisture from 1596 to 9596 not condensing Output contacts 2 NA 115 Vac 2 5 A max Operative distance according to the type of photocell 55 5 8m 5 10 8m 530 5 50m Outer controls start control test muting and override Container plastic container for installation on a din omega guide Protection class of control unit IP 20 Protection class of photocells IP 67 Protection class of the cabinet containing the control unit IP54 at least Weight control unit 300 g Features of fuses muting signalling lamp internal re settable fuse 315mA 60V Muting signalling LMS 25 TGR T2 User s manual 13 OVERALL DIMENSIONS 99 mm 22 5 mm ww yr Control unit TGR T2 26 TGR T2 User s manual 27 TGR T2 User s manual 28
6. E oep e 0160 S max gt It is not possible to out a muting request if the barrier is the opened relay state 21 TGR T2 User s manual 8 LED DIAGNOSTIC The user can be informed of the unit operative state by means of four LEDs The LED state has the following meaning e GREEN LEDS OUT if switched on the related photocells work regularly and no object is interposed the relays are closed GREEN LED STATUS if switched on all the unit test are correctly passed if blinking an error occurs RED LED BREAK if switched on the unit has detected an object or an error which can be possibly recovered by pressing the reset button has occurred in this condition the relays are opened GREEN LED GUARD if switched on in green the barrier is working regularly and there are no interposed obstacles in this condition the relays are closed The TGR T2 has inside an easy diagnosis with the four green leds to detect the most common errors or failure that can be presents One led flashing Probable error in a photocells pair Two leds flashing Probable incorrect setting of numbers of beams connected Tree leds flashing Probable fail in muting lamp connection Four leds flashing Probable internal error All this error are resettable by the TEST pushbutton if the error condition can be removed THE TWO LED OUT 1 AND OUT 2 CAN BRING INDICATIONS ONLY IF THE OPTICAL BEAMS ASSOCIATED
7. G Always maintain the safety distance between the safety PES and a hazardous part of a machine 4 2 REFLECTIVE SURFACES In case that reflective surface exist the distance must be sufficient to avoid the possibility of passive reflections Top View reflective material _ RX bar TX bar v e 2 Object reflective material Distance between emitter Minimum installation distance receiver detection distance L D 0 3 to 3m 0 27 m 3m or more L x tan 2 L x 0 034 AN WARNING Do not install the safety PES in a location affected by shiny surface reflections TGR T2 User s manual 5 CONNECTIONS 5 1 REFERENCES ON THE TERMINAL BOARD Here is a table reporting the function and the connection to be carried out for each number which is present on the label near the terminal board TERMI OUTER CONNECTION NAL Input of the muting A sensor Connect to the N O contact of the muting sensor photocell proximity switch other Input of the muting B sensor Connect to the N O contact of the muting sensor photocell proximity switch other Connect the photocells test input of transmitters TX1 Black wire 11 pin 4 of connector In case of photocell S30 with terminal board connect these terminals with terminal 3 of the photocell Connect to the PNP output of the receivers RX1 black wire pin 4 of connector In case of photo
8. TGR T2 User s manual TGR T2 series Multiray safety control unit safety level 2 from 1 to 2 pairs of photocells USER S MANUAL TGR T2 User s manual The device conforms with the EC requirements in compliance with the following standards Low Voltage Directive 73 23 EEC EMC Directive 89 336 EEC Machinery Directive 89 392 EEC IEC 61496 1 1997 FDIS IEC 61496 2 1997 DIN V 0801 1990 amendment 1 1994 50081 2 1993 55022 1994 DIN 60204 1 1993 prEN 50178 1996 IEC 664 1 1997 PRODUCER TECHNO GR s r l via Torino 13 15 10046 Poirino TO ITALY Tel 39 011 9452041 FAX 39 011 9452090 USER MANUAL Versione 1 0 del 4 02 2003 TGR T2 User s manual INDEX 1 BEFORE USING THE 4 11 GENERAL INSTRUCTIONS certet terere tnn 4 1 2 ROUTINE MAINTENANCE rettet teet tette 4 1 3 ROUTINE MAINTENANCE rettet tette teet 4 GENERAL INFORMATION AND MAIN APPLICATIONS 5 OPERA TION mee 7 PRECAUTIONS AND INSTALLATION CRITERIA 8 4 1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE 8 4 2 REFLECTIVE SURFACES eerte tetris 9 5 2 55 10 5 1 REFERENCES ON THE TERMINAL BOARD ces 10 5 2 PIN OVERVIEW cree
9. a system forcing for this reason to activate these functions some precautions limiting the reduction of the safety level have been added The muting and override function is available by simply connecting the LMS luminous warning light supplied separately The presence of a limb or an object interrupting a beam causes the opening of the emergency exits and the consequent locking of the duly connected machine It is necessary for the unit to be connected in the right position in comparison with the passage to be protected in such a way that there isn t any possibility to climb over Here is a list of the commonly used applications o Machines for the processing of wood glass and ceramic products o Automatic warehouses o Conveying lines Palletizers TGR T2 User s manual 3 OPERATION The control electronic system is fitted inside the control unit The core of the device is made up of a microprocessors By means of the suitable hardware it continuously control and check the connected photocells No interference among the photocells is possible as they are controlled sequentially it will be thus possible to install one or two adjacent photocells When one or more rays are interrupted the electronic system opens the output relays signalling which photocells have triggered by means of LEDs which can be seen on the container The control unit can work in two different modes please refer to par 7 page 14 which he can carry out the
10. achine has a single locking circuit the two normally opened contacts must be connected in series Photocells of the type 55 5 and 510 5 are delivered with wired cable or standard M12 connector and the wiring on the control unit is indicated according to the cable colour or to the male connector pin number Photocells of the type 530 5 are available also in the version with terminal board in this case it is necessary to carry out the connections by respecting the same symbols present both on the terminal board of the control until and on the photocell one The connection cables of the photocells of muting request start and test must be masked with minimum section 22AWG The screen braids must be all earthed towards the control unit side User s manual TGR T2 User s manual ALIGNMENT PROCEDURE After having carried out the correct mechanical assembly and the correct connections as described in the previous paragraphs it is necessary to align the pairs of photocells Follow the operative modes as follows Turn off the power supplying the control unit Open the TEST pushbutton Power the control unit e Align the photocells by observing the LEDs on the control unit If the alignment of the relevant pair of photocell is correct the LED is turned on After the alignment turn off the power supplying the control unit close the TEST pushbutton and re power the control unit again Wait for the control unit to carry out the
11. cell S30 with terminal board connect these terminals with terminal 6 of the photocell Connect the photocells test input of transmitters TX2 Black wire pin 4 of connector In case of photocell S30 with terminal board connect these terminals with terminal 3 of the photocell Connect to the PNP output of the receivers RX2 black wire pin 4 of connector In case of photocell S30 with terminal board connect these terminals with terminal 6 of the photocell 13 14 OUT1 safety output 1 with N O contact 15 16 OUT2 safety output 2 with N O contact 10 TGR T2 User s manual TGR T2 User s manual 5 2PIN OVERVIEW 5 3 WIRING EXAMPLE Here is a connection example of the control unit TGR T2 relating to a mixed configuration in which all the available models of photocells have been used OUT1 B OUT1 OUT2 B OUT2 A Muting A B MAIN SUPPLY 13 14 15 16 MUTING B MUTING A START TEST EXTERNAL FUSE GUARD CO BREAK C C STATUS 2 T STATUS 1 1 2 4 5 6 7 8 contiol unik Q OUT 1 9 10 11 12 13 14 15 16 9 Safety output 1
12. ch switching on operation a test is carried out to check that the buttons are not locked The override function has been activated The muting lamp blinks to signal the barrier disconnection The maximum duration of the override function amounts to 60 seconds after that the unit is connected again even if the buttons are pressed Obviously if the buttons are released before this time has elapsed the override function will be immediately stopped 20 TGR T2 User s manual 7 6 MUTING RESTRICTIONS muting function a The request of muting must occur according to the correct time sequence it is necessary to activate input MUTE A at first and then input MUTE B The request of this last one must arrive within a maximum time of 3 seconds If not the muting request will not be activated A wrong sequence on the entrances of muting does not activate this function b Since when the muting state is active an object can remain for a period of time not longer than 60 s otherwise the muting function is switched off This mechanism is optional and can be deactivated when the barrier is set up with the dip switch c For all the cases in which the muting function is automatically disabled because of time out the request must be cut out and re activated to generate the following muting state MUTE A y 30 MS min 74 MUTE B gt 3 5 max 68 oc m MUTE_STAT
13. e factory with the following configuration e Automatic restoring all two optics in muting the maximum duration of the muting is of sixty seconds 7 2 CONFIGURATION OF THE NUMBER OF PHOTOCELLS In case you use only a pair of photocells operate as follows Turn off the power and short the terminal 11 12 At least one pair of photocells must be connected otherwise the control unit is locked 15 7 3MUTING FUNCTION 7 3 1 DESCRIPTION As mentioned in the introduction the muting function can be enabled with any unit by simply connecting the LMS muting indicator when the unit is switched off This presence of this indicator is recognised everytime the unit is powered on If its presence is detected the unit will enable the muting function and if its presence is not detected the unit will ignore any request for muting It is important to note that if the muting indicator is connected when the TGR T2 is connected to the power supply it will not be recognised and the muting function will not be enabled Once enabled if the indicator develops a fault or is removed without first disconnecting the unit s power supply it will signal an error as described in section 8 To disenable the muting function therefore the unit s power supply must be turned on without the LMS muting indicator connected In brief this function present on all units is enabled and disenabled by means of the following simple procedure Disconnect the uni
14. initial tests e At the end of this operation the unit indicate the right alignment whit the guard led green on e Carry out all the checks described in the final checks and in the routine maintenance operations During aligning operations or normal working check that the photocells connected to the same or other units do not interfere which each other modifying their mutual position for instance by positioning some pairs of transmitters on the other receiver side NOTICE The control unit can detect the mutual interference between safety PESs The control unit forces the output contact to open when it detects external disturbance light including mutual interference light The safety PESs should be installed the following way to avoid mutual interference The safety PESs are installed with sufficient distance Emitters and receivers of safety PES are installed alternately as follows Tx Rx O 4 o 14 TGR T2 User s manual 7 OPERATING PROCEDURES 7 1 DIP SWITCHES CONFIGURATION The configuration indicated in the table must be selected on the dip switch available in the front label 3 Off muting act on the sensor couples 1 and 2 ON On muting A B act on the sensor couple 1 Off muting 60 s On muting oo S Off manual restoring On automatic restoring The control unit is manufactured from th
15. ion photocells it is necessary to install the sensor receivers on the photocell sender side to avoid interference COEM e system is anyway protected from possible failures due to the cable damage it is necessary to prepare the wiring of all connections so as to avoid damage to the connection cables e control unit must be located in cabinet with protection degree of at least IP54 7 4 OVERRIDE This function makes it possible to force a muting condition if it is necessary to start the machine despite one or more rays have been interrupted by the material The aim is that of removing from the protected area the material which has possibly gathered before the photocells for instance because of a failure of the machine cycle Lets suppose that a pallet has stopped before one or more used optical devices the conveyor belt cannot be started again because the control unit after having detected one or more interrupted rays will not close the output relays thus making it impossible to free the controlled area By starting the override function it will be possible to carry out this operation 19 TGR T2 7 5 User s manual STARTING THE OVERRIDE FUNCTION Switch off the device Make sure that the TEST e START buttons are connected N C for the TEST button N O for the START button Switch on the device Within 10 seconds press together the test and reset buttons and keep pressing At ea
16. n into account such as a room temperature electromagnetic interference intense light sources etc Please refer to the manual for specification or contact the manufacturer for details 4 1 CALCULATION OF THE MINIMUM INSTALLATION DISTANCE The safety distance S must be sufficient to guarantee that the dangerous area cannot be reached by the operator up to the moment in which the machine with moving part stops The safety distance must be calculated according EN999 European Standards Safety of Machinery The positioning of protective equipment in respect of approach speeds of part of the human body Using EN 999 formula S K T C 5 safety distance T T2 whereas T1 machine response time in seconds T2 unit response time in seconds including Safety sensor response time K 1600 mm s speed of the body approaching the dangerous area C additional distance depend on resolution of SLC and applicable standard 1 Multiple separate beams 999 clause 6 1 4 1600 mm s 850 mm Heights recommended 4 Beams 3 Beams 2 Beams in EN999 Heights of 15 ray 300 mm 300 mm 400 mm Heights of 2 ray 600 mm 700 mm 900 mm 2 Single height beam EN999 clause 6 1 5 WHERE THE RISK ASSESSMENT ALLOWS THE USE OF A SINGLE BEAM THE FOLLOWING VALUES CAN BE USED K 1600 mm s 1200 mm The height of beam from the ground or reference plan 750mm EN 999 TGR T2 User s manual A WARNIN
17. r tette tte teet tetti 11 5 3 WIRING EXAMPLE ertet teet ettet tton 12 ALIGNMENT 14 OPERATING PROCEDURES 15 71 DIP SWITCHES CONFIGURATION cerneret 15 7 2 CONFIGURATION OF THE NUMBER OF PHOTOCELLS 15 7 3 MUTING FUNCTION 16 7 8 1 DESCRIPTION tette tttttnett 16 7 8 2 INSTALLATION CRITERIA eene 17 T4 OVERRIDE a m 19 7 5 STARTING THE OVERRIDE FUNCTION centes 20 7 6 MUTING RESTRICTIONS MUTING FUNCTION eet 21 LED 2 6 neu Omen 22 FINAL CHECKS 23 10 ROUTINE MAINTENANCE OPERATIONS 23 11 GENERAL INFORMATION AND USEFUL DATA 24 12 TECHNICAL 25 13 OVERALL 5 2 26 TGR T2 1 User s manual BEFORE USING THE DEVICE 1 1 GENERAL INSTRUCTIONS Read this manual and the manual of safety PES safety photoelectric Switch carefully and completely Make sure the user informa
18. rsons in areas where it is necessary to protective devices guarantee the safety of the operator using machines robots or in general General requirements and test automatic systems which are considered dangerous or subject to casual or FDIS IEC 61496 2 1997 Safety of machinery electro sensitive undesired access to unsafe parts protective devices The system conforms with the requirements for safety devices of level 2 in Particular requirements for system compliance with what described in the latest international standards that using active opto electronic devices is to say IEC 61496 1 2 This safety device is made up of a control unit protected by a plastic container so that it can be installed on DIN OMEGA guide it has 16 removable screw terminals to which it is possible to connect from 1 to 2 pairs of photocells This version of the multi ray safety barrier has the muting function by means of this function it is possible to connect or disconnect one or more pair of photocells in order to allow for instance the material passage without stopping the machine If the device has this function an other function must be also possible The override function It represents the possibility to force the system that is to say to close the output relays even with occupied rays in order to make it possible for the material which has gathered before the optical devices to proceed Both the muting and the override functions represent
19. t s power supply Connect the appropriate LMS and the muting sensors Restore the unit s power supply Bypass the muting function as follows Disconnect the unit s power supply Disconnect the LMS device and the muting sensors Restore the unit s power supply TGR T2 User s manual 16 TGR T2 User s manual TGR T2 User s manual Typical application with four muting sensors 7 3 2 INSTALLATION CRITERIA 1 The muting sensors must recognise the material namely pallets vehicles etc in all its length Muting sensor connection 2 The sensors must be arranged in such a way that the material is 24 Voc recognised even when it must be lifted for the relevant processing e 3 In case of different transport speeds in the muting area always bear contact of A1 4 All the safety photocells and the muting sensors must be arranged such a way that the previous material has already passed the last in mind their influence on the muting total duration Ces muting sensor before the new material has reached the first sensors i t6 4 1 1 tt contact of A2 7 MUTEA 1 1 1 1 1 e eea contact of B1 8 MUTEB S v al di 9 TGR T2 D JG terminals contact of B2 Application with two muting sensors passage permitted only for package 1 Muting sensor connection 2 24 Voc Ne Z eo e EN contact of A 7 MUTEA
20. t exceed the established limits The frequency of these operations depends on the special applications and operative conditions according to which the unit is working 23 TGR T2 11 cg User s manual GENERAL INFORMATION AND USEFUL DATA Safety MUST be part of our consciousness The safety devices are useful only if installed correctly by respecting the indications reported on the standards If you believe not to have the sufficient competence to correctly install the safety devices apply to our advisory service or request the installation We recommend to leave free space on the cover side to allow a possible easy access to the inner parts Trouble that cause voltage interruption on power supply may cause temporary openings of the outputs that are not damaging in any case the safety work of the unit The guarantee is complete for a period of 12 months starting from the delivery date of the device Defects which are clearly due to damage caused by an incorrect use accidental causes or catastrophic events are not covered by the guarantee In case of failure send the barrier to TECHNO GR via Torino 13 15 10046 Poirino TO ITALY Tel 39 011 9452041 FAX 439 011 9452090 always indicating the detected failure and the operational period 24 TGR T2 User s manual 12 TECHNICAL DATA Voltage 24 Vdc 10 Electrical input 420 mA max Combinable photocells Omron serie Technogr S5 5 510 5 S30
21. tion provided is understood before attempting to operate the safety PES Keep the manual in a secure and convenient location and confirm information if necessary To guarantee correct installation carefully follow the instructions of this manual e Do not touch non insulated cables unless they have been disconnected from the power supply e Make sure that the cables connected to the control unit are not taut and that they do not hinder the movement of persons or objects e Before carrying out any outer operation turn off the power Failure to do so may result in lethal or serious injury 1 2 ROUTINE MAINTENANCE The following symbols are used for highlighted items in order to ensure safe and proper use of the TGR T2 Highlighted items are critical for safe operation and must be heeded at all time AN WARNING 1 3 ROUTINE MAINTENANCE Be sure to conduct inspection regularly Please refer to sec 10 and the safety PES instruction manual Techno GR refuses to accept any responsibility for damage to persons or object due to the incorrect use installation of the control unit and safety PES TGR T2 User s manual TGR T2 User s manual 2 GENERAL INFORMATION AND MAIN APPLICATIONS The barrier has been planned with reference to the following standards The multiray safety control unit of the TGR T2 series has been produced IEC 61496 1 1997 Safety of machinery electro sensitive to meet the need to protect pe
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