ABB Orion 3 Base Original Instructions Manual Download

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ABB Jokab Safety

Varlabergsvägen 11, SE-434 39 Kungsbacka, Sweden

www.abb.com/jokabsafety

Original instructions

Orion3 Base

Safety light grids

Type 4 Active Opto-electronic Protective Device (AOPD)

Summary of Contents for Orion 3 Base

Page 1: ...ABB Jokab Safety Varlabergsvägen 11 SE 434 39 Kungsbacka Sweden www abb com jokabsafety Original instructions Orion3 Base Safety light grids Type 4 Active Opto electronic Protective Device AOPD ...

Page 2: ...SAFETY 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 attent...

Page 3: ... installation of the AOPD 12 3 2 General information on positioning the AOPD 12 Minimum installation distance 13 Minimum distance to reflecting surfaces 13 Minimum distance between adjacent devices 16 Installation of several adjacent AOPDs 17 Active and passive units orientation 18 Use of deviating mirrors 18 3 3 Checks after first installation 19 4 Mechanical mounting 20 4 1 Mounting with angled ...

Page 4: ...tion of the status of the AOPD 33 8 2 Diagnostic messages 33 Active unit 33 9 Periodical checks 35 10 Device maintenance 36 11 Technical data 37 12 Model overview 39 13 Dimensions 40 13 1 Profiles 40 13 2 Angled fixing bracket 41 13 3 Fixing bracket with profile 41 14 EC Declaration of conformity 42 ...

Page 5: ... safety 1 4 Abbreviations ACM Advanced Configuration Mode AOPD Active Opto electronic Protective Device BCM Basic Configuration Mode EDM External Device Monitoring MPCE Machine Primary Control Element OSSD Output Signal Switching Device switching output RX Receiver TX Transmitter 1 5 Special notes Pay attention to the following special notes in the document Warning Danger of severe personal injury...

Page 6: ...e electronic safety related systems Part 3 Software requirements EN 61508 4 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 4 Definitions and abbreviations EN 62061 2005 A1 2013 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems The device consisting of one active unit and one...

Page 7: ...zone The resolution R is calculated using the following formula R I d where I Distance between the centers of two adjacent optics d Diameter of the lens Figure 1 Resolution Therefore the resolution depends only on the geometrical characteristics of the lenses diameter and distance between centers and is independent of any environmental and operating conditions of the AOPD See paragraph 12 Model ov...

Page 8: ...cted height The following figures illustrate what is meant with protected height Hp for Orion3 Base For the values of Hp for each model see paragraph 12 Model overview Figure 2 Orion3 Base with 2 beams Figure 3 Orion3 Base with 3 beams Figure 4 Orion3 Base with 4 beams ...

Page 9: ... the hazard zone is calculated using S K T C S Minimum distance mm between safeguard and hazard zone K Approach speed of body parts towards the hazard zone mm s See below for values T Overall system stopping performance s with T T1 T2 where T1 response time of the AOPD s T2 stopping time of the machine including the response time of the safety control system s C Intrusion distance mm C depends on ...

Page 10: ...ation of the AOPD This value depends on the height of the hazard zone and the height of the uppermost beam see EN ISO 13855 2010 Horizontally assembled AOPD Orion3 cannot be used horizontally Angled assembled AOPD See the latest version of EN ISO 13855 Practical examples Let s suppose we have an Orion3 Base light grid in a vertical position and with no risk of reaching over it S K T1 T2 C Orion3 4...

Page 11: ... a particular position so that access to the hazard zone is not possible without the interruption of the beams see paragraph 3 Installation The personnel operating in the hazard zone must be well trained and must have adequate knowledge of all the operating procedures of the AOPD The TEST button must be located outside the hazard zone because the operator must check the entire hazard zone during a...

Page 12: ...e contact your ABB Jokab Safety representative for advice The operating distance of the device can be reduced in presence of smog fog or airborne dust A sudden change in environment temperature with very low minimum peaks can generate a small condensation layer on the lenses and so jeopardize the function 3 2 General information on positioning the AOPD The AOPD must be carefully positioned in orde...

Page 13: ...ional mechanical protection must be mounted to prevent the access Figure 8 Incorrect installation Figure 9 Correct installation Minimum installation distance See paragraph 2 4 Minimum installation distance Minimum distance to reflecting surfaces Reflecting surfaces placed near the light beams of the AOPD over under or laterally can cause passive reflections These reflections can affect the recogni...

Page 14: ...rfaces The minimum distance Dsr depends on the operating distance between active and passive units effective aperture angle EAA of the AOPD For a Type 4 AOPD EAAMAX 5 α 2 5 The diagram below shows the minimum distance to the reflecting surface Dsr based on the operating distance for a Type 4 AOPD Figure 11 Minimum distance to a reflective surface as a function of the operating distance ...

Page 15: ...an the correct height to the floor that still must be respected The correct function of the AOPD is guaranteed and certified up to a maximum operating distance of 6 5 m for Orion3 4 K2C 090 B and 8 m for Orion3 4 K1C 050 B Orion3 4 K2C 080 B and Orion3 4 K2C 120 B The use of the AOPD at longer distances is not recommended Always check the correct function and that no dangerous reflections towards ...

Page 16: ...etween Passive A and Active A the effective aperture angle of the AOPD EAA For a Type 4 AOPD EAAMAX 5 α 2 5 The diagram below shows the minimum distance to the interfering devices Ddo based on the operating distance Dop of the couple Passive A Active A for a Type 4 AOPD Figure 14 Minimum distance to an adjacent device as a function of the operating distance The formula to get Ddo for a Type 4 AOPD...

Page 17: ...ral AOPDs must be installed close to each other interferences between the transmitter of one device and the receiver of the other must be avoided Figure 15 provides some examples of correct and incorrect installations when it comes to interferences Figure 15 Installation of several devices close to each other ...

Page 18: ...me a very critical operation when deviating mirrors are used Even a very small displacement of the mirror is enough to loose alignment The use of an Orion laser pointer available as accessory is recommended in these conditions The minimum installation distance S must be respected for each single section of the beams The effective operating range decreases by about 15 by using only one deviating mi...

Page 19: ...he OSSD outputs switch off the red LED turns on and the controlled machine stops when the Test function is activated The stopping time of the machine including the response times of the AOPD and of the machine is within the limits defined when calculating the minimum installation distance see paragraph 2 4 Minimum installation distance The minimum installation distance between the hazard zone and ...

Page 20: ...ange of the model used see paragraph 11 Technical data The two units must be aligned and as parallel as possible The next step is the fine alignment as shown in paragraph 6 Alignment procedure 4 1 Mounting with angled fixing brackets Angled fixing brackets are supplied with all Orion3 Base models To mount the AOPD insert the supplied double nut plate M5 into the grooves on the two units see Figure...

Page 21: ... contact to 24 VDC Manual Reset NC contact to 0 V 2 Brown Supply 24 VDC 3 Green2 EDM SELECTION Activate EDM Not connected or 0 V 7 3 Deactivate EDM 24 VDC 4 Yellow EDM Function used activated NC contact of force guided relay 7 3 Function not used deactivated Not connected or 0 V 5 Grey OSSD1 Safety control module for ex 6 Pink OSSD2 Safety control module for ex 7 Blue Supply 0 V 8 Red Earth Earth ...

Page 22: ... red wire It can be connected or left floating depending on the application Do not place connection cables in contact with or near high voltage cables and or cables undergoing high current variations e g motor power supplies inverters etc Do not connect the OSSD wires of different AOPDs in the same multi pole cable The device is already equipped with internal overvoltage and overcurrent suppressio...

Page 23: ...2TLC 172289M0201 Rev C 23 www abb com jokabsafety 2018 04 17 5 3 Connection examples Figure 19 Connection to a RT9 safety relay ...

Page 24: ...2TLC172289M0201 Rev C 24 www abb com jokabsafety 2018 04 17 Figure 20 Connection to a Pluto B20 safety PLC ...

Page 25: ...he OSSD1 and OSSD2 safety contacts cannot be connected in series or in parallel but must be used separately according to the safety requirements of the plant If one of these configurations is erroneously used the device enters the OSSD Error mode see paragraph 8 Diagnostic functions NB Connect both OSSD outputs to the activating device Failure to connect an OSSD to the activating device jeopardise...

Page 26: ...2TLC172289M0201 Rev C 26 www abb com jokabsafety 2018 04 17 Figure 23 Time chart of the OSSD outputs ...

Page 27: ... symbols are easily interpreted whatever the orientation of the AOPD Figure 24 Display Each arrow is associated to a yellow LED and refers to either the first or the last transmitter receiver couple Figure 25 shows that the first transmitter receiver couple is the nearest to the M12 connector and the last transmitter receiver couple is the farthest from the M12 connector A 7 segment display inform...

Page 28: ...st 0 5 s at power on see Figure 27 Figure 27 Time chart of the Alignment mode Once the optimal alignment has been reached the device is returned to normal function by turning the active unit off and on NB The OSSD outputs are off in alignment mode 6 2 Correct alignment procedure The alignment is performed after having completed the mechanical installation and the electrical connections as describe...

Page 29: ...s axis until the yellow LED LAST turns off NB Make sure that the green LED is on and steady 3 Slightly turn both units both ways to find the limits of the area in which the green LED is steady and 4 is displayed Maximum alignment Place both units in the centre of this area 4 Fix the two units firmly using brackets Check that the green LED on the active unit is on when the beams are not interrupted...

Page 30: ... quality Every couple over the lower light reception threshold and no couple over the upper light reception threshold Min Every couple over the lower light reception threshold and one couple over the upper light reception threshold Every couple over the upper light reception threshold Excellent ...

Page 31: ...ion of a beam by an opaque object causes the OSSD outputs to switch off OSSD OFF state The AOPD can be reset to the OSSD ON state in two different ways Automatic Reset When activated the AOPD returns to OSSD ON once the object has been removed from the detection zone Manual Reset When activated the AOPD returns to OSSD ON once the RESET button has been pushed provided that the object has been remo...

Page 32: ...sed contacts of the devices to be monitored EDM deactivated 1 Connect pin 3 of the connector to 24 VDC EDM selection OFF 2 Disconnect the EDM input pin 4 or connect it to 0 V NB The decimal dot on the display shows that the function is activated This function checks that the normally closed contact switches state when the OSSD outputs change state Figure 31 Time chart of the EDM function TC and T0...

Page 33: ...paragraph 6 Alignment procedure Display Status Description Action Interlock Detection zone free OSSD outputs off Push the RESET button to return to normal operation Interlock Beam s interrupted OSSD outputs off Remove the object from the detection zone and push the RESET button OSSD ON OSSD outputs on OSSD OFF OSSD outputs off Normal operation mode OSSD OFF interlock EDM function activated Normal ...

Page 34: ...esentative Error mode EDM error OSSD outputs off Check the wiring and the connections of EDM SELECTION and EDM as well as the time sequence see the Time chart Figure 31 Acknowledge the error If the error persists contact your ABB Jokab Safety representative AOPD OFF Power supply error OSSD outputs off Check the wiring and connections of the power supply Check that its value is within the allowed r...

Page 35: ...ng the response times of the AOPD and of the machine is within the limits defined for the calculation of the minimum installation distance see paragraph 2 4 Minimum installation distance The minimum installation distance between the hazard zone and the AOPD is in accordance with the instructions included in paragraph 2 4 Minimum installation distance Access of a person between the AOPD and the haz...

Page 36: ...duction of the operating distance optic protective front surfaces must be cleaned at regular intervals Use soft cotton cloths damped in water Do not apply too much pressure on the surface in order to avoid making it opaque Do not use the following on plastic surfaces or on painted surfaces Alcohol or solvents Wool or synthetic cloths Paper or other abrasive materials ...

Page 37: ... connector Cable length for power supply 70 m max Pollution degree 2 Optical Data Light source Infrared LED 950 nm Resolution See paragraph 12 Model overview Protected height See paragraph 12 Model overview Operating distance From 0 5 to 6 5 m or 8 m See paragraph 12 Model overview Ambient light rejection According to IEC 61496 2 2013 Mechanical and environmental data Operating temperature 0 55 C ...

Page 38: ...080 passive Orion3 4 M2C 090 passive Orion3 4 M2C 120 passive 1 3 Kg 1 8 Kg 2 1 Kg 2 6 Kg 1 2 Kg 1 7 Kg 1 9 Kg 2 5 Kg Functional safety data EN ISO 13849 1 2008 PL e Cat 4 EN IEC 61508 1 2010 EN IEC 61508 2 2010 EN IEC 61508 3 2010 EN IEC 61508 4 2010 SIL 3 EN IEC 62061 2005 A1 2013 SIL CL 3 Prob of Dangerous Failure Hour 1 h PFHd 9 28 10 9 Life span years T1 20 Mean Time to Dangerous Failure year...

Page 39: ...e m Orion3 4 K1C 050 B 2TLA022306R0000 500 2 519 75 11 500 0 5 8 Orion3 4 K2C 080 B 2TLA022306R0100 800 3 399 75 12 380 0 5 8 Orion3 4 K2C 090 B 2TLA022306R0200 900 4 319 75 12 300 0 5 6 5 Orion3 4 K2C 120 B 2TLA022306R0300 1200 4 419 75 12 400 0 5 8 Orion3 4 M1C 050 2TLA022306R1000 500 Orion3 4 M2C 080 2TLA022306R1100 800 Orion3 4 M2C 090 2TLA022306R1300 900 Orion3 4 M2C 120 2TLA022306R1400 1200 ...

Page 40: ...illimetres Model L1 mm L2 mm Orion3 4 K1C 050 B Figure 33 606 35 520 5 Orion3 4 K2C 080 B Figure 33 906 35 820 5 Orion3 4 K2C 090 B Figure 33 1006 35 920 5 Orion3 4 K2C 120 B Figure 33 1306 35 1220 5 Orion3 4 M1C 050 Figure 34 580 5 520 5 Orion3 4 M2C 080 Figure 34 880 5 820 5 Orion3 4 M2C 090 Figure 34 980 5 920 5 Orion3 4 M2C 120 Figure 34 1280 5 1220 5 ...

Page 41: ...2018 04 17 13 2 Angled fixing bracket Figure 35 Dimensions of the angled fixing bracket NB All dimensions in millimetres 13 3 Fixing bracket with profile Figure 36 Dimensions of the angled fixing bracket with a profile NB All dimensions in millimetres ...

Page 42: ...2TLC172289M0201 Rev C 42 www abb com jokabsafety 2018 04 17 14 EC Declaration of conformity ...

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