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EN P1ELxxx Retro-Reflex Sensor with Light Band Operating Instructions Translation of the Original Operating Instruction Subject to change without notice Available as PDF version only Version 1.0.0 Status: 28.06.2019 www.wenglor.com Table of Contents 1. General���������������������������������������������������������������������������������������������������������������������������������� 3 1.1 Information Concerning these Instructions���������������������������������������������������������������������������������������������3 1.2 Explanations of Symbols�������������������������������������������������������������������������������������������������������������������������3 1.3 Limitation of Liability���������������������������������������������������������������������������������������������������������������������������������4 1.4 Copyrights������������������������������������������������������������������������������������������������������������������������������������������������4 2. For Your Safety���������������������������������������������������������������������������������������������������������������������� 5 2.1 Use for Intended Purpose������������������������������������������������������������������������������������������������������������������������5 2.2 Use for Other than the Intended Purpose������������������������������������������������������������������������������������������������5 2.3 Personnel Qualifications��������������������������������������������������������������������������������������������������������������������������6 2.4 Modification of Products��������������������������������������������������������������������������������������������������������������������������6 2.5 General Safety Precautions���������������������������������������������������������������������������������������������������������������������6 2.6 Laser Warnings����������������������������������������������������������������������������������������������������������������������������������������6 2.7 Approvals and protection class���������������������������������������������������������������������������������������������������������������6 3. Technical Data����������������������������������������������������������������������������������������������������������������������� 7 3.1 Switching distance�����������������������������������������������������������������������������������������������������������������������������������8 3.2 Complementary Products������������������������������������������������������������������������������������������������������������������������8 3.3 Housing Dimensions��������������������������������������������������������������������������������������������������������������������������������9 3.4 Control Panel������������������������������������������������������������������������������������������������������������������������������������������10 3.5 Scope of Delivery�����������������������������������������������������������������������������������������������������������������������������������10 4. Transport and Storage�������������������������������������������������������������������������������������������������������� 11 4.1 Transport������������������������������������������������������������������������������������������������������������������������������������������������11 4.2 Storage���������������������������������������������������������������������������������������������������������������������������������������������������11 5. Installation and Electrical Connection������������������������������������������������������������������������������� 12 5.1 Installation����������������������������������������������������������������������������������������������������������������������������������������������12 5.1.1 Reference Setup��������������������������������������������������������������������������������������������������������������������������12 5.1.2 Lateral Reflector Inclination���������������������������������������������������������������������������������������������������������13 5.1.3 Aligning the Reflector������������������������������������������������������������������������������������������������������������������14 5.1.4 Sensor Inclination������������������������������������������������������������������������������������������������������������������������15 5.2 Electrical Connection�����������������������������������������������������������������������������������������������������������������������������17 5.3 Diagnostics���������������������������������������������������������������������������������������������������������������������������������������������17 6. Settings�������������������������������������������������������������������������������������������������������������������������������� 19 6.1 Standard Teach �������������������������������������������������������������������������������������������������������������������������������������19 6.2 Precision Teach – with Stationary (static) Conveyor Belt����������������������������������������������������������������������19 6.3 Precision Teach – with Running (dynamic) Conveyor Belt�������������������������������������������������������������������20 7. Maintenance Instructions��������������������������������������������������������������������������������������������������� 20 8. Proper Disposal������������������������������������������������������������������������������������������������������������������ 20 9. Appendix������������������������������������������������������������������������������������������������������������������������������ 21 9.1 List of Abbreviations�������������������������������������������������������������������������������������������������������������������������������21 9.2 Change Index, Operating Instructions���������������������������������������������������������������������������������������������������21 9.3 EU Declaration of Conformity����������������������������������������������������������������������������������������������������������������21 2 Table of Contents 1. General 1.1 Information Concerning these Instructions • These instructions apply to the product with ID code P1ELxxx. • They make it possible to use the product safely and efficiently. • These instructions are an integral part of the product and must be kept on hand for the entire duration of its service life. • Local accident prevention regulations and national work safety regulations must be complied with as well. • The product is subject to further technical development, and thus the information contained in these o ­ perating instructions may also be subject to change. The current version can be found at www.wenglor.com in the product’s separate download area. NOTE! The operating instructions must be read carefully before using the product and must be kept on hand for later reference. 1.2 Explanations of Symbols • Safety precautions and warnings are emphasized by means of symbols and attention-getting words • Safe use of the product is only possible if these safety precautions and warnings are adhered to The safety precautions and warnings are laid out in accordance with the following principle: Attention-Getting Word! Type and Source of Danger! Possible consequences in the event that the hazard is disregarded. ••Measures for averting the hazard. The meanings of the attention-getting words, as well as the scope of the associated hazards, are listed below. DANGER! This word indicates a hazard with a high degree of risk which, if not avoided, results in death or severe injury. WARNING! This word indicates a hazard with a medium degree of risk which, if not avoided, may result in death or severe injury. CAUTION! This word indicates a hazard with a low degree of risk which, if not avoided, may result in minor or moderate injury. ATTENTION! This word draws attention to a potentially hazardous situation which, if not avoided, may result in property damage. NOTE! A note draws attention to useful tips and suggestions, as well as information regarding efficient, error-free use. Retro-Reflex Sensor 3 1.3 Limitation of Liability • The product has been developed in consideration of the current state-of-the-art and applicable standards and guidelines. Subject to change without notice. • A valid declaration of conformity can be accessed at www.wenglor.com in the product’s separate ­download area. • wenglor sensoric elektronische Geräte GmbH (hereinafter referred to as “wenglor”) excludes all liability in the event of: • Non-compliance with the instructions • Use of the product for purposes other than those intended • Use by untrained personnel • Use of unapproved replacement parts • Unapproved modification of products • These operating instructions do not include any guarantees from wenglor with regard to the described procedures or specific product characteristics. • wenglor assumes no liability for printing errors or other inaccuracies contained in these operating ­instructions, unless wenglor was verifiably aware of such errors at the point in time at which the operating ­instructions were prepared. 1.4 Copyrights • The contents of these instructions are protected by copyright law. • All rights are reserved by wenglor. • Commercial reproduction or any other commercial use of the provided content and information, in ­particular graphics and images, is not permitted without previous written consent from wenglor. 4 General 2. For Your Safety 2.1 Use for Intended Purpose The product is based on the following functional principle: Retro-reflex sensor with light band The retro-reflex sensor with light band scans a significantly larger range than a retro-reflex sensor with a dot-shaped spot. As a result it’s ideally suited for the reliable detection of objects with irregular shapes or varying sizes, for example polybags. The light barrier’s light band is nearly collimated, making it very precise and homogenous. The sensor has a very small blind spot and detects objects as of emitter beam overlap of 4 mm within the overall range of detection. It’s compact design permit installation in extremely small spaces, for example on the side panels of a conveyor system. This product can be used in the following industry sectors: • Special machinery manufacturing • Consumer goods industry • Heavy machinery manufacturing • Paper industry • Logistics • Electronics industry • Automotive industry • Glass industry • Food industry • Steel industry • Packaging industry • Aviation industry • Pharmaceuticals industry • Chemicals industry • Plastics industry • Alternative energy • Woodworking industry • Raw materials extraction 2.2 Use for Other than the Intended Purpose • Not a safety component in accordance with 2006/42/EC (Machinery Directive). • The product is not suitable for use in potentially explosive atmospheres. • The product may only be used with accessories supplied or approved by wenglor, or combined with approved products. A list of approved accessories and combination products can be accessed at www.wenglor.com on the product detail page. DANGER! Risk of personal injury or property damage in case of use for other than the intended purpose! Use for other than the intended purpose may lead to hazardous situations. • Observe instructions regarding use for intended purpose. Retro-Reflex Sensor 5 2.3 Personnel Qualifications • Suitable technical training is a prerequisite. • In-house electronics training is required. • Trained personnel must have uninterrupted access to the operating instructions. DANGER! Risk of personal injury or property damage in case of incorrect initial start-up and maintenance! Personal injury and damage to equipment may occur. ••Adequate training and qualification of personnel. 2.4 Modification of Products DANGER! Risk of personal injury or property damage if the product is modified! Personal injury and damage to equipment may occur. Non-observance may result in loss of the CE marking and the guarantee may be rendered null and void. ••Modification of the product is impermissible. 2.5 General Safety Precautions NOTE! • These instructions are an integral part of the product and must be kept on hand for the entire duration of its service life. • In the event of possible changes, the respectively current version of the operating ­instructions can be accessed at www.wenglor.com in the product’s download area. • Read the operating instructions carefully before using the product. • Protect the sensor against contamination and mechanical influences. 2.6 Laser Warnings LASER CLASS 1 EN 60825-1:2014 Laser Class 1 (EN 60825-1) Applicable standards and safety regulations must be observed. T = 250 µs, tp = 20 µs, λ = 650 nm , Pp < 200 µW 2.7 Approvals and protection class RoHS 6 For Your Safety 3. Technical Data P1EL 100 Optical Data Range Light band height 200 300 1600 mm 27 mm 42 mm Light source Laser (red) Wavelength 650 nm Laser Class (EN 60825-1) 1 Smallest detectable part * 4 mm Service life (ambient temp. = +25° C) 100000 h Max. permissible ambient light 10000 Lux Electrical Data Supply power 54 mm 12…30 V DC Current consumption (operating voltage = 24 V) < 30 mA Switching frequency 275 Hz 175 Hz 125 Hz Response time 1,8 ms 2,9 ms 4,0 ms Temperature range −30...60 °C Switching output switching current < 2,5 V Switching output residual current 100 mA Switching output residual current < 50 µA Short-circuit protection Yes Reverse polarity protected Yes Overload-proof Yes Lockable Yes Protection class Mechanical Data Setting method III Teach-in Housing material Degree of protection Plastic IP67 / IP68 Lens cover PMMA Output function PNP NO Connection M12×1 Connection Diagram No. Suitable Mounting Technology No. 150 2 * The smallest detectable part depends on the utilized teach-in mode and alignment to the reflector: Teach-in for interference-free detection: 5 mm Teach-in for precise detection: 4 mm Retro-Reflex Sensor 7 3.1 Switching distance Achievable switching distance depends on the utilized reflector. Depending on the utilized sensor type, types Z90R007 through Z90R009 serve as reference reflectors. Other reflectors can also be used, which are shown in the following table along with their corresponding ranges. Reflector ZRDF03K01 ZRDF10K01 Z90R004 Z90R005 Z90R007 Z90R008 Z90R009 Range 0,40…1,60 m 0,40…1,60 m 0,40…1,60 m 0,40…1,60 m 0,40…1,60 m 0,40…1,60 m 0,40…1,60 m Sensor P1EL100 P1EL200 P1EL300 Reference Reflector Z90R007 Z90R008 Z90R009 3.2 Complementary Products wenglor can provide you with suitable connection technology for your product. Suitable connection technology no. 2 S02 PNP-NPN converter BG7V1P-N-2M 8 Technical Data 3.3 Housing Dimensions P1EL100 P1EL200 Retro-Reflex Sensor 9 P1EL300 1 = emitter diode 2 = receiver diode M3 screw = 0.5 Nm Dimensions specified in mm (1 mm = 0.03937”) 3.4 Control Panel 1E1 68 30 06 06 = teach-in key 30 = switching status indicator / contamination warning 68 = supply power indicator 3.5 Scope of Delivery • Sensor • Safety precautions • Spacer sleeves Z1PE002 10 Technical Data 4. Transport and Storage 4.1 Transport Upon receipt of shipment, the goods must be inspected for damage in transit. In the case of damage, conditionally accept the package and notify the manufacturer of the damage. Then return the device, making reference to damage in transit. 4.2 Storage The following points must be taken into condition with regard to storage: • Do not store the product outdoors. • Store the product in a dry, dust-free place. • Protect the product against mechanical impacts. • Protect the product against exposure to direct sunlight. ATTENTION! Risk of property damage in case of improper storage! The product may be damaged. • Storage instructions must be complied with. Retro-Reflex Sensor 11 5. Installation and Electrical Connection 5.1 Installation • Protect the product from contamination during installation. • Observe all applicable electrical and mechanical regulations, standards, and safety rules. • Protect the product against mechanical influences. • Make sure that the sensor is mounted in a mechanically secure fashion. • Specified torque values must be complied with (see Technical Data on page 10). The following installation instructions must be observed in order to assure that the sensor can function correctly: 5.1.1 Reference Setup All sensor values are based on a reference setup which demonstrates the following characteristics: ••The P1ELxxx sensor and the conveyor belt’s zero level (conveyor level) are arranged at a right angle to each other. ••The conveyor level doesn’t fluctuate at all. ••The sensor is mounted such that the bottom edge of the emitted light band is at the conveyor level. ••The sensor’s light band is parallel to the conveyor level (max. tolerance: +0/–2 mm). ••The utilized reflector is inclined 2° and captures the entire light band. 12 Installation and Electrical Connection 5.1.2 Lateral Reflector Inclination Z90R007 through Z90R009 reflectors, which are laid out for the P1ELxxx, are inclined 2° due to their format and can be mounted without lateral tilting. The reflectors listed in section 3.1, “Switching Distance”, are not inclined and must therefore be mounted at an inclined angle of 2° (±0.5°). The direction in which the reflector is tilted depends on the installation situation and must correspond exactly to the illustration. Insulation situation 1 Insulation situation 2 Retro-Reflex Sensor 13 5.1.3 Aligning the Reflector Z90R007 through Z90R009 reflectors must be mounted as shown in the following illustration. Correct inclination of the surface of the reflector relative to the sensor is described in section „5.1.2 Lateral Reflector Inclination“ on page 13. 14 Installation and Electrical Connection 5.1.4 Sensor Inclination Deviation of the top edge of the light band should not exceed +0 to –2 mm of downward sloping to the conveyor plane in order to permit detection of the smallest object. Deviation amounting to more than this value leads to poor detection of small or flat objects. Ideal Alignment Incorrect Alignment Excessive tilting of the sensor (> 2 mm downward sloping of the top edge of the light band) towards the conveyor plane results in an area with reduced detection of small objects which are in close proximity to the sensor. Retro-Reflex Sensor 15 Tilting the sensor away from the conveyor plane results in an area with reduced detection of small objects which are far away from the sensor, i.e. close to the reflector. NOTE! Ideal alignment can be easily determined by means of the band of light above the conveyor belt. First of all, height is determined from the conveyor belt to the uppermost point of the band of light directly on the sensor. Afterwards, height is determined from the conveyor belt to the uppermost point of the band of light on the reflector. Alignment is ideal when these two distances are identical. wenglor recommends a sensor adjustment range with parallel upper light-band edge, or maximum downward sloping of the upper edge of the light band amounting to 2 mm within the corresponding working range. ATTENTION! Risk of property damage in case of improper installation! The product may be damaged. • Installation instructions must be complied with. CAUTION! Risk of personal injury or property damage during installation! Personal injury and damage to the product may occur. • A safe installation environment must be assured. 16 Installation and Electrical Connection 5.2 Electrical Connection 150 Legend PT Supply Voltage + Supply Voltage 0 V Supply Voltage (AC Voltage) Switching Output Switching Output Contamination/Error Output Contamination/Error Output Input (analog or digital) Teach Input Time Delay (activation) Shielding Interface Receive Path Interface Send Path Ready Ground Clock Output/Input programmable (NO) (NC) (NO) (NC) Power over Ethernet Safety Input Safety Output Signal Output Ethernet Gigabit bidirect. data line (A-D) Encoder 0-pulse 0-0 (TTL) Platinum measuring resistor not connected Test Input Test Input inverted Trigger Input Ground for the Trigger Input Analog Output Ground for the Analog Output Block Discharge Valve Output Valve Control Output + Valve Control Output 0 V Synchronization Ground for the Synchronization Receiver-Line Emitter-Line Grounding Switching Distance Reduction Ethernet Receive Path Ethernet Send Path Interfaces-Bus A(+)/B(–) Emitted Light disengageable Magnet activation Input confirmation Contactor Monitoring Encoder A/A (TTL) Encoder B/B (TTL) Encoder A Encoder B Digital output MIN Digital output MAX Digital output OK Synchronization In Synchronization OUT Brightness output Maintenance reserved Wire Colors according to IEC 60757 Black Brown Red Orange Yellow Green Blue Violet Grey White Pink Green/Yellow DANGER! Risk of personal injury or property damage due to electric current! Voltage conducting parts may cause personal injury or damage to equipment. ••The electric device may only be connected by appropriately qualified personnel. 5.3 Diagnostics Causes for Triggering the Contamination Warning (blinking LED): Display LED Diagnosis/Cause Contamination Continuous blinking Aged emitter diode at approx. 2.5 Hz Unreliable working range Continuous blinking Short-circuit at approx. 5 Hz Hardware error Retro-Reflex Sensor Elimination Carefully clean the optic cover and the reflector with a cloth. Replace the sensor. Check distance to the sensor (see “3.1 Switching distance” on page 8). Check electrical wiring and eliminate the short-circuit. Replace the sensor. 17 Contamination Warning Flowcharts Retro Reflective Barrier no contamination Reflector Object t not detected on Switching Status Indicator Reflector Object Sensor Object Reflector Sensor detected Object Sensor not detected off on beginning contamination Reflector Object Switching Status Indicator Reflector Object Sensor Object Reflector not detected Sensor detected off blinking Object Sensor not detected blinking advanced contamination Reflector Object Object Sensor Object Switching Status Indicator Reflector not detected off Sensor not detected off Reflector Object Sensor not detected off Required action in case of fault: NOTE! • Shut down the machine. • Analyze and eliminate the cause of error with the help of the diagnostics information. • If the error cannot be eliminated, please contact wenglor’s support department. • Do not operate in case of indeterminate malfunctioning. • The machine must be shut down if the error cannot be unequivocally clarified or reliably eliminated. DANGER! Risk of personal injury or property damage in case of non-compliance! The system’s safety function is disabled. Personal injury and damage to equipment. ••Required action as specified in case of fault. 18 Installation and Electrical Connection 6. Settings NOTE! It takes three minutes for the sensor to warm up. In order to assure interference-free operation, teach-in should not be conducted until after the warm-up phase. 6.1 Standard Teach The sensor is taught in such that it demonstrates stable switching performance despite interference such as vibration. In this mode, the smallest part which can be detected is somewhat larger than in the precise detection mode. • Install the sensor in accordance with the mounting instructions. • Align the sensor to the reflector. • Press and hold the teach-in key until switching status indicator A1 starts blinking slowly (2 Hz) after two seconds. • Release the teach-in key. • The switching threshold is taught in and the LED for A1 blinks twice in order to confirm successful teach-in. 6.2 Precision Teach – with Stationary Conveyor Belt The sensor is taught in such that the detection of very small parts is possible. With the conveyor belt at a standstill, the sensor is set to a signal analysis phase which lasts for 10 seconds. The sensor’s receive signals are analyzed during this time, on the basis of which the switching threshold is calculated. • Install the sensor in accordance with the mounting instructions. • Align the sensor to the reflector. • Press and hold the teach-in key until switching status indicator A1 starts blinking rapidly (4 Hz) after five seconds. • Release the teach-in key. • Recording is started during which the LED continues to blink at a rate of 4 Hz. • The calculated switching threshold is taught in and the LED for A1 blinks twice in order to confirm successful teach-in. If teach-in has not been successful, LED A1 blinks 4 times. If this is the case, the procedure must be repeated. Retro-Reflex Sensor 19 6.3 Dynamic Teach – with Running Conveyor Belt The sensor is taught in such that, depending on the application, minimal thresholds can be set in order to detect smallest possible parts by means of this process. With running conveyor belt, the sensor is set to a signal analysis phase which lasts for 10 seconds. The application-specific receive signals are analyzed by the sensor during this time, on the basis of which the switching threshold is calculated. And thus application-specific receive signals do not result in erroneous sensors switching. • Install the sensor in accordance with the mounting instructions. • Align the sensor to the reflector. • Press and hold the teach-in key until switching status indicator A1 starts blinking rapidly (4 Hz) after five seconds. • Release the teach-in key. • Recording is started during which the LED continues to blink at a rate of 4 Hz. • The sensor analyzes the receive signals for 10 seconds, on the basis of which it calculates a precise switching threshold that’s matched to the application. • The calculated switching threshold is taught in and the LED for A1 blinks twice in order to confirm successful teach-in. If teach-in has not been successful, LED A1 blinks 4 times. If this is the case, the procedure must be repeated. NOTE! If the sensor is used at a very small distance above a conveyor belt, it’s advisable to activate the belt during the recording phase. Height fluctuations, impacts, belt seams etc. are analyzed as a result and made use of when calculating the switching threshold. Erroneous switching due to the conveyor belt can be avoided in this way. 7. Maintenance Instructions NOTE! • This wenglor sensor is maintenance-free. • Cleaning and inspection of the plug connections at regular intervals are advisable. • Do not clean the sensor with solvents or cleansers which could damage the product. • The product must be protected against contamination during initial start-up. 8. Proper Disposal wenglor sensoric GmbH does not accept the return of unusable or irreparable products. Respectively valid national waste disposal regulations apply to product disposal. 20 Maintenance Instructions 9. Appendix 9.1 List of Abbreviations Abbreviation Tu Meaning Ambient temperature Ub MTTFd Supply voltage Mean Time to Dangerous Failure 9.2 Change Index, Operating Instructions Version 1.0.0 Date 06.06.19 Description/Change Initial version of the operating instructions 9.3 EU Declaration of Conformity The EU declaration of conformity can be found on our website at www.wenglor.com in the product’s ­download area. Retro-Reflex Sensor 21
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Table of contents
- 3 1. General
- 3 1.1 Information Concerning these Instructions
- 3 1.2 Explanations of Symbols
- 4 1.3 Limitation of Liability
- 4 1.4 Copyrights
- 5 2. For Your Safety
- 5 2.1 Use for Intended Purpose
- 5 2.2 Use for Other than the Intended Purpose
- 6 2.3 Personnel Qualifications
- 6 2.4 Modification of Products
- 6 2.5 General Safety Precautions
- 6 2.6 Laser Warnings
- 6 2.7 Approvals and protection class
- 7 3. Technical Data
- 8 3.1 Switching distance
- 8 3.2 Complementary Products
- 9 3.3 Housing Dimensions
- 10 3.4 Control Panel
- 10 3.5 Scope of Delivery
- 11 4. Transport and Storage
- 11 4.1 Transport
- 11 4.2 Storage
- 12 5. Installation and Electrical Connection
- 12 5.1 Installation
- 12 5.1.1 Reference Setup
- 13 5.1.2 Lateral Reflector Inclination
- 14 5.1.3 Aligning the Reflector
- 15 5.1.4 Sensor Inclination
- 17 5.2 Electrical Connection
- 17 5.3 Diagnostics
- 19 6. Settings
- 19 6.1 Standard Teach
- 19 6.2 Precision Teach – with Stationary (static) Conveyor Belt
- 20 6.3 Precision Teach – with Running (dynamic) Conveyor Belt
- 20 7. Maintenance Instructions
- 20 8. Proper Disposal
- 21 9. Appendix
- 21 9.1 List of Abbreviations
- 21 9.2 Change Index, Operating Instructions
- 21 9.3 EU Declaration of Conformity