Leuze RSL 440, RSL 445 Operating Instructions

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RSL 440 RSL 445

Safety Laser Scanner

EN 2018/03 - 50128257

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make technical changes

S A F E I M P L E M E N T A T I O N A N D O P E R A T I O N

O r i g i n a l o p e r a t i n g i n s t r u c t i o n s

Leuze electronic RSL 440 2

Table of contents

1 About this document ............................................................................................7

1.1 Other applicable documents ................................................................................................... 7

1.2 Downloading configuration software from the Internet ........................................................... 7

1.3 Used symbols and signal words .............................................................................................7

1.4 Checklists................................................................................................................................ 8

2 Safety .....................................................................................................................9

2.1 Intended use ........................................................................................................................... 9

2.1.1 Vapors, smoke, dust, particles ..........................................................................................10

2.1.2 Stray light ..........................................................................................................................10

2.1.3 Obstructions in the protective field ....................................................................................10

2.2 Foreseeable misuse ............................................................................................................. 11

2.3 Competent persons .............................................................................................................. 11

2.4 Disclaimer ............................................................................................................................. 12

2.5 Laser safety notices – Laser class1 for wavelength range outside 400-700 nm ...............12

2.6 Responsibility for safety........................................................................................................ 12

3 Device description ..............................................................................................13

3.1 Device overview.................................................................................................................... 14

3.1.1 Protective function of RSL400 safety sensors.................................................................. 14

3.1.2 Parameters for protective function ....................................................................................15

3.1.3 Device and monitoring functions .......................................................................................15

3.2 Connection unit..................................................................................................................... 16

3.3 Display elements .................................................................................................................. 16

3.3.1 LED indicator.....................................................................................................................16

3.3.2 Alphanumerical display .....................................................................................................17

3.3.3 Field-of-view display..........................................................................................................18

3.4 Mounting system (optional)................................................................................................... 19

3.5 Loop guard (optional)............................................................................................................ 19

4 Configuration and diagnostic software SensorStudio...................................20

4.1 System requirements............................................................................................................ 20

4.2 Installing software ................................................................................................................. 20

4.3 User interface........................................................................................................................ 22

4.4 FDT frame menu................................................................................................................... 23

4.4.1 Project wizard....................................................................................................................23

4.4.2 DTM change......................................................................................................................24

4.4.3 User management.............................................................................................................24

4.4.4 Exiting SensorStudio ........................................................................................................24

4.5 Using configuration projects ................................................................................................. 25

4.5.1 Selecting access level .......................................................................................................27

4.5.2 IDENTIFICATION..............................................................................................................28

4.5.3 PROCESS.........................................................................................................................28

4.5.4 CONFIGURATION ............................................................................................................28

4.5.5 DIAGNOSIS ......................................................................................................................28

4.5.6 SETTINGS ........................................................................................................................29

Leuze electronic RSL 440 3

Table of contents

5 Functions.............................................................................................................31

5.1 Authorization concept of safety sensor................................................................................. 31

5.2 Function modes of safety sensor.......................................................................................... 32

5.2.1 One protective function .....................................................................................................33

5.2.2 One protective function – 100 field pairs ...........................................................................33

5.2.3 Two protective functions.................................................................................................... 34

5.2.4 One protective function – four field mode.......................................................................... 34

5.2.5 Two protective functions – four field mode........................................................................35

5.2.6 One protective function – multi configuration .................................................................... 36

5.2.7 Two protective functions - multi configuration ...................................................................36

5.3 Selectable resolution for hand, leg and body detection ........................................................ 36

5.4 Speed-dependent protective function for vehicles................................................................ 37

5.5 Response time...................................................................................................................... 37

5.6 Configurable start-up behavior ............................................................................................. 37

5.6.1 Automatic start/restart .......................................................................................................37

5.6.2 Start interlock/automatic restart......................................................................................... 37

5.6.3 Start/restart interlock (RES) ..............................................................................................38

5.7 Field pair changeover ...........................................................................................................39

5.7.1 Fixed selection of one field pair.........................................................................................39

5.7.2 Changeover of five field pairs in changeover mode Overlapped monitoring.....................40

5.7.3 Changeover of ten field pairs in changeover mode Fixed changeover moment ............... 41

5.7.4 Changeover of 100 field pairs ...........................................................................................42

5.7.5 Changeover of 2x ten field pairs........................................................................................ 43

5.7.6 Changeover of 10x ten field pairs...................................................................................... 43

5.8 Monitoring of field pair changeover....................................................................................... 43

5.9 Reference contour monitoring .............................................................................................. 44

5.10 Field pair monitoring .............................................................................................................44

5.11 Internal safe time delay......................................................................................................... 44

5.12 EDM contactor monitoring ....................................................................................................44

5.13 E-Stop linkage ...................................................................................................................... 45

5.13.1 Contact-based safety circuit ..............................................................................................45

5.13.2 Linkage of electronic safety-related switching outputs ......................................................46

5.14 Signaling functions................................................................................................................ 46

6 Applications ........................................................................................................47

6.1 Stationary danger zone guarding.......................................................................................... 47

6.2 Stationary point of operation guarding.................................................................................. 48

6.3 Stationary access guarding .................................................................................................. 49

6.4 Mobile danger zone guarding ...............................................................................................50

6.5 Danger zone safeguarding on side-tracking skates.............................................................. 52

6.6 Vehicle navigation................................................................................................................. 53

6.6.1 Signal strength and reflector detection..............................................................................53

Leuze electronic RSL 440 4

Table of contents

7 Mounting..............................................................................................................55

7.1 Basic infos............................................................................................................................. 55

7.1.1 Calculation of safety distanceS ........................................................................................55

7.1.2 Suitable mounting locations ..............................................................................................56

7.1.3 Mounting the safety sensor ...............................................................................................56

7.1.4 Mounting examples ...........................................................................................................59

7.1.5 Information on protective field dimensioning .....................................................................60

7.2 Stationary danger zone guarding.......................................................................................... 63

7.3 Stationary point of operation guarding.................................................................................. 66

7.4 Stationary access guarding .................................................................................................. 67

7.5 Mobile danger zone guarding on DTSs ................................................................................68

7.5.1 Minimum distanceD..........................................................................................................69

7.5.2 Protective field dimensions................................................................................................ 70

7.6 Mobile side guarding on DTSs.............................................................................................. 71

7.7 Mounting accessories ........................................................................................................... 71

7.7.1 Mounting system ...............................................................................................................71

7.7.2 Loop guard ........................................................................................................................72

8 Electrical connection..........................................................................................73

8.1 Electrical supply.................................................................................................................... 73

8.2 Interfaces .............................................................................................................................. 74

8.2.1 Connection cable, control..................................................................................................74

8.2.2 Connection cable with M30 connector ..............................................................................75

8.2.3 Pin assignment of M12 Ethernet interface (communication) ( D-coded)........................... 77

8.3 Connection unit CU429......................................................................................................... 77

8.4 Circuit diagram example ....................................................................................................... 79

9 Configuring the safety sensor ...........................................................................80

9.1 Defining safety configuration ................................................................................................ 80

9.2 Connecting safety sensor to PC ...........................................................................................82

9.2.1 Connection via Ethernet cable ..........................................................................................82

9.2.2 Connection via Bluetooth ..................................................................................................82

9.2.3 Communication between safety sensor and PC ...............................................................82

9.3 Determine the configuration project...................................................................................... 83

9.4 Configuring protective function .............................................................................................84

9.4.1 Creating simple safety configuration .................................................................................85

9.4.2 Entering administration parameters ..................................................................................85

9.4.3 Activating protective function and contactor monitoring ....................................................85

9.4.4 Creating and configuring protective/warning field pairs..................................................... 86

9.4.5 Configuring field pair monitoring........................................................................................ 88

9.5 Defining permissible field pair changeovers .........................................................................88

9.6 Configuring signal outputs ....................................................................................................88

9.7 Saving configuration .............................................................................................................89

9.8 Transferring configuration project to safety sensor............................................................... 89

9.9 Selecting access level .......................................................................................................... 91

9.10 Reset safety configuration ....................................................................................................91

Leuze electronic RSL 440 5

Table of contents

10 Starting up the device ........................................................................................92

10.1 Switching on ......................................................................................................................... 92

10.2 Aligning the safety sensor..................................................................................................... 92

10.3 Unlocking start/restart interlock ............................................................................................ 92

10.4 Shutting down ....................................................................................................................... 93

10.5 Restarting.............................................................................................................................. 93

10.6 Starting up replacement scanner unit ................................................................................... 93

11 Testing .................................................................................................................95

11.1 Before the initial start-up and following modifications........................................................... 95

11.1.1 Checklist for integrator – to be performed prior to the initial start-up and following modifica-

tions...................................................................................................................................95

11.2 To be performed periodically by competent persons............................................................ 96

11.3 Periodically by the operator ..................................................................................................97

11.3.1 Checklist – periodically by the operator............................................................................. 97

12 Diagnostics and troubleshooting ......................................................................98

12.1 What to do in case of failure? ...............................................................................................98

12.2 Diagnostics displays .............................................................................................................98

13 Care, maintenance and disposal .....................................................................102

13.1 Changing scanner unit........................................................................................................ 102

13.2 Cleaning the optics cover ................................................................................................... 103

13.3 Servicing ............................................................................................................................. 104

13.4 Disposing ............................................................................................................................ 104

14 Service and support .........................................................................................105

15 Technical data ...................................................................................................106

15.1 General specifications ........................................................................................................ 106

15.2 Dimensions ......................................................................................................................... 111

15.3 Dimensional drawings: Accessories ...................................................................................113

15.4 Representation of safety sensor status .............................................................................. 121

16 Standards and legal regulations .....................................................................125

17 Order guide and accessories...........................................................................126

18 EC Declaration of Conformity ..........................................................................131

Leuze electronic RSL 440 6

1 About this document

1.1 Other applicable documents

The information on the safety sensor is distributed over several documents to make working with the documents easier. You will find the documents and software for the safety sensor in the following table:

About this document

Purpose and target group of the document Document/software ti-

tle

Software for users of the machine a) for safety sensor diagnostics if a fault occurs and for machine de-

SensorStudio DTM RSL400

sign engineers for configuring the safety sensor

Notes for the machine design engineer

"Safe implementation and operation" (this document)

Notes for the machine design engineer a) for config-

Online help for software Supplied with the safety

uring the safety sensor (software instructions)

Notices regarding mounting, alignment and connection of the safety sensor

"Quick Start Guide RSL400"

a) Machine identifies the product that the safety sensor is installed in.

1.2 Downloading configuration software from the Internet

Ä Call up the Leuze home page: www.leuze.com. Ä Enter the type designation or part number of the device as the search term. Ä The configuration software can be found on the product page for the device under the Downloads tab.

1.3 Used symbols and signal words

Source

Supplied with the safety sensor on data carrier

PDF, supplied with the safety sensor on data carrier

sensor on data carrier

Print document, supplied with the safety sensor

Tab.1.1: Warning symbols and signal words

Symbol indicating dangers to persons

Symbol indicating dangers from harmful laser radiation

Symbol indicating possible property damage

NOTE Signal word for property damage

Indicates dangers that may result in property damage if the measures for danger avoidance are not followed.

CAUTION Signal word for minor injuries

Indicates dangers that may result in minor injury if the measures for danger avoidance are not followed.

WARNING Signal word for serious injury

Indicates dangers that may result in severe or fatal injury if the measures for danger avoidance are not followed.

DANGER Signal word for life-threatening danger

Indicates dangers with which serious or fatal injury is imminent if the measures for danger avoidance are not followed.

Leuze electronic RSL 440 7

Tab.1.2: Other symbols

Symbol for tips

Text passages with this symbol provide you with further information.

Symbol for action steps

Text passages with this symbol instruct you to perform actions.

Symbol for action results

Text passages with this symbol describe the result of the preceding action.

Tab.1.3: Terms and abbreviations

CS Switching signal from a control

(Controller Signal)

DTM Software device manager of the safety sensor

(Device Type Manager)

EDM Contactor monitoring

(External Device Monitoring)

About this document

FDT Software frame for management of device managers (DTM)

(Field Device Tool)

Field pair A protective field with an associated warning field

DTS Driverless Transportation System

LED LED, display element in the safety sensor

(Light Emitting Diode)

OSSD Safety-related switching output

(Output Signal Switching Device)

PFH

Probability of a dangerous failure per hour

(Probability of dangerous Failure per Hour)

PL Performance Level

Quad Two field pairs (four fields) that are monitored simultaneously in four field mode

TSS Transverse Side-tracking Skate

RES Start/restart interlock

(Start/REStart interlock)

SIL Safety Integrity Level

State ON: device intact, OSSDs switched on

OFF: device intact, OSSDs switched off

Locking: device, connection or control/operation faulty, OSSDs switched off (lock-out)

1.4 Checklists

The checklists serve as a reference for the machine manufacturer or supplier (see chapter 11 "Testing"). They replace neither testing of the complete machine or system prior to the initial start-up nor their periodic testing by a competent person. The checklists contain minimum testing requirements. Depending on the application, other tests may be necessary.

Leuze electronic RSL 440 8

2 Safety

Before using the safety sensor, a risk assessment must be performed according to valid standards (e.g. ENISO12100, ENISO13849-1, IEC61508, ENIEC62061). The result of the risk assessment determines the required safety level of the safety sensor (see chapter 15.1 "Safety-relevant technical data"). For mounting, operating and testing, this document as well as all applicable national and international standards, regulations, rules and directives must be observed. Relevant and supplied documents must be observed, printed out and handed to affected persons.

Ä Before working with the safety sensor, completely read and observe the documents applicable to your

task.

In particular, the following national and international legal regulations apply for the commissioning, technical inspections and work with safety sensors:

• Machinery directive 2006/42/EC

• Low voltage directive 2006/95/EC

• EMC directive 2004/108/EC

• Use of work equipment directive 89/655/EEC supplemented by directive 95/63EC

• OSHA 1910 Subpart O

• Safety regulations

• Accident-prevention regulations and safety rules

• Ordinance on Industrial Safety and Health and employment protection act

• Product Safety Law (ProdSG)

Safety

NOTICE

For safety-related information you may also contact local authorities (e.g., industrial inspectorate, employer's liability insurance association, labor inspectorate, occupational safety and health authority).

2.1 Intended use

The safety sensor protects persons or body parts at points of operation, danger zones or access points of machines and systems.

A running machine may result in serious injury!

Ä Make certain that the safety sensor is correctly connected and that the protective function of

Ä Make certain that, during all conversions, maintenance work and inspections, the system is

• The safety sensor may only be used after it has been selected in accordance with the respectively applicable instructions and relevant standards, rules and regulations regarding labor protection and safety at work, and after it has been installed on the machine, connected, commissioned, and checked by a competent person (see chapter 2.3 "Competent persons").

• When selecting the safety sensor it must be ensured that its safety-related capability meets or exceeds the required Performance Level PLr ascertained in the risk assessment (see chapter 15.1 "Safety-relevant technical data").

• The safety sensor may only be used in North America in applications that satisfy the requirements specified by NFPA79.

• With the “access guarding” function, the safety sensor detects persons only when they enter the danger zone but cannot tell whether there are any persons inside the danger zone. For this reason, a start/ restart interlock in the safety chain is essential in this case.

• The construction of the safety sensor must not be altered. When manipulating the safety sensor, the protective function is no longer guaranteed. Manipulating the safety sensor also voids all warranty claims against the manufacturer of the safety sensor.

WARNING

the protective device is ensured.

securely shut down and protected against being restarted.

Leuze electronic RSL 440 9

Safety

• The safety sensor must be inspected regularly by a competent person to ensure proper integration and mounting (see chapter 15.1 "Safety-relevant technical data").

• The safety sensor must be exchanged after a maximum of 20 years. Repairs or the exchange of wear parts do not extend the mission time.

CAUTION

Observe intended use!

The protection of personnel and the device cannot be guaranteed if the device is operated in a manner not complying with its intended use.

Ä Only operate the device in accordance with its intended use. Ä LeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use. Ä Read these operating instructions before commissioning the device. Knowledge of the oper-

ating instructions is an element of proper use.

NOTICE

Comply with conditions and regulations!

Ä Observe the locally applicable legal regulations and the rules of the employer's liability insur-

ance association.

2.1.1

2.1.2

2.1.3

Vapors, smoke, dust, particles

Vapors, smoke, dust and all particles visible in the air can cause the machine to switch off unintentionally. This can mislead the user into bypassing the safety devices.

Ä Do not use the safety sensor in environments in which heavy vapors, smoke, dust or other visible parti-

cles occur at the beam level.

Stray light

Light sources can impair the safety sensor's availability. Interfering light sources are:

• Infrared light

• Fluorescent light

• Strobe light

Ä Ensure that there are no interfering light sources at beam level. Ä Prevent reflective surfaces at beam level. Ä Where applicable, take protective field addition distances into account. Ä Implement all additional measures to ensure that any special application of any effected beam types

does not impair the safety sensor's operation.

Obstructions in the protective field

Ä Do not bring any additional window materials into the area monitored by the safety sensor.

NOTICE

No screen between optics cover and monitoring area!

Ä Between the optics cover of the safety sensor and the monitored area, no further screen

may be mounted to protect the safety sensor.

Leuze electronic RSL 440 10

2.2 Foreseeable misuse

Any use other than that defined under "Intended use" or which goes beyond that use is considered improper use.

In principle, the safety sensor is not suitable as a protective device for use in the following cases:

• Danger posed by ejected objects or the spraying of hot or hazardous liquids from within the danger zone.

• Applications in explosive or easily flammable atmospheres.

• Use for outdoor applications or under extreme temperature fluctuations.

Humidity, condensation and other weather influences can impair the protective function.

• Use on vehicles with combustion engines.

Alternators and ignition systems can cause EMC interferences.

NOTICE

Do not modify or otherwise interfere with the safety sensor!

Ä Do not carry out modifications or otherwise interfere with the safety sensor. The safety sen-

sor must not be tampered with and must not be changed in any way.

Ä The safety sensor must not be opened. There are no user-serviceable parts inside. Ä The construction of the safety sensor must not be altered. When manipulating the safety

sensor, the protective function is no longer guaranteed.

Ä Manipulating the safety sensor voids all warranty claims against the manufacturer of the

safety sensor.

Ä Repairs must only be performed by Leuze electronic GmbH + Co. KG.

Safety

2.3 Competent persons

Connecting, mounting, commissioning and adjustment of the safety sensor must only be carried out by competent persons.

Prerequisites for competent persons:

• They have a suitable technical education.

• They know the rules and regulations for labor protection, safety at work and safety technology and can assess the safety of the machine.

• They know the operating instructions for the safety sensor and the machine.

• They have been instructed by the responsible person on the mounting and operation of the machine and of the safety sensor.

• They perform a task related to the subject matter shortly thereafter and keep their knowledge up to date through continuous further training.

Certified electricians

Electrical work must be carried out by a certified electrician.

Due to their technical training, knowledge and experience as well as their familiarity with relevant standards and regulations, certified electricians are able to perform work on electrical systems and independently detect possible dangers.

In Germany, certified electricians must fulfill the requirements of accident-prevention regulations DGUV Regulation3 (e.g. electrician foreman). In other countries, there are respective regulations that must be observed.

Leuze electronic RSL 440 11

2.4 Disclaimer

LeuzeelectronicGmbH+Co.KG is not liable in the following cases:

• The safety sensor is not used as intended.

• Safety notices are not adhered to.

• Reasonably foreseeable misuse is not taken into account.

• Mounting and electrical connection are not properly performed.

• Proper function is not tested (see chapter 11 "Testing").

• Changes (e.g., constructional) are made to the safety sensor.

2.5 Laser safety notices – Laser class1 for wavelength range outside 400-700 nm

NOTICE

Additional measures for shielding the laser radiation are not necessary (safe for eyes).

WARNING

LASER RADIATION – LASER CLASS 1

The device satisfies the requirements of IEC60825-1:2007 (EN60825-1:2007) safety regulations for a product of laser class1 as well as the FDA Radiation Performance Standards, 21CFR, SubchapterJ, Part1010 and Part1040 with deviations corresponding to "Laser Notice No.50" from June 24, 2007.

Ä Observe the applicable statutory and local laser protection regulations. Ä The device must not be tampered with and must not be changed in any way.

There are no user-serviceable parts inside the device.

Ä Repairs must only be performed by Leuze electronic GmbH + Co. KG.

Safety

2.6 Responsibility for safety

Manufacturer and operator must ensure that the machine and implemented safety sensor function properly and that all affected persons are adequately informed and trained.

The type and content of all imparted information must not lead to unsafe actions by users.

The manufacturer of the machine is responsible for:

• Safe machine construction

• Safe implementation of the safety sensor, verified by the initial test performed by a competent person

• Imparting all relevant information to the operating company

• Adhering to all regulations and directives for the safe commissioning of the machine

The operator of the machine is responsible for:

• Instructing the operator

• Maintaining the safe operation of the machine

• Adhering to all regulations and directives for labor protection and safety at work

• Regular testing by competent persons

Leuze electronic RSL 440 12

3 Device description

The safety sensors from the RSL400 series are optoelectronic, two-dimensional measuring safety laser scanners. They satisfy the following standards:

Type in accordance with IEC/EN61496 3

Category in accordance with ENISO13849 3

Safety Integrity Level (SIL) in accordance with IEC61508 2

SILCL in accordance with IEC/EN62061 2

Performance Level (PL) in accordance with ENISO13849‑1 d

Device description

RSL400

1 Scanner unit 2 Connection unit 3 Optics cover 4 Alphanumerical display (displayed) 5 LED indicators

Fig.3.1: Device overview of RSL400 safety laser scanners

Leuze electronic RSL 440 13

All safety sensors of the RSL440 series are equipped as follows:

• Laser scanner with the range class S, M, L or XL:

Device description

Operating range class

S 3.00

M 4.5

L 6.25

XL 8.25

• 24-digit alphanumerical display

• Integrated electronic spirit level for aligning the safety sensor

• LED indicator

• Connection unit:

• Configuration memory

• Ethernet connection for communication and configuration with the PC/laptop

• Electrical connection to the machine via connection cable

3.1 Device overview

The following table provides an overview of the possible uses, features and functions of the RSL400 safety sensors.

Tab.3.1: Device overview

Operating range [m]

RSL410 RSL420

RSL425

RSL430 RSL440

RSL445

Stationary danger zone guarding x x x x

Mobile danger zone guarding x x x x

Access guarding x x x x

Point of operation guarding x x x x

Safety-related switching outputs

Protective functionA

Protective functionB

1 OSSD pair

2 OSSD pairs

Signal outputs Up to 3 Up to 4 Up to 9 Up to 9

Configurable signal outputs x x x x

Number of changeover-capable pro-

1 10 10+10 100

tective/warning field pairs

E-stop linkage - x x x

Four field mode (quads) x x x x

Internal safe time delay - - x x

Measurement data output optimized

- Only RSL425 - Only RSL445

for vehicle navigation

3.1.1

Protective function of RSL400 safety sensors

The safety sensor transmits periodic light pulses via a rotating deflection unit. The light pulses are scattered in all directions by obstacles, e.g. persons. A part of the light pulses is received again by the safety sensor and evaluated. The safety sensor calculates the precise position of the object from the propagation time of the radiated light and the current angle of the deflection unit at that time. If the object is within a predefined area, the protective field, the safety sensor performs a safety-related switching function. It switches the safety-related switching outputs off.

Leuze electronic RSL 440 14

Device description

Only when the protective field is free again does the safety sensor reset the safety-related switching function, either automatically or following acknowledgment, depending on the operating mode.

The safety sensor can even detect people when they are wearing very dark clothes, which have a very weak diffuse reflectance.

3.1.2

Parameters for protective function

The following parameters for switching off the safety-related switching outputs of the safety sensor are taken into consideration for the protective function:

• Configurable protective fields

• Reference contour of protective fields

• Configurable field pair changeover

• Selectable resolution for hand, leg or body detection

• Safety sensor response time

• Selectable start-up behavior

The following non-safety-oriented functions and signals also belong to the protective function:

• Configurable warning fields

• Configurable indication signals

Additional functions of the protective function

• Warning field evaluation

• Selectable dynamic contactor monitoring (EDM)

• E-Stop

Two protective functions function mode

• The safety sensor can be configured for two independent protective functions.

• If the safety sensor is configured for one protective function, an internal safe time delay can be selected for switch-off of the second OSSD pair.

3.1.3

Device and monitoring functions

• Monitoring and release of field pair changeover

• Configurable output of the indication signals for the following functions groups:

• Protective function

• Warning messages

• Error messages

• Diagnostics

• Status messages

Leuze electronic RSL 440 15

3.2 Connection unit

M5 2x

2 3 4 5 6

The safety sensor is mounted, connected and aligned using the connection unit.

Device description

1 Connection cable, connection to the machine 2 M12 socket, D-coded, Ethernet communication connection M5 Connection for functional earth with M5x10 self-cutting/self-tapping (gas tightness) and ground strap

Fig.3.2: Device overview, connection unit

Functions of connection unit:

• Attachment point for mounting, either directly or using an optional mounting system. When devices are swapped out, the connection unit remains mounted and aligned.

• EMC wiring for signal inputs/outputs and supply using connection cable

Safety sensor Connection unit Connection

RSL440 CU429-y

• Connector bushing and EMC for the Ethernet TCP/IP communication and configuration interface to the PC/laptop

• Memory for the configuration files and automatic parameter transfer in the event of device swap-out

• Quick-release connection to the scanner unit (see Quick Start Guide) for easy device swap-out

3.3 Display elements

The display elements of the safety sensors simplify start-up and fault analysis.

3.3.1

LED indicator

Located on the connection unit are six LEDs for displaying the operating state.

• Protective function A: LEDs 1, 2, 3

• Protective function B: LEDs 4, 5, 6

y=5000, 10000, 25000

Connection cable, 29-wire

5m, 10m, 25m

Leuze electronic RSL 440 16

Tab.3.2: Meaning of the LEDs

LED Color State Description

1, 6 Red/green OFF Device switched off

Red OSSD off

Red, flashing Error

Green OSSD on

2, 5 Yellow OFF RES deactivated

RES activated and enabled

Flashing Protective field occupied

ON RES activated and blocked but ready to be unlocked

Protective field free and linked sensor enabled (if applicable)

3, 4 Blue OFF Free warning field

ON Warning field interrupted

Device description

3.3.2

Alphanumerical display

In normal operation, the 24-digit alphanumerical display of the safety sensor shows the monitored protective and warning field pairs. It also provides assistance during detailed error diagnostics (see chapter 12 "Diagnostics and troubleshooting").

Tab.3.3: Alphanumerical displays

Display Description Example

Upon startup without configuration/upon initial commissioning

Sensor type Sensor type 420M

Sensor serial number Sensor serial number SN: 21513123456

Sensor name / Network name Name of the sensor / network A123456789

Configuration necessary Configuration required CONFIG REQUESTED

Repeated until end of booting phase / start phase, then

Spirit level permanent Horizontal alignment in degrees: H

H -3° V +9°

Vertical alignment in degrees: V

Upon startup with configuration

Sensor type Sensor type 410XL

Sensor serial number Sensor serial number SN: 21513123456

Sensor name / Network name Name of the sensor / network A123456789

IP: DHCP/FIX DHCP or permanent IP address IP: DHCP or

10.25.45.2

Bluetooth on/off Bluetooth detection ON/OFF Bluetooth ON

Date of configuration Date of configuration 11/13/2014 08:15

Signature Signature of configuration DG45L8ZU

Level Horizontal alignment in degrees: H

H-3° V+9°

Vertical alignment in degrees: V

Repeated until end of booting phase / start phase, then

Display following configuration of normal operation

e.g. display of active field pair A1.1

Leuze electronic RSL 440 17

Display Description Example

Transfer of the configuration data

AWAITING CONFIG Until downloading of configuration data is confirmed

DOWNLOAD CONFIG During transfer of configuration data

Level

Device description

H +/- ..° V +/- .. ° Horizontal alignment in degrees: H

H -3° V +9°

Vertical alignment in degrees: V

Sensor detection

PING received Display for identification by device

PING received Device name

name

Message

Message via a signal output or diagnosis ID

ProtF A: E123

Device: P007 - wrong Config

Error diagnostics

F… Failure, internal device error

E… Error, external error

U… Usage info, application error

I… Information

P… Parameter, inconsistency in the con-

figuration

For error diagnostics, the error's respective letter is displayed first followed by the number code. An AutoReset is carried out after 10 seconds for errors that do not cause locking, with an unauthorized restart being impossible. In the case of blocking errors, the voltage supply must be separated and the cause of the error must be eliminated. Before switching on again, the steps taken before initial commissioning must be repeated (see chapter 10 "Starting up the device").

When the protective field has been free for about 5 seconds, the device switches back to the display in normal operation.

3.3.3

Displays in normal operation

The display in normal operation depends on the operating state of the safety sensor. The display can be switched off or rotated by 180° by means of the software.

Field-of-view display

The upper and lower limit of the safety sensor's field of view can be displayed by means of horizontal lines on the optics cover.

Ä Make sure that the safety sensor's field of view is always completely unobstructed.

NOTICE

Always check the protective field configuration!

Ä Check all defined protective fields each time the configuration is changed.

The field-of-view display is a comfort function and is not intended as a substitute for checking the protective field configuration.

Ä The safety sensor's field of view must be completely unobstructed on the application side.

Leuze electronic RSL 440 18

3.4 Mounting system (optional)

Mounting systems and mounting brackets simplify mounting and alignment of the safety sensor. Mounting systems and mounting brackets are available as accessories (see chapter 17 "Order guide and accessories").

3.5 Loop guard (optional)

The loop guard for the optics cover prevents damage to the safety sensor caused by light contact with foreign objects. The loop guard is available as an accessory (see chapter 17 "Order guide and accessories").

Device description

Leuze electronic RSL 440 19

Configuration and diagnostic software SensorStudio

4 Configuration and diagnostic software SensorStudio

To start up a safety sensor in your application, the safety sensor must be set up according to its specific use using the configuration and diagnostic software. The software is used to set up the safety configuration of the safety sensor, to change the communication and diagnostics settings and to perform diagnostic routines. Communication takes place via the PC.

The software is designed according to the FDT/DTM concept:

• You make the individual configurations for the safety sensor in the Device Type Manager (DTM).

• The individual DTM configurations of a project can be called up via the frame application of the Field Device Tool (FDT).

• Each device DTM has a communication DTM that sets up and monitors the communication connections to the sensor.

NOTICE

Only use the software for safety sensors manufactured by Leuze electronic.

4.1 System requirements

To use the software, you need a PC or laptop with the following specifications:

Hard disk space At least 250MB free memory

Screen display Color

External drive DVD drive

Input device Keyboard and mouse or touchpad

Output device Printer (black-white or color)

Interfaces RJ45 Ethernet network

Operating system Microsoft® Windows7 and Windows8.1

NOTICE

Only the term "PC" is used below.

4.2 Installing software

Prerequisites:

• You do not need the safety sensor to install the software on the PC.

• All Windows applications are closed.

If you want to save the protective field or configuration values, you will need more memory.

Bluetooth (optional) - If the PC does not have integrated Bluetooth technology, use an appropriate USB or PCMCIA adapter if necessary.

NOTICE

The software is installed in two steps:

Ä Installing the SensorStudio FDT frame. Ä Installing LeSafetyCollection device manager (DTM).

Leuze electronic RSL 440 20

Configuration and diagnostic software SensorStudio

Installing the SensorStudio software

NOTICE

If FDT frame software is already installed on your PC, you do not need the SensorStudio installation.

You can install the device manager (DTM) in the existing FDT frame.

Ä Insert the data carrier. ð The installation will start automatically. Ä If installation does not start automatically, double-click the file SensorStudioSetup.exe. Ä If you want to call up the menu of the CD, double-click the file start.exe. Ä Select a language for the interface text in the installation wizard and software and confirm with [OK]. ð The installation wizard starts. Ä Click [Next]. ð The installation wizard opens the software license agreement. Ä If you want to accept the license agreement, select the appropriate option field and click [Next]. Ä If the suggested installation path is OK, click [Next].

If you want to specify a different path, click the [Browse] button. Select a different path, confirm with [OK] and click [Next].

Ä Click the [Install] button to start installation.

ð The wizard installs the software and places a shortcut on the desktop ( ). Ä Click the [Finish] button to complete installation.

Installing LeSafetyCollection device manager (DTM)

Prerequisites:

• The Sensor Studio software is installed on the PC.

• Data carrier inserted.

Ä Double-click the file LeSafetyCollectionSetup.exe. Ä Select a language for the interface text in the installation wizard and software and confirm with [OK]. ð The installation wizard starts. Ä Click [Next]. ð The installation wizard opens the software license agreement. Ä If you want to accept the license agreement, select the appropriate option field and click [Next]. Ä If the suggested installation path is OK, click [Next].

If you want to specify a different path, click the [Browse] button. Select a different path, confirm with [OK] and click [Next].

Ä Click the [Install] button to start installation. ð The wizard installs the software. Ä Click the [Finish] button to complete installation.

NOTICE

During installation of the software, a user admin (without password query) is created so that you can start the software without user identification. If other users are registered (Tools > User management in the FDT frame menu), you must log in at the software with a user name and password.

This setting allows you to connect to the safety sensor and to read out, upload, enter or change the safety configuration and all settings using the RSL400 device DTM. The password for the safety sensor only needs to be entered (i.e. the access level only needs to be changed) when the changes are downloaded to the safety sensor (see chapter 4.5.1 "Selecting access level").

Leuze electronic RSL 440 21

4.3 User interface

2 3

Configuration and diagnostic software SensorStudio

1 FDT frame menu with toolbar 2 RSL400 device manager (DTM) 3 Navigation tabs 4 Information area 5 Dialog box 6 Status line 7 Navigation area

Fig.4.1: User interface of the software

FDT frame menu

The device managers (DTM) of the safety sensors are created and managed in the FDT frame menu.

Device manager DTM

Configuration projects for setting up the selected safety sensor are created and managed in the device managers (DTM) of the safety sensors.

Leuze electronic RSL 440 22

Project tree view

Configuration and diagnostic software SensorStudio

1 FDT frame menu 2 Device manager (DTM) tabs 3 Project tree view

Fig.4.2: User interface with project tree view

The project tree view shows the structure of the currently installed device managers (DTM). In the project tree view you can, for example, add copies of an already configured device manager (DTM) quickly and easily to the DTM structure if you want to operate multiple safety sensors with the same configuration settings.

Example: DTS with safety sensors on front and rear side

4.4 FDT frame menu

NOTICE

You can find complete information on the FDT frame menu in the online help system. Select the

Help menu item in the menu [?].

4.4.1

Project wizard

Using the Project Wizard you can create and change configuration projects for setting up the safety sensor (see chapter 4.5 "Using configuration projects").

Ä Start the Project Wizard in the FDT frame menu by clicking the button.

NOTICE

Information on the Project Wizard can be found in the online help for the FDT frame menu under Sensor Studio Options.

Leuze electronic RSL 440 23

Configuration and diagnostic software SensorStudio

4.4.2

4.4.3

DTM change

The DTM Change function makes it easier for you to call up the communication DTM of a device or change from device DTM to communication DTM.

Ä Start the DTM change function in the FDT frame menu by clicking the button.

NOTICE

Information on DTM change can be found in the online help for the FDT frame menu under Sensor Studio Options.

User management

Using the user management in the FDT frame menu, you can create users, log users in/out and manage passwords.

Creating users

When creating a user in the user management via Tools > User management in the software frame menu, select the access level for the user. For information on access permissions and access levels (see chapter 5.1 "Authorization concept of safety sensor").

Ä In the FDT frame menu, click Tools > User management > Create user.

Logging users in/out

Prerequisites:

• Users have been created

Ä In the FDT frame menu, click Tools > Log in/log out.

4.4.4

Managing passwords

Prerequisites:

• Users have been created

Ä In the FDT frame menu, click Tools > Change password.

NOTICE

Password management via the FDT frame menu applies to all installed device managers (DTM) of the project.

Whenever write access occurs, the safety sensors of the RSL400 series always check the access level (Engineer, Expert) and the password defined via the device manager (DTM) (SET-

TINGS > Passwords) independently of the password management via the FDT frame menu.

Exiting SensorStudio

When you have finished making the configuration settings, close the configuration and diagnostics software.

Ä Exit the program via File > Exit. Ä Save the configuration settings as a configuration project on the PC.

You can open the configuration project again at later time via File > Open or with the SensorStudio Project

Wizard ( ).

Leuze electronic RSL 440 24

4.5 Using configuration projects

Configuration projects are created and managed in the device manager (DTM) of the selected safety sensor.

NOTICE

This setting allows you to connect to the sensor and to read out, upload, enter or change the safety configuration and all settings using the RSL400 device DTM. The password for the sensor only needs to be entered (i.e. the access level only needs to be changed) when the changes are downloaded to the safety sensor (see chapter 4.5.1 "Selecting access level").

Ä Start the configuration and diagnostics software on the PC by double-clicking the button.

ð The mode selection of the Project Wizard is displayed. ð If the mode selection is not shown, start the Project Wizard in the FDT frame menu by clicking the

[Project Wizard] button ( ).

Configuration and diagnostic software SensorStudio

Fig.4.3: Project wizard

Ä Select the configuration mode and click [Next].

ð Automatic connection to a connected safety sensor (Online) ð Device selection without communication connection (offline)

ð Load a saved project again ð The project wizard displays the SEARCH DEVICES dialog box. Ä Select the interface and click the [Start] button. Ä Find the safety sensor for your configuration project using the search function of the communication

DTM.

Leuze electronic RSL 440 25

Configuration and diagnostic software SensorStudio

1 FDT frame menu 2 Communication DTM 3 Device list 4 Search function

Fig.4.4: Communication DTM with search function

ð The project wizard displays the device list of configurable safety sensors in the SEARCH DEVICES di-

alog box.

Fig.4.5: Device selection in project wizard

Ä Select the safety sensor from the device selection list and click [Next]. ð The device manager (DTM) of the safety sensor shows the initial screen for the configuration project.

Leuze electronic RSL 440 26

Configuration and diagnostic software SensorStudio

4.5.1

Fig.4.6: Initial screen for safety configuration

NOTICE

The device manager (DTM) starts without querying the access level of the user. During communication with the safety sensor, the safety sensor does however query the access level of the user. To change the access levels (see chapter 4.5.1 "Selecting access level").

Setting device manager

Using the menus of the device manager (DTM) you can set the parameters of the safety configuration. The online help system provides information on the menu items and adjustment parameters. Select the Help menu item in the menu [?].

Selecting access level

Using the device manager you can change the access level of the user if necessary. For the authorization concept of the software, see chapter see chapter 5.1 "Authorization concept of safety sensor".

Ä Click in the DTM menu bar on the [Change access level]button ( ).

ð The Change access level dialog box opens. Ä In the Access level list, select the item Expert, Engineer or Observer and enter the default password or

the password defined for the individual user.

The following access levels are available:

• Observer can read everything (no password)

• Expert can change communication and diagnostics settings (default password = comdiag)

• Engineer can additionally change the safety configuration (default password = safety)

The password is case-sensitive (i.e. a distinction is made between upper-case and lower-case letters).

Ä Confirm with [OK].

Leuze electronic RSL 440 27

Configuration and diagnostic software SensorStudio

4.5.2

4.5.3

IDENTIFICATION

Detailed information on the menu items and setting parameters can be found in the information area and in the online help. Select the Help menu item in the menu [?].

• RSL400 safety laser scanner

• Sensor and configuration data

• Technical data

PROCESS

Detailed information on the menu items and setting parameters can be found in the information area and in the online help. Select the Help menu item in the menu [?].

• Sensor display Device display in the DTM menu

• SENSOR DISPLAY

• STATE OF THE ACTIVE PROTECTIVE AND WARNING FIELDS

• SENSOR DATA

• Measurement contour

• Inputs / outputs

• SENSOR DISPLAY

• CONNECTIONS AND SIGNALS

• Simulation – only with access level Engineer

• Measurement contour

• Inputs / outputs

4.5.4

4.5.5

CONFIGURATION

see chapter 9 "Configuring the safety sensor"

NOTICE

You can only transfer changes made in the CONFIGURATION menu to the safety sensor if you are logged in with the access level Engineer.

DIAGNOSIS

Adjustment / Alignment

Display of safety sensor alignment using the integrated electronic spirit level

Prerequisites: The software and safety sensor are connected.

Ä In the DIAGNOSIS menu, click the [Align sensor mechanically]button ( ). ð The safety sensor display shows the horizontal and vertical alignment in degrees.

Visually identify device

If you have installed multiple safety sensors, identify the safety sensor that is connected to the currently open device manager (DTM).

Prerequisites: The software and safety sensor are connected.

Ä In the DIAGNOSIS menu, click the [Visually identify sensor]button ( ). ð In the display of the safety sensor connected to the device manager (DTM), the message "PING re-

ceived" flashes for ten seconds.

Reset sensor

Acknowledge messages and faults

Set safety sensor to safety mode

Leuze electronic RSL 440 28

Configuration and diagnostic software SensorStudio

Create and save service file

The service file contains all available information on the safety sensor as well as configuration and settings.

When requesting support, send the service file to the Leuze electronic customer service (see chapter 14 "Service and support").

Sensor display

Device display in the DTM menu

• SENSOR DISPLAY

• STATE OF THE ACTIVE PROTECTIVE AND WARNING FIELDS

• SENSOR DATA

Diagnostics list

Access list

EventLog

4.5.6

SETTINGS

NOTICE

You can only transfer changes made in the SETTINGS menu to the safety sensor if you are logged in with the access level Engineer.

Communication

• LAN

• DHCP

• CONNECTION SETTINGS

• MAC address

• Bluetooth

• Activate Bluetooth module

• Activate device scan

• Bluetooth address

Data telegrams

A UDP telegram can be configured which sends the status profile of the safety sensor as well as the measurement data to a receiving device connected via Ethernet, e.g. to a PC.

EventLog

Trigger signals output when certain events occur, are recorded and shown in the event list of the safety sensor.

Information on the monitored signals can be found in the information area and in the online help. Select the

Help menu item in the menu [?].

Sensor display

Activation of the safety sensor alphanumerical display.

Information on the display options can be found in the information area and in the online help. Select the

Help menu item in the menu [?].

Passwords

NOTICE

If a user has forgotten his password for login at the safety sensor or has repeatedly entered the password incorrectly, he cannot log in at the safety sensor. The CHANGE PASSWORD function is therefore not available.

To reset the password, a user must generate a reset password and have it confirmed by the manufacturer.

Leuze electronic RSL 440 29

Configuration and diagnostic software SensorStudio

CHANGE PASSWORD

Ä Define individual passwords for the access levels Engineer and Expert. These passwords replace the

default passwords set by the manufacturer. The password is case-sensitive (i.e. a distinction is made between upper-case and lower-case letters).

Reset password

Prerequisites:

• The software is connected to the safety sensor.

Ä Generate a one-time password.

Note down the generated reset password.

Ä Send the reset password to the Leuzeelectronic customer service for confirmation (see chapter 14

"Service and support"). The device can now be switched off and the connection can be terminated.

Ä Enter the confirmed reset password and create a new password.

Optics cover

• Monitoring of optics cover

• Dialog box for calibrating a replacement optics cover

Field editor display options

Display settings for the field editor when defining protective/warning fields.

• CONTOUR ALIGNMENT

• COORDINATE DISPLAY

• EDITOR BEHAVIOR

Information on the display options can be found in the information area and in the online help. Select the Help menu item in the menu [?].

Leuze electronic RSL 440 30

5 Functions

The functions of the safety sensor must be matched to the respective application and its safety requirements. You can activate/deactivate the functions and adapt them using parameters. You configure the functions with the help of the configuration and diagnostics software (see chapter 9 "Configuring the safety sensor").

• You configure the functions of the safety sensor in the software as configuration projects.

• In each configuration project you determine the protective function and the configurable field pairs via the selected function mode.

• The changeover-capable protective/warning field pairs for the selected function mode are defined in configuration banks.

• You determine the resolution, the start-up behavior, the response time and, where applicable, the vehicle speed together for all protective/warning field pairs of a configuration bank.

5.1 Authorization concept of safety sensor

User management allows target-group-oriented communication between the software and the safety sensor. Which functions are available depends on the selected access level of the user. For information on the software and on user management (see chapter 4 "Configuration and diagnostic software SensorStudio").

• Changing the safety configuration as well as the communication and diagnostics settings of the sensor is only permitted for certain access levels.

• Installation and operation of the software do not depend on the access level of the user.

The following access levels are available:

Functions

Tab.5.1: Access levels and functions available

Access level Functions

Observer • Display the measurement contour

• Upload and display configuration data from the safety sensor

• Display status information from the safety sensor

• Display diagnostics list

• Customize display

• Display and evaluate the measurement contour

• Load configuration data from the safety sensor

• Load status information from the safety sensor

• Display diagnostics list

• Create service file

• Reset password

Expert In addition to the functions of the Observer

• Load the signed safety configuration from a file and transfer/download to the safety sensor

• Transfer changed communication and diagnostics settings from the PC to the safety sensor

• Print configuration data incl. protective/warning fields

• Calibrate optics cover

Leuze electronic RSL 440 31

Functions

Access level Functions

Engineer In addition to the functions of the Expert, full access to all user-relevant func-

tions and parameters:

Create and change a safety configuration:

• Save configuration data to file

• Change all parameters of configuration

• Reset safety sensor to default values

• Define and change protective/warning fields

• Set reference contour in protective field

• Print and delete protective/warning fields

• Load protective/warning field data from file

• Save protective/warning field data

• Transfer protective/warning field data from the PC to the safety sensor

• Change passwords

NOTICE

The software saves individual passwords in the connected safety sensor, thereby ensuring that only authorized users can change the existing configuration.

Determining access level

When creating a user in the user management via Tools > User management in the FDT frame menu, select the access level for the user. In the user management you can also create and change passwords for the users.

Using the device manager (DTM) you can change the access level of the user (see chapter 4.5.1 "Selecting access level").

Ä Click in the DTM menu bar on the [Change access level]button ( ).

5.2 Function modes of safety sensor

You configure the functions of the safety sensor in configuration projects with the help of the configuration and diagnostics software. In each configuration project you determine the protective function and the configurable field pairs via the selected function mode.

You select the function mode of the safety sensor in the software device manager (DTM) with CONFIGU- RATION > OSSDs (see chapter 9 "Configuring the safety sensor").

You use the protective function to define the criteria for switching off the safety-related switching outputs (see chapter 3.1.2 "Parameters for protective function").

The changeover-capable protective and warning field pairs for the selected function mode are defined in the configuration banks, e.g. CONFIGURATION > Protective functionA > BankA1.

Overview of the function modes

Tab.5.2: Function modes

Function mode Field pairs (FP)

Field pair activation Protective fields (PF) Warning fields (WF)

One protective function 1FP / 1PF + 1WF Fixed selection of one field pair

5FP / 5PF + 5WF Selection by signal input:

• Overlapped monitoring

10FP / 10PF + 10WF Selection by signal input:

• Fixed changeover moment

Leuze electronic RSL 440 32

Functions

Function mode Field pairs (FP)

Protective fields (PF) Warning fields (WF)

One protective function -

100FP / 100PF + 100WF Selection by signal input:

100FP

One protective function – four field mode

One protective function – multi configuration

1FP / 1PF + 3WF Fixed selection of one field pair

10FP+ 10FP / 10PF + 30WF Selection by signal input:

1FP / 1PF + 1WF Fixed selection of one field pair

10 x 10FP /

10 x (10PF + 10WF)

Two protective functions Protective function A:

1FP / 1PF + 1WF

Protective function B: 1FP / 1PF + 1WF

Protective function A: 5FP / 5PF + 5WF

Protective function B: 5FP / 5PF + 5WF

Protective function A: 10FP / 10PF + 10WF

Protective function B: 10FP / 10PF + 10WF

Field pair activation

• Fixed changeover moment

Selection by signal input:

• Fixed changeover moment

Fixed selection of one field pair

Selection by signal input:

• Overlapped monitoring

Selection by signal input:

• Fixed changeover moment

5.2.1

5.2.2

Two protective functions – four field mode

Protective function A: 50FP / 50PF + 50WF

Selection by signal input:

• Fixed changeover moment Protective function B: 50FP / 50PF + 50WF

Two protective functions – multi configuration

2 x 1 x 1FP

2 x 1 bank x (1PF + 1WF)

2 x 5 x 10FP

2 x 5 banks x (10PF + 10WF)

Fixed selection of one field pair

Selection by signal input:

• Fixed changeover moment

One protective function

Ten changeover-capable field pairs for safety-related switching outputs OSSD-A. For the field pair changeover, see chapter 5.7 "Field pair changeover".

Safe, time-delayed switch-off of safety-related switching outputs OSSD-B.

One protective function – 100 field pairs

A configuration bank with 100 changeover-capable field pairs for safety-related switching outputs OSSD-A. For the field pair changeover, see chapter 5.7 "Field pair changeover".

Safe, time-delayed switch-off of safety-related switching outputs OSSD-B.

Example of use:

• DTS with varying operating conditions and different speed levels

Leuze electronic RSL 440 33

Functions

A1.1P

B1.1P

A1.1W

B1.1W

5.2.3

5.2.4

Two protective functions

In this function mode, you configure independent protective functions with all associated safety parameters for safety-related switching outputs OSSD-A and OSSD-B.

• For each protective function you can define up to ten field pairs in one configuration bank.

• Field pair actuation and field pair changeover take place separately and independently for each configuration bank.

For the field pair changeover, see chapter 5.7 "Field pair changeover".

One protective function – four field mode

The safety sensor monitors one protective field and three warning fields.

Monitoring is performed together for the field pairs of protective functionA and protective functionB. If, for example, the control system is monitoring field pair A1.1 for protective functionA, field pair B1.1 for protective functionB is also monitored.

1 Protective function A: protective field 2 Protective function B: protective field 3 Protective function A: warning field 4 Protective function B: warning field

Fig.5.1: Four field mode

If the protective field of protective functionA is violated, safety-related switching outputs OSSD-A switch.

If the protective field of protective functionB is violated, the indication signal B-CLEAR is generated – the safety-related switching outputs do not switch.

The signals are assigned to the switching outputs via the configuration and diagnostics software (CONFIG- URATION > Outputs; see chapter 9 "Configuring the safety sensor").

Tab.5.3: Example: Assignment of signals to switching outputs

Logic signal Electrical switching output Description

OSSDA Safety-related switching outputs OSSDA Protective functionA: protective field violation

B-CLEAR Switching output MELD – not safe Protective functionB: protective field violation

A-WF-VIO Switching output A1 Protective functionA: Violation of warning field

B-WF-VIO Switching output EA1 Protective functionB: Violation of warning field

Leuze electronic RSL 440 34

Functions

A4.2P

B4.2P

A4.2W

B4.2W

5.2.5

Two protective functions – four field mode

In this function mode, you configure the protective functions for safety-related switching outputs OSSD-A and OSSD-B.

• The safety sensor monitors two protective fields and two warning fields.

• Controlled switch-off via safety-related switching outputs OSSD-A and OSSD-B.

• If the protective field of protective functionA is violated, safety-related switching outputs OSSD-A switch.

• If the protective field of protective functionB is violated, safety-related switching outputs OSSD-B switch.

• Field pair actuation and field pair changeover take place together for the field pairs of protective function A and protective function B.

If, for example, the control system actuates the field pair A4.2 for protective function A, the field pair B4.2 for protective function B is also actuated.

1 Protective function A: protective field 2 Protective function B: protective field 3 Protective function A: warning field 4 Protective function B: warning field

Fig.5.2: Four field mode

Tab.5.4: Assignment of signals to switching outputs

Logic signal Electrical switching output Description

OSSDA Safety-related switching outputs OSSDA Protective functionA: protective field violation

OSSDB Safety-related switching outputs OSSDB Protective functionB: protective field violation

A-WF-VIO Switching output A1 or A3 Protective functionA: Violation of warning field

B-WF-VIO Switching output A2 or A4 Protective functionB: Violation of warning field

Leuze electronic RSL 440 35

Functions

5.2.6

5.2.7

One protective function – multi configuration

Ten configuration banks each with ten changeover-capable field pairs for safety-related switching outputs OSSD-A. You can configure the resolution, DTS speed, start-up behavior and response time separately for each configuration bank. For the field pair changeover, see chapter 5.7.6 "Changeover of 10x ten field pairs".

• Manual restart when the configuration bank is changed over

• Safe, time-delayed switch-off of safety-related switching outputs OSSD-B.

Examples of use:

• Machine with multiple operating modes

• DTS with different speed levels and multiple load states

Two protective functions - multi configuration

In this function mode, you configure the protective functions for safety-related switching outputs OSSD-A and OSSD-B.

• For each protective function, you can define five configuration banks each with ten field pairs.

For the field pair changeover, see chapter 5.7 "Field pair changeover".

• You can configure the safety parameters separately for each configuration bank.

• For each configuration bank, field pair actuation and field pair changeover take place together for the field pairs of protective functionA (A1.1 to A5.10) and protective functionB (B1.1 to B5.10).

If, for example, the control system in configuration bank2 actuates the field pair A2.5 for protective functionA, the field pair B2.5 for protective functionB is also actuated.

5.3 Selectable resolution for hand, leg and body detection

The application-specific resolution of the safety sensor is defined in the configuration project together for all protective/warning field pairs of a configuration bank.

Tab.5.5: Resolution of the safety sensor depending on the function

Safety sensor resolution [mm]

30 Hand detection Point of operation guarding

40 Arm detection Point of operation guarding

50 Leg detection with the safety sensor

60 • Leg detection with the safety

70 • Leg detection with the safety

Function Application(s)

mounted close to floor level

sensor mounted at a height of 150mm

• Leg detection and detection of lying persons in the case of mounting on vehicles, mounting height approx. 200mm

sensor mounted at a height of 300mm

Danger zone safeguarding

Stationary danger zone safeguarding Mobile danger zone safeguarding

150 Body detection Access guarding

Mobile side guarding

Mounting height = Height of the scan level above floor level

Leuze electronic RSL 440 36

5.4 Speed-dependent protective function for vehicles

For object detection in the case of mobile applications, the safety sensor evaluates the relative speed of the object. If the safety sensor is mounted on vehicles or on moving parts of machines, the maximum speed of the vehicle must be entered during configuration of the protective function.

The maximum vehicle speed (Max. DTS speed) is selected in the configuration project together for all protective/warning field pairs of a configuration bank.

5.5 Response time

The response time is the maximum time from a protective field violation to switch-off of the safety-related switching outputs.

The response time is selected in the configuration project together for all protective/warning field pairs of a configuration bank.

5.6 Configurable start-up behavior

The start-up behavior is selected in the configuration project together for all protective/warning field pairs of a configuration bank.

Functions

5.6.1

5.6.2

Automatic start/restart

The machine starts automatically as soon as the machine is switched on or the supply voltage returns and when the protective field is free again.

Using automatic start/restart

You can use the automatic start/restart function under the following prerequisites:

• The start/restart interlock function is taken over by a downstream safety-related component of the machine control system.

or:

• It is not possible to walk behind or go around the effective protective field.

Ä Allow for an optical and/or acoustic start warning.

Automatic start-up

The automatic start-up function starts the machine automatically as soon as the supply voltage is present.

Automatic restart

The automatic restart function starts the machine automatically as soon as the protective field is free again.

Start interlock/automatic restart

With start interlock/automatic restart, the safety sensor remains in the OFF state when, following a power supply interruption, the voltage supply is restored. After violation of the protective field, the system restarts when the protective field is free again.

The start/restart interlock has two functions:

• Start interlock

• Automatic restart

Using start interlock/automatic restart

Ä In addition to the safety sensor you must also install the reset button. The machine operator starts the

machine with this reset button.

Ä Position the reset button outside the danger zone so that it cannot be activated from the protective

fields and danger zones. The operator must be able to see all danger zones from this position.

Ä Identify the area to be released on the reset button so that its meaning is clear and easy to understand. Ä Ensure that nobody is in the danger zone before pressing the reset button. Ä Hold down the reset button for between 0.12s and 4s to enable the safety-related switching outputs.

Leuze electronic RSL 440 37

Functions

DANGER

Risk of death if start-up is operated unintentionally!

Ä Ensure that the reset button for unlocking the start interlock cannot be reached from the

danger zone.

Ä Before unlocking the start interlock, make certain that no people are in the danger zone.

Start interlock

The start interlock function prevents the machine from starting automatically after switching on or after the supply voltage returns.

The machine only starts when you press the reset button.

Automatic restart

The automatic restart function starts the machine automatically as soon as the protective field is free again.

5.6.3

Start/restart interlock (RES)

When accessing the protective field, the start/restart interlock ensures that the safety sensor remains in the OFF state after the protective field has been cleared. It prevents automatic release of the safety circuits and automatic start-up of the system, e.g. if the protective field is again clear or if an interruption in the voltage supply is restored.

The start/restart interlock has two functions:

• Start interlock

• Restart interlock

NOTICE

For access guarding, the start/restart interlock function is mandatory. The protective device may only be operated without start/restart interlock in certain exceptional cases and under certain conditions acc. to ISO12100.

Using start/restart interlock

Ä In addition to the safety sensor you must also install the reset button. The machine operator starts the

machine with this reset button.

Ä Position the reset button outside the danger zone so that it cannot be activated from the protective

fields and danger zones. The operator must be able to see all danger zones from this position.

DANGER

Risk of death if start/restart is operated unintentionally!

Ä Ensure that the reset button for unlocking the start/restart interlock cannot be reached from

the danger zone.

Ä Before unlocking the start/restart interlock, make certain that no people are in the danger

zone.

Start interlock

The start interlock function prevents the machine from starting automatically after switching on or after the supply voltage returns.

The machine only starts when you press the reset button.

Restart interlock

The restart interlock function prevents the machine from starting automatically, as soon as the protective field is free again. The restart interlock function always includes the start interlock function.

The machine only starts again when you press the reset button.

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5.7 Field pair changeover

The safety sensor has 10x ten field pairs or 100 field pairs. Switchover between the field pairs is possible at all times, provided the operating situation allows this.

The information for field pair changeover applies both for the field pairs of protective functionA and for the field pairs of protective functionB.

Use the field pair changeover when the danger zones vary depending on the activity of the machine or the operating state, e.g. driverless transportation system (DTSs), to control the field pair changeover for straight and curved stretches.

If the rules for field pair changeover are not complied with, the safety sensor signals a fault and the safetyrelated switching outputs are switched off.

The safety sensor has the following modes for field pair activation and field pair changeover:

• Fixed selection of one field pair

• Selection by signal inputs with the changeover mode Overlapped monitoring

• Selection by signal inputs with the changeover mode Fixed changeover moment

Field pair activation and field pair changeover are configured via the protective function, e.g. CONFIGURA-

TION > Protective functionA > MODE FOR FIELD PAIR ACTIVATION AND CHANGEOVER.

The field pair changeover can be monitored by means of configurable measures (see chapter 5.8 "Monitoring of field pair changeover").

During the changeover process, the safety sensor monitors the field pair active before the field pair changeover, according to the configured changeover mode and changeover time.

Functions

5.7.1

Using field pair changeover

You can configure and switch over the field pairs according to the different requirements. The field pairs are changed over via the corresponding control inputs.

The rules for field pair changeover depend on the changeover mode and changeover time. The activated field pair must correspond with the respective operating mode. The time of the field pair changeover must correspond with the machine's risk assessment. You must take the lead time, braking distances, response times and machine stopping times, e.g. influenced by overlapping protective fields, into account.

If the rules are not observed, the safety-related switching outputs switch off and a message is displayed (see chapter 12 "Diagnostics and troubleshooting").

The following rules apply for the field pair changeover:

• The field pair changeover performed by the control system must agree with the safety sensor's configuration. This configuration is specified with the configuration and diagnostics software (see chapter 9.4 "Configuring protective function").

• With field pair changeover to an occupied protective field, the safety sensor only switches off the safety-related switching outputs after the set response time plus a synchronization time of 40ms.

NOTICE

Take the lead time into consideration!

Ä Take the lead time of the changeover time and response time into consideration before op-

erating the machine in its new operating situation.

Fixed selection of one field pair

If Fixed selection of one field pair is set as the mode for field pair activation, field pair A1.1 is monitored irrespective of how the control inputs are connected.

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Functions

PF1.1

PF1.2

PFA…

PFA.x

2 3

A1.2

XX XX

A1.2 & A1.x A1.x

5.7.2

Changeover of five field pairs in changeover mode Overlapped monitoring

Changeover mode Overlapped monitoring: This changeover mode is only permitted for up to five field pairs.

The field pair changeover must take place within a configurable time period of the changeover time. Two field pairs can be monitored simultaneously during the changeover time.

• First the control unit must switch to a new field pair before it switches off the previously active one.

• A maximum of two field pairs are active.

Each field pair is then only active if it is selected by the control unit.

• The changeover time starts when the second field pair is connected. When the changeover time has expired, only one field pair should still be active.

• The changeover time is specified with the configuration and diagnostics software (see chapter 9.4.4 "Creating and configuring protective/warning field pairs").

Tab.5.6: Connection of control inputs F1 to F5 with activation of field pairs A1.1 to A1.5 for protective function A

Field pair Control input Description

F1 F2 F3 F4 F5

A1.1 1 0 0 0 0 Field pair A1.1 is active

A1.2 0 1 0 0 0 Field pair A1.2 is active

A1.3 0 0 1 0 0 Field pair A1.3 is active

A1.4 0 0 0 1 0 Field pair A1.4 is active

A1.5 0 0 0 0 1 Field pair A1.5 is active

In the case of two protective functions, connection of control inputs F6 to F10 applies analogously for activation of field pairs B1.1 to B1.5 for protective function B.

1 Active protective field 2 An old protective field is active 3 Set changeover time 4 A new protective field is active 5 Changeover complete PF Field pair or quad XX Field pair changeover

Leuze electronic RSL 440 40

Fig.5.3: Signal/time diagram: Overlapped monitoring

Functions

5.7.3

Changeover of ten field pairs in changeover mode Fixed changeover moment

Changeover mode Fixed changeover moment: The field pair changeover must take place within the configurable changeover time, i.e. after the changeover time has expired, a valid and stable input connection must be present. The old field pair is monitored during the changeover time.

• The previously active field pair is monitored during the changeover time.

• The changeover time starts when the safety sensor registers a change at control inputs F1 to F5. When the changeover time has expired, only one field pair should still be active.

• Monitoring of the newly activated field pair starts when the changeover time has expired.

• The changeover time is specified with the configuration and diagnostics software (see chapter 9.4.4 "Creating and configuring protective/warning field pairs").

Tab.5.7: Connection of control inputs F1 to F5 with activation of field pairs A1.1 to A1.10 for protective function A

Field pair Control input Description

F1 F2 F3 F4 F5

A1.1 1 0 0 0 0 Field pair A1.1 is active

A1.2 0 1 0 0 0 Field pair A1.2 is active

A1.3 0 0 1 0 0 Field pair A1.3 is active

A1.4 0 0 0 1 0 Field pair A1.4 is active

A1.5 0 0 0 0 1 Field pair A1.5 is active

A1.6 1 1 1 1 0 Field pair A1.6 is active

A1.7 1 1 1 0 1 Field pair A1.7 is active

A1.8 1 1 0 1 1 Field pair A1.8 is active

A1.9 1 0 1 1 1 Field pair A1.9 is active

A1.10 0 1 1 1 1 Field pair A1.10 is active

In the case of two protective functions, connection of control inputs F6 to F10 applies analogously for activation of field pairs B1.1 to B1.10 for protective function B.

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Functions

2 3 4

PF1.1

PF1.2

PFA…

PFA.x

0 0

A1.2

0 0

1 1

0 1

1 1

00 0

A1.2 A1.x

A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10

A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10

A3.1 A3.2 A3.3 A3.4 A3.5 A3.6 A3.7 A3.8 A3.9 A3.10

A4.1 A4.2 A4.3 A4.4 A4.5 A4.6 A4.7 A4.8 A4.9 A4.10

A5.1 A5.2 A5.3 A5.4 A5.5 A5.6 A5.7 A5.8 A5.9 A5.10

A6.1 A6.2 A6.3 A6.4 A6.5 A6.6 A6.7 A6.8 A6.9 A6.10

A7.1 A7.2 A7.3 A7.4 A7.5 A7.6 A7.7 A7.8 A7.9 A7.10

A8.1 A8.2 A8.3 A8.4 A8.5 A8.6 A8.7 A8.8 A8.9 A8.10

A9.1 A9.2 A9.3 A9.4 A9.5 A9.6 A9.7 A9.8 A9.9 A9.10

A10.1 A10.2 A10.3 A10.4 A10.5 A10.6 A10.7 A10.8 A10.9 A10.10

F5F4F3F2F1

F10

A1.x

Ay.1

1 Active protective field 2 An old protective field is active 3 Set changeover time 4 A new protective field is active 5 Initiation of the field pair changeover caused by a change in the signal – the old protective field is monitored

until the end of the changeover time 6 Fixed end – field pair changeover complete 7 …Only one field pair change PF Field pair or quad XX Field pair changeover

Fig.5.4: Signal/time diagram: Overlapped monitoring

5.7.4

Changeover of 100 field pairs

One protective function, one configuration bank

Leuze electronic RSL 440 42

1 Configuration bank 2 Selection of field pairs A1.x via control inputs F1 to F5 3 Selection of field pairs Ay.1 via control inputs F6 to F10

Fig.5.5: Field pair matrix: Connection of control inputs F1 to F5 and F6 to F10 with activation of field pairs A1.1 to

A10.10 for protective function A

Functions

A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10

A2.1 A2.2 A2.3 A2.4 A2.5 A2.6 A2.7 A2.8 A2.9 A2.10

A3.1 A3.2 A3.3 A3.4 A3.5 A3.6 A3.7 A3.8 A3.9 A3.10

A4.1 A4.2 A4.3 A4.4 A4.5 A4.6 A4.7 A4.8 A4.9 A4.10

A5.1 A5.2 A5.3 A5.4 A5.5 A5.6 A5.7 A5.8 A5.9 A5.10

A6.1 A6.2 A6.3 A6.4 A6.5 A6.6 A6.7 A6.8 A6.9 A6.10

A7.1 A7.2 A7.3 A7.4 A7.5 A7.6 A7.7 A7.8 A7.9 A7.10

A8.1 A8.2 A8.3 A8.4 A8.5 A8.6 A8.7 A8.8 A8.9 A8.10

A9.1 A9.2 A9.3 A9.4 A9.5 A9.6 A9.7 A9.8 A9.9 A9.10

A10.1 A10.2 A10.3 A10.4 A10.5 A10.6 A10.7 A10.8 A10.9 A10.10

F5F4F3F2F1

F10F9F8F7

A10

A1.x

Ay.1

5.7.5

5.7.6

Changeover of 2x ten field pairs

Two protective functions

• The connection of control inputs F1…F5 controls the field pair changeover for protective function A (safety-related switching outputs OSSD-A)

• The connection of control inputs F6…F10 controls the field pair changeover for protective function B (safety-related switching outputs OSSD-B)

• The connection of the control inputs corresponds to the changeover of ten field pairs for protective function A (field pairs A1.1 to A1.10) and ten field pairs for protective function B (field pairs B1.1 to B1.10); see chapter see chapter 5.7.3 "Changeover of ten field pairs in changeover mode Fixed changeover moment".

Changeover of 10x ten field pairs

Multi configuration: one protective function, ten configuration banks each with ten field pairs

Examples of use:

• Machine with multiple operating modes (y)

• DTS with different speed levels (x; control inputs F1toF5) and multiple load states (y; control inputs F6toF10)

1 Configuration banks 2 Field pair changeover within one configuration bank via control inputs F1 to F5 3 Changeover of the configuration banks via control inputs F6 to F10

Fig.5.6: Matrix of configuration banks/field pairs: Connection of control inputs F1 to F5 and F6 to F10 with activa-

tion of field pairs A1.1 to A10.10 for protective function A

5.8 Monitoring of field pair changeover

The Changeover order function determines the permissible field pair changeovers, e.g. if field pair A1.3 must be changed over to field pair A2.5. If the Changeover order function is active, the safety-related switching outputs (OSSDs) switch off in the following cases:

Leuze electronic RSL 440 43

• the control initiates an impermissible field pair changeover.

• the field pair to which the system is changed over has been deactivated.

Activating the function

Ä The Changeover order is defined using the configuration and diagnostics software (see chapter 9.5

"Defining permissible field pair changeovers").

5.9 Reference contour monitoring

The reference contour monitoring function prevents unintentional misalignment and deliberate manipulation of the safety sensor. If a protective field contains an area with reference contour, the safety sensor not only monitors interruptions of the protective field, it also monitors the concurrence of the measured area contour with the set reference contour. If the measurement values of the area contour deviate from the defined reference contour by more than the tolerance zone of 200mm, i.e., if no object is detected in the area with reference contour, the safety sensor switches off and the safety-related switching outputs (OSSDs) switch to off.

Activation of the function

Ä Activate the Reference contour monitoring function together with the definition of the protective field

boundaries using the configuration and diagnostics software (see chapter 9.4.4 "Creating and configuring protective/warning field pairs").

5.10 Field pair monitoring

The Field pair monitoring function is used to set the monitoring mode for the selected field pair.

The Standby request monitoring mode is used to switch off field pair monitoring and the safety-related switching outputs (OSSDs). This is advisable when parking vehicles, for example.

Activation of the function

Ä Activate field pair monitoring in the configuration and diagnostics software (see chapter 9.4.5 "Configur-

ing field pair monitoring").

Functions

5.11 Internal safe time delay

In the One protective function function mode, you can use the OSSDB safety-related switching outputs for a second time-delayed switching function, e.g. for an emergency mechanism following controlled switch-off via the OSSDA safety-related switching outputs.

NOTICE

If the protective function is required, restarting is not possible until the set delay time has expired.

Activation of the function

Ä Activate the internal safe time delay and the switch off delay time in the configuration and diagnostics

software (see chapter 9.4.3 "Activating protective function and contactor monitoring").

5.12 EDM contactor monitoring

The EDM contactor monitoring function dynamically monitors the contactors, relays or valves connected downstream of the safety sensor. Prerequisite for this are switching elements with positive-guided feedback contacts (normally closed contacts).

Activation of the function

Ä Activate the contactor monitoring function using the configuration and diagnostics software (see chap-

ter 9.4 "Configuring protective function").

If contactor monitoring is activated, it operates dynamically, i.e., in addition to monitoring the closed feedback circuit every time before the OSSDs are switched on, it also checks whether the feedback circuit has opened within 500ms after release and whether it has closed again within 500ms after the OSSDs switched off. If this is not the case, the OSSDs return to the OFF state after being switched on briefly. A message is displayed on the alphanumerical display and the safety sensor switches to the fault interlock state:

• With the OSSDs switched off, +24V must be present at the EDM input.

• With the OSSDs switched on, the EDM circuit must be open (high impedance).

Leuze electronic RSL 440 44

5.13 E-Stop linkage

Through linkage, the behavior of the safety sensor can be controlled via a two-channel safety circuit.

The upstream safety devices and operational controls perform safety-relevant switch-off of the safety-related switching outputs of the safety sensor.

The following upstream sensors and operational controls are possible regarding the linkage:

• Safety device with two-channel contact-based switching output (normally closed contact), e.g. safety switch, E-Stop rope switch, safety position switch and the like (see chapter 5.13.1 "Contact-based safety circuit").

• Safety device with two-channel electronic OSSD switching output (see chapter 5.13.2 "Linkage of electronic safety-related switching outputs").

E-Stop buttons connected to the safety sensor act only on the safety circuit to which the AOPD is assigned. Thus, it can be considered to be an area E-Stop. The regulations for E-Stops apply to it, including those in accordance with EN60204-1 and ENISO13850, among others.

Ä In this case, observe the regulations for E-Stops.

If linkage is utilized, the response time of the linked device is extended by 20ms.

Ä Take the extended response time into account when calculating the safety distance.

NOTICE

Extended response time in combination with an internal safe switching delay!

If the E-Stop linkage is used in combination with the internal safe time delay (see chapter 5.11 "Internal safe time delay"), the response time of the delayed switch-off increases by up to 40ms.

Ä Take the extended response time of the delayed switch-off into account when configuring

the system.

Functions

5.13.1

Contact-based safety circuit

This function switches off the safety-related switching outputs of the safety sensor by means of an upstream 2-channel contact-based safety circuit, e.g. by means of safety switches with separate actuators.

The safety sensor only switches on if the following conditions have been fulfilled:

• The protective field is free.

• The safety circuit is closed or both contacts have been closed simultaneously within 0.5s.

Activation of the function

Ä Activate the linkage using the configuration and diagnostics software (see chapter 9.4.3 "Activating pro-

tective function and contactor monitoring").

Leuze electronic RSL 440 45

Functions

5.13.2

Linkage of electronic safety-related switching outputs

This function is used to construct a serial connection of devices with electronic safety OSSD switching outputs. The OSSDs of an upstream safety device switch off the safety-related switching outputs of the safety sensor as a central safety device. Regarding the downstream safety circuit, a linked system behaves like a single device, i.e. only inputs are necessary in the downstream safety relay.

The following conditions have to be fulfilled for the OSSDs to switch on:

• The protective field must be free.

• The OSSDs of the upstream device must be switched on or have been switched on simultaneously within 0.5s.

NOTICE

A contact-based safety sensor, e.g. a safety switch with two positive-guided normally closed contacts, can be switched in the safety circuit when linking electronic safety-related switching outputs.

Ä If this switch opens, it must close both circuits again simultaneously within a time tolerance

of 0.5s. A message will otherwise be displayed on the safety sensor.

Activation of the function

Ä Activate the linkage using the configuration and diagnostics software (see chapter 9.4.3 "Activating pro-

tective function and contactor monitoring").

5.14 Signaling functions

The device and monitoring functions of the safety sensor deliver indication signals for the following function groups:

• Protective functions, e.g.

• Protective field violated

• Warning field violated

• Field pair changeover active

• Device functions

• Error messages

• Warnings

• Diagnosis

The assignment of the individual functions within the function groups to the indication signals is defined using the configuration and diagnostics software (see chapter 9.6 "Configuring signal outputs").

For an overview of all logic and electrical signals of the safety sensor, see chapter 15.4 "Representation of safety sensor status".

Leuze electronic RSL 440 46

6 Applications

The following chapters essentially describe the safety sensor's usage possibilities.

• To safely mount the safety sensor for the respective application, see chapter 7 "Mounting".

• For the electrical connection of the safety sensor, see chapter 8 "Electrical connection".

• To safely configure the safety sensor for the respective application, see chapter 9 "Configuring the safety sensor".

6.1 Stationary danger zone guarding

Stationary danger zone guarding enables a very spacious protection of people on machines that are to remain as accessible as much as possible. The safety sensor is applied as a stop-activating and presencedetecting protective device. The safety sensor's protective field is set up horizontally in front of the machine or system's point of operation.

You can also use the stationary danger zone guarding if you do have to guard areas under the machine or at the rear that are not visible.

If the danger zone changes during operation, the respective danger zone is guarded by means of a field pair changeover while the working area is accessible.

Applications

1 Safety sensor 2 Danger zone, protective function activated

Fig.6.1: Stationary danger zone guarding

Leuze electronic RSL 440 47

Applications

Guarding of two danger zones

The safety sensor allows two danger zones to be guarded simultaneously and independently. The dangerous machine or system parts (e.g. different movement areas of robots, telpher line) are actuated separately. If a protective field violation occurs, only the movement of the affected part of the system is stopped.

The protective function for each danger zone is defined separately using the configuration and diagnostics software (see chapter 9.4 "Configuring protective function").

1 Safety sensor 2 Danger zone 1, protective function activated 3 Danger zone 2, protective function deactivated

Fig.6.2: Stationary danger zone guarding for two danger zones

6.2 Stationary point of operation guarding

Hand and arm protection are always required when people must work at the point of operation. The safety sensor is applied as a stop-activating and presence-detecting protective device. The safety sensor's protective field is set up vertically in front of the machine or system's point of operation. In accordance with ENISO13855, resolutions from 14to40mm make sense here. This yields the necessary safety distance for finger protection, amongothers (see chapter 7.3 "Stationary point of operation guarding").

Leuze electronic RSL 440 48

6.3 Stationary access guarding

Stationary access guarding protects people that step into a danger zone. The vertically aligned protective field of the safety sensor detects the passage of a person. A side post and the floor serve as reference contour for monitoring the position of the protective field. In contrast to danger zone guarding, the safety sensor no longer registers a person in the danger zone after the passage. This is why the start/restart interlock function is vital for access guarding.

Applications

1 Safety sensor 2 Reference contour 3 Danger zone 1, protective function activated 4 Danger zone 2, protective function deactivated

Fig.6.3: Stationary access guarding

Leuze electronic RSL 440 49

6.4 Mobile danger zone guarding

Mobile danger zone guarding protects people that are located in the transportation path of a driverless transportation system (DTS). The distance between the protective field front edge and the vehicle front must be greater than the stopping distance of the vehicle with selected speed and maximum load. A safe control system selects speed-dependent protective fields and can activate side horizontal protective fields for curved stretches.

Applications

1 Warning field for forward travel 2 Protective field 1 for forward travel, deactivated 3 Protective field 2 for forward travel, activated 4 Protective field 1 for reverse travel, activated 5 Protective field 2 for reverse travel, deactivated 6 Warning field for reverse travel

Fig.6.4: Mobile danger zone guarding

Leuze electronic RSL 440 50

Applications

Fig.6.5: Mobile danger zone guarding

Leuze electronic RSL 440 51

6.5 Danger zone safeguarding on side-tracking skates

Side-tracking skate guarding

Side-tracking skate guarding protects personnel who are located in the transportation path of a transverse side-tracking skate (TSS). One safety sensor is mounted in each direction of travel. The safety sensor that is mounted opposite the current direction of travel is deactivated. Evaluation of the warning field allows the transverse side-tracking skate to be braked gently. To ensure optimum material transport, the control changes over the protective/warning field pair depending on the state and speed.

Mobile side guarding

Mobile side guarding protects people and objects that are located on the vehicles path. This application is used when very low arranged roller conveyors do not permit an unobstructed passage of horizontal, lateral protrude protective fields. The safety sensors are positioned laterally and the protective fields are arranged vertically, at a slight tilt. The position of the front edges of the side protective fields is oriented here on the position of the front edge of the horizontal protective field.

Applications

1 Protective and warning field pair for forward travel, activated 2 Protective and warning field pair for side guarding, left, activated 3 Protective and warning field pair for side guarding, right, activated 4 Protective and warning field pair for reverse travel, deactivated

Fig.6.6: Mobile side guarding on side-tracking skates

Leuze electronic RSL 440 52

6.6 Vehicle navigation

NOTICE

This function is only available with RSL445 devices.

The measurement data cyclically transmitted by the safety sensor can be used for navigation by driverless transportation systems.

For each measurement point of the scan level, values for distance and signal strength are part of the measurement data. A navigation system evaluates the measurement data and calculates the position of the vehicle. With the help of the transmitted signal strength, highly reflective landmarks can be detected.

Applications

6.6.1

1 Safety sensor 2 Retro-reflector

Fig.6.7: Vehicle navigation

In addition to the measurement data, a status profile of the safety sensor is also transmitted. The status profile contains information about the status of the inputs and outputs as well as other status information. The status profile thereby offers a possibility for performing diagnostics on the safety sensor.

You can find additional information in document RSL400 UDP specification, which is available for download on the Leuze electronic website: www.leuze.com

Signal strength and reflector detection

NOTICE

This function is only available with RSL445 devices.

The signal strength transmitted via UDP is a measure of the the optical power received by the safety sensor, which is largely dependent on the following values:

• Distance

• Brightness of the object or structure of the object surface

• Angle of incidence of the laser beam on the object surface 0°: vertically incident light

• Share of area of the light spot on the object 100%: the light spot lies completely on the measured object

Leuze electronic RSL 440 53

Applications

The signal strength transmitted by the safety sensor can be used to navigate automated guided vehicles. The transmitted signal strength value is a unitless, non-calibrated measurement value that is output unprocessed by the safety sensor.

To navigate automated guided vehicles, highly reflective landmarks are distinguished from the less-reflective surroundings. These landmarks usually consist of retro-reflector films.

Retro-reflectors can be identified by analyzing the signal strength values. If the signal strength exceeds a limit value, a retro-reflector can be mapped at this angle. Reliable detection of retro-reflectors is normally possible with a signal strength limit value of 180 or higher at a distance > 0.6 m.

For reflective surfaces, the safety sensor usually measures a signal strength value of maximum 500. Signal strength values > 500 can be caused by object edge effects and do not normally correspond to any real object diffuse reflection.

Due to the narrow light spot of the RSL400, object edge effects rarely occur. Object edge effects can be caused if a light beam is incident on multiple objects at different distances.

1 Object distance [m] 2 Signal strength 3 Retro-reflector film 4 White surface

Fig.6.8: Signal strength curves depending on the distance

The figure shows a typical curve of the signal strength transmitted by the safety sensor as a function of the measured object distance and object diffuse reflection for the following boundary conditions:

• Angle of incidence of the laser beam: 0°

• Share of area of the light spot on the object: 100%

The upper curve (3) represents the typical, distance-dependent change of the signal strength for a typical retro-reflector film, e.g., 3M™ Diamond Grade 983-10™.

The lower curve (4) shows the typical, distance-dependent change of the signal strength for a white, naturally scattering surface with 90% diffuse reflection, e.g., a white wall.

Leuze electronic RSL 440 54

7 Mounting

The safety sensor's protective function is only guaranteed when the device arrangement, configuration, protective field dimensioning and mounting are coordinated with the respective application.

The installation work must only be performed by a competent person in compliance with the applicable standards and these instructions. The mounting must be thoroughly inspected on completion.

Ä You must observe and comply with the respective relevant machine-specific standards and regulations

(see chapter 16 "Standards and legal regulations").

Ä Observe the basic information on mounting (see chapter 7.1 "Basic infos").

Improper mounting may result in serious injury!

The protective function of the safety sensor is only ensured if appropriately and professionally mounted for the respective, intended area of application.

Mounting

WARNING

Ä Only allow competent persons to install the safety sensor. Ä Maintain the necessary safety distances (see chapter 7.1.1 "Calculation of safety dis-

tanceS").

Ä Make sure that stepping behind, crawling under or stepping over the protective device is reli-

ably ruled out and reaching under, over or around is taken into account in the safety distance, if applicable with additional distanceCRO corresponding to ENISO13855.

Ä Take measures to prevent that the safety sensor can be used to gain access to the danger

zone, e.g. by stepping or climbing into it.

Ä Observe the relevant standards, regulations and these instructions. Ä After mounting, check the safety sensor for proper function. Ä Clean the safety sensor at regular intervals.

Environmental conditions: see chapter 15 "Technical data" Care: see chapter 13 "Care, maintenance and disposal"

7.1 Basic infos

7.1.1

Calculation of safety distanceS

Optical protective devices can only perform their protective function if they are mounted with adequate safety distance. When mounting, all delay times must be taken into account, such as the response times of the safety sensor and control elements as well as the stopping time of the machine, among others.

The following standards specify calculation formulas:

• ENISO13855, "Safety of machines - The positioning of protective device in respect of approach speeds of parts of the human body": mounting situation and safety distances.

General formula for calculating the safety distanceS of an Optoelectronic Protective Device acc. to ENISO13855

S [mm] = Safety distance K [mm/s] = Approach speed T [s] = Total time of the delay, sum from (ta+ti+tm) t

C [mm] = Additional distance to the safety distance

[s] = Response time of the protective device [s] = Response time of the safety relay [s] = Stopping time of the machine

NOTICE

If longer stopping times are determined during regular inspections, an appropriate additional time must be added to tm.

Leuze electronic RSL 440 55

Mounting

7.1.2

Suitable mounting locations

Area of application: mounting

Tester: Technician who mounts the safety sensor

Tab.7.1: Checklist for mounting preparations

Check: Yes No

Is the safety distance to the hazard location maintained?

Has the scanning angle of the safety sensor as given on the marking/template on the top of the sensor been taken into consideration?

Can the point of operation or the danger zone only be accessed through the protective field?

Have measures been taken to prevent the protective field from being bypassed by crawling under?

Is stepping behind the protective device prevented or is mechanical protection available?

Can the safety sensors be fastened in such a way that they cannot be moved and turned?

Is the safety sensor accessible for testing and replacing?

Is it impossible to actuate the reset button from within the danger zone?

7.1.3

Can the entire danger zone be seen from the installation site of the reset button?

NOTICE

If you answer one of the items on the checklist with no, the mounting location must be changed.

Mounting the safety sensor

NOTICE

Detailed information on mounting the safety sensor can be found in the document "Quick Start Guide RSL400".

Proceed as follows:

Ä Calculate the necessary safety distance and determine the required additional distances for your appli-

cation.

Ä Determine the mounting location.

• Observe the information regarding the mounting locations; see chapter 7.1.2 "Suitable mounting locations"

• Ensure that machine parts, safety guards or covers do not impair the safety sensor's field of vision.

• Make sure that the scanning range of the safety sensor is not limited. To mount the safety sensor taking the scanning range into consideration, a template must be attached to the top cover of the safety sensor.

Leuze electronic RSL 440 56

all dimensions in mm

1 Safety sensor 2 Template (markings on safety sensor) 3 Mounting location 4 Reference point for distance measurement and protective field radius 5 Area with unobstructed view; must remain free

Mounting

Fig.7.1: Mounting taking the scanning range of 270° into consideration

all dimensions in mm 1 Scan level 2 Area with unobstructed view; must remain free (40mm)

Fig.7.2: Mounting: area with unobstructed view

Ä Determine whether you are going to install the safety sensor with or without the mounting system.

During mounting, use the four supplied M5 screws or four similar screws with a diameter of 5mm, and make certain that the mounting elements or mounting construction supports at least four times the weight of the device with or without mounting system.

Ä Have the appropriate tools at the ready and mount the safety sensor. Ä Install protective enclosures or safety bars if the safety sensor is in an exposed position. Ä If there is a risk that the safety sensor will be used as a climbing aid, install a suitable physical cover

over the safety sensor.

Leuze electronic RSL 440 57

Mounting

Ä Align the mounted safety sensor horizontally and vertically using the integrated electronic spirit level.

• For the electronic spirit level to work, the supply voltage of 24V must be present at the safety sensor.

• The electronic spirit level indicates the vertical (V) and horizontal (H) alignment of the safety sensor. The spirit level is displayed

• permanently after the end of the booting phase/start phase when starting without configuration

• repeatedly until the end of the booting phase/start phase when starting with configuration

• using the configuration and diagnostic software: Diagnosis > [Align sensor mechanically] button ( )

• When mounting without a mounting system, the safety sensor can be aligned only slightly along the horizontal axis.

Ä Attach safety notice stickers to the mounted safety sensor (the stickers are included in the delivery con-

tents).

Ä Configure the safety sensor with the configuration and diagnostics software; see chapter 9 "Configuring

the safety sensor":

• Observe the information on the response times, the stopping time of the machine and the protective field dimensioning for your application.

• Determine the size of the protective field on the basis of the mounting location, the calculated safety distances and additional distances.

NOTICE

Protective fields with a radius of less than 200mm (safety sensor short range) are not permitted and are therefore preset as minimum contour.

• Configure the protective field so that the safety-related switching outputs are switched off from every accessible point with sufficient minimum distanceD.

• Determine the start-up/restart operating mode required for the application.

• If you are using start and/or restart interlock, determine the position for the reset button.

• Many safety-relevant parameters are preset for each application in the configuration and diagnostics software. Use these preset values where possible.

• Determine the conditions for the field pair changeover and the sequence of the field pair changeover.

Ä Create a record document for the device configuration and protective field dimensioning.

• The document must be signed by the person responsible for the configuration.

• Include this document with the machine documentation.

Ä Mark the protective field boundaries on the floor.

You can easily test the safety sensor along this marking.

After mounting, you can electrically connect (see chapter 8 "Electrical connection"), start up, align (see chapter 10 "Starting up the device"), and test (see chapter 11 "Testing") the safety sensor.

Leuze electronic RSL 440 58

Mounting

54,6

7.1.4

Mounting examples

all dimensions in mm 1 Safety sensor 2 Column 3 BT856M mounting bracket

Fig.7.3: Example: mounting on a post

all dimensions in mm 1 Safety sensor 2 BT840M mounting bracket

Fig.7.4: Example: mounting on a chamfered corner

Leuze electronic RSL 440 59

2 3

1 BTF815M mounting bracket (only in combination with the BTU800M mounting system) 2 BTU800M mounting system 3 Safety sensor

Mounting

7.1.5

Fig.7.5: Example: mounting on floor

Information on protective field dimensioning

NOTICE

Protective fields with a radius of less than 200mm (safety sensor short range) are not permitted and are therefore preset as minimum contour.

Ä Dimension the protective field big enough that the safety sensor's switching signal can stop the danger-

ous movement in good time. If several protective fields are selected with field pair changeover, this condition applies for all protective fields. Protective fields with a radius of less than 200mm (safety sensor short range) are not permitted and are therefore preset as minimum contour.

Ä If you cannot sufficiently dimension a protective field, use additional protective measures, e.g. safety

guards.

Ä Ensure that the protective field cannot be walked behind in the direction of the danger zone. Ä Observe all delay times, e.g. safety sensor response times, control element response times, braking

times or machine or driverless transportation system stopping times (DTS).

Ä Take changed delay times, which, for example, can be caused by reducing the braking force, into ac-

count.

Ä Observe shadowing effects, e.g. surfaces and areas behind static objects. People in the shadows of

these objects will not be detected by the safety sensor.

Ä Observe the lateral tolerance when dimensioning the protective fields (see chapter 15 "Technical

data").

Ä Do not use cone-shaped protective field contours, as these do not guarantee any protective function. Ä Take the additional distances required for the application into account.

Handling unmonitored areas

There is an area behind the safety sensor that the safety sensor does not monitor. Unmonitored areas can also materialize, e.g. if you install a safety sensor on a rounded off vehicle front.

It must not be possible to walk behind unmonitored areas.

Leuze electronic RSL 440 60

2 3

1 Safety sensor

4 5 4 53

2 Protective field 3 Unmonitored area;

Optimum availability at a distance of 50mm to fixed contours

Mounting

Fig.7.6: Unmonitored area

Ä Prevent access to an unmonitored area with screens. Ä Prevent walking behind by countersinking the safety sensor into the machine contour.

1 Countersinking into the machine contour, min. 100mm 2 Minimum distance above the scanner unit, min. 34mm 3 Protective field 4 Safety sensor 5 Machine 6 Angled physical cover

Leuze electronic RSL 440 61

Fig.7.7: Stepping behind protection by countersinking into the machine contour

Mounting

2 23

4 4

1 1

Ä Use a physical cover set at an angle over the safety sensor if you expect that the safety sensor will be

used as a climbing aid or standing surface.

Protective field setup with adjacent safety sensors

The safety sensor has been developed in a way that prevents several safety sensors from interfering with one another as much as possible. Nevertheless, if several safety sensors are positioned adjacent to each other, this may result in a reduction in the availability of the safety sensors.

Ä When mounting the safety sensor, avoid glossy surfaces directly behind the optics cover. Ä Plan for shielding with stationary applications.

The shielding must be at least as high as the safety sensor's optics cover and embedded with the front housing edge. If you plan for a shielding that is still within the countersinking in the machine contour, the resolution of the protective fields must not be impaired at any accessible points. You require the reciprocal shielding with both horizontal and vertical alignment of the protective fields.

1 Point of operation 2 Safety sensor 3 Machine with countersinking for sensor installation 4 Protective fields 5 Shielding

Fig.7.8: Shielding prevents reciprocal influencing of safety sensors set up beside one another

Ä Install the safety sensors off-set on the height.

1 Minimum distance, min. 100mm 2 Scan level

Fig.7.9: Height offset mounting, parallel alignment

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Ä Install the safety sensors with crossed alignment.

1 Scan level

Fig.7.10: Mounting beside one another, without height offset, crossed alignment

Mounting

1 Scan level

Fig.7.11: Mutually opposing mounting, without height offset, crossed alignment

7.2 Stationary danger zone guarding

The safety sensor takes over the stop-activating and presence-detecting function.

Calculation of safety distanceS for parallel approach to the protective field

S K [mm/s] = Approach speed for danger zone guarding with approach direction parallel to the protective

T [s] = Total time of the delay, sum from (ta+ti+tm) t

C [mm] Additional distance for danger zone guarding with approach reaction

Response times, stopping time of the machine

The safety sensor's rotary mirror rotates on its own axis every 40ms. One revolution is a scan. At least two consecutive scans must be interrupted so that the safety-related switching outputs switch off. The safety sensor's minimum response time is therefore 80ms.

If you want to increase the safety sensor's availability in an environment with fine particles, increase the number of interrupted scans after which the safety-related switching outputs switch off. With each additional scan the response time ta increases by 40ms. With K=1600mm/s the safety distance increases by 64mm per additional scan.

Ä Select a response timeta of at least 120ms or higher. Ä Determine the machine/system's stopping timetm.

Ä If an increase in the stopping time within the regular test periods is to be expected, take an additional

[mm] = Safety distance

field (resolution up to 90mm): 1600mm/s

[s] = Response time of the protective device [s] = Response time of the safety relay [s] = Stopping time of the machine

H=height of the protective field, H than0, d=resolution of the protective device C=1200mm-0.4×H; H

If data is not available, you can commission Leuze electronic to perform measurements; see chapter 14 "Service and support".

time into account for the machine's stopping timetm.

=minimum installation height permitted, but no smaller

min

=15×(d-50)

min

Leuze electronic RSL 440 63

Additional distanceC for danger zone guarding with approach reaction

You prevent reaching the point of operation by reaching over with the additional distanceC:

H [mm] = Height of protective field above floor (installation height) C H

[mm] = 850mm

MIN

[mm] = 1000mm

MAX

The minimum permissible installation height depends on the resolution of the safety sensor:

Tab.7.2: Additional distanceC depending on the resolution of the safety sensor

Mounting

Safety sensor resolution (mm) Minimum permissible installation

height (mm)

Additional distance C (mm)

50 0 1200

60 150 1140

70 300 1080

Application-related additional distances for safety distanceS

The protective field boundaries must be defined so that the calculated safety distance S to the point of operation, extended by the additional distances, is complied with everywhere. Where this is not possible or does not make sense, you can use hard guards as supplementary measures.

1 Routing machine with free space for sensor protective field in the area under the machine table 2 Safety sensor 3 Protective field contour 4 Warning field contour S Calculated safety distanceS D Minimum distanceD (= safety distanceS + additional distanceZSM + Z R

Fig.7.12: Defining the protective field contour for a stationary, horizontal protective field

Largest protective field radius without additional distances, measured from the rotation axis of the rotary

mirror

, where required)

REFL

Leuze electronic RSL 440 64

Mounting

Ä Define the limits of the protective field using the safety distance S without an additional distance. Ä Determine the biggest protective field radius RG for this protective field.

The biggest protective field radius determines the additional distanceZSM for the system-related measurement error, by which the protective field contour must be enlarged. The position of the rotary mirror's center point with regard to the housing is provided by the dimensioned drawings.

Tab.7.3: Additional distance ZSM for the protective field contour because of measurement error

Biggest protective field radiusRG without additional distances Additional dis-

tanceZ

< 6.25m 100mm

> 6.25m 120mm

Ä Avoid retro-reflectors at the beam level beyond the protective field boundaries. If this is not possible,

add another additional distanceZ

of 100mm.

REFL

Minimum distanceD to the protective field contour

The minimum distanceD is the distance between point of operation and protective field contour.

D [mm] = Minimum distance between the point of operation and the protective field contour Z Z

[mm] = Additional distance for system-related measurement error

[mm] = Additional distance for retro-reflectors

REFL

Ä If the protective field runs up against fixed boundaries, such as walls or machine frames, take a coun-

tersinking into the machine contour of at least the size of the necessary additional distance ZSM, and Z

where required, into account. With the protective field contour under these conditions, stay about

REFL

50mm away from the machine surface.

Ä If the protective field runs up against hard guards, ensure that the protective field ends under instead of

in front of the hard guards. The width of the lower post must correspond with the size of the required additional distances.

Ä If all hazards in the fenced off area are covered by the safety sensor and the height of the beam level is

300mm, you can raise the bottom edge of the hard guards from 200 mm to 350 mm in the protective field range. The protective field reaching to under the hard guards takes over the protective function of preventing an adult from crawling under in this case.

NOTICE

The beam level of the safety sensor is level with the alphanumerical display.

Ä Prevent obstructions within the calculated protective field boundaries. If this is not possible, implement

protective measures so that the point of operation cannot be reached from out of the shadow of the obstruction.

Leuze electronic RSL 440 65

7.3 Stationary point of operation guarding

The safety sensor takes over the stop-activating and presence-detecting function.

Calculation of safety distanceSRO for access over the vertical protective field

Mounting

S K [mm/s] = Approach speed for point of operation guarding with approach reaction and normal approach

T [s] = Total time of the delay, sum from (ta+ti+tm) t

[mm] = Safety distance

direction to the protective field (resolution 14to40mm): 2000mm/s or 1600mm/s, when SRO>500mm

[s] = Response time of the protective device [s] = Response time of the safety relay [s] = Stopping time of the machine [mm] = Additional distance in which a body part can move towards the protective device before the

protective device triggers

Response times, stopping time of the machine

The safety sensor's rotary mirror rotates on its own axis every 40ms. One revolution is a scan. With each additional scan the response time ta increases by 40ms. With K=2000mm/s approach speed this corresponds with an increase in the safety distance of 80mm per additional scan. With K=1600mm/s it is 64mm.

Ä Select a response timeta of at least 80ms or higher. Ä Determine the machine/system's stopping timetm.

If data is not available, you can commission Leuze electronic to perform measurements (see chapter 14 "Service and support").

Ä If an increase in the stopping time within the regular test periods is to be expected, take an additional

time into account for the machine's stopping timetm.

Additional distanceCR0 for finger protection

The required finger protection is ensured here by an additional distance C, which depends on the safety sensor resolution, in addition to the safety distance.

• Detection of an adult's hand:

• Resolution: 30mm

• Additional distance CRO: 128mm

• Arm detection:

• Resolution: 40mm

• Additional distance CRO: 208mm

Protective field contour and reference contour

With a vertical protective field, you must define at least two sides of the protective field contour as reference contour. The objective is to monitor the position of the protective field with regard to its marginal area. If the arrangement misaligns and the distance of the safety sensor to the reference surface changes as a result, switch the safety-related switching outputs off.

Leuze electronic RSL 440 66

Mounting

1 Physical frame for reference contour 2 Reference contour, must cover at least two sides of the protective field 3 Safety sensor 4 Distancee between the reference contour frame and machine opening, recommended: e=150mm 5 Machine opening contour

Fig.7.13: Defining the protective field contour and reference contour, stationary point of operation guarding, verti-

cal protective field

7.4 Stationary access guarding

The vertical protective field used for access guarding only detects people during passage through. After a person has passed through, a start/restart interlock must ensure that the dangerous movement does not start again automatically.

S K [mm/s] = Approach speed for access guarding with approach direction orthogonal to the protective

T [s] = Total time of the delay, sum from (ta+ti+tm) t

Response times, stopping time of the machine

Ä Select a response timeta of 80ms or higher.

Ä Determine the machine/system's stopping timetm.

Ä If an increase in the stopping time within the regular test periods is to be expected, take an additional

[mm] = Safety distance

field: 2000mm/s or1600mm/s, when SRT>500mm

[s] = Response time of the protective device, max. 80ms [s] = Response time of the safety relay [s] = Stopping time of the machine [mm] = Additional distance for access guarding with approach reaction with resolutions of

14to40mm, d=resolution of protective device CRT=8×(d-14)mm. Additional distance for access guarding for resolutions>40mm: CRT=850mm (standard value for arm length)

Never define a value higher than 80ms for ta for access guarding or passage controls. With higher values it can happen that a person might not be detected when passing through the protective field with an approach speed of 1600mm/s.

If data is not available, you can commission Leuze electronic to perform measurements (see chapter 14 "Service and support").

time into account for the machine's stopping timetm.

Leuze electronic RSL 440 67

Mounting

Additional distanceCRT for finger protection

The required finger protection is ensured here by an additional distance C, which depends on the safety sensor resolution, in addition to the safety distance.

• Detection of an adult's hand:

• Resolution: 30mm

• Additional distance CRT: 128mm

• Arm detection:

• Resolution: 40mm

• Additional distance CRT: 208mm

Protective field contour and reference contour

Ä When defining the protective field ensure that there are no gaps bigger than 150mm. Ä When defining the protective field boundaries, specify the sectors that monitor the position of the pro-

tective field as reference contour.

7.5 Mobile danger zone guarding on DTSs

Danger zone guarding protects people and objects that are in rooms in which vehicles move in, e.g. automated guided vehicle systems (DTSs).

A horizontally arranged protective field protects people and objects that are in the vehicle's path and are detected by the front edge of the protective field.

WARNING

Danger of injury because of insufficient vehicle stopping distance

Ä The operator of the machine must use organizing measures to prevent people from entering

the protective field of the vehicle from the sides or being able to move towards an approaching vehicle.

Ä Only use the safety sensor on vehicles with electrical drive and electrically influenced drive and braking

devices.

Ä Only install the safety sensor on the front of the vehicle.

If you must also guard the reverse travel, you must also install a safety sensor on the rear of the vehicle.

Ä Mount the safety sensor on the vehicle so that there are no unmonitored areas ≥70mm between the

protective field and vehicle front.

Ä Set the mounting height such that the beam level is not more than 200mm above the floor.

A person lying on the floor can therefore be safely detected. This is required by the C standard, EN1525 "Safety of industrial trucks – Driverless corridor supply vehicles and their systems".

NOTICE

The beam level of the safety sensor is level with the alphanumerical display.

Leuze electronic RSL 440 68

Mounting

D · L · L

V · (T +T )

max

GES

200

7.5.1

Minimum distanceD

D [mm] = Minimum distance, vehicle front (danger) to protective field front edge D Z

[mm] = Stopping distance

[mm] = Sum of required additional distances

TOT

Fig.7.14: Mobile danger zone guarding, calculation of required minimum distanceD

Stopping distanceD

D v T T D L L

[mm] = Stopping distance

[mm/s] = Maximum vehicle speed

max

[s] = Response time of the safety sensor

[s] = Response time of the FTS

[mm] = Braking distance with v

[---] = Factor for brake wear

[---] = -Factor for problematic floor conditions, e.g. dirt, wet conditions

and maximum vehicle load

max

Additional distancesZ

Z Z

[mm] = Total of the required additional distances

tot

[mm] = Additional distance for system-related measurement error, see chapter 7.2 "Stationary dan-

ger zone guarding"

[mm] = Additional distance required with lack of floor space H

[mm] = Additional distance required with retro-reflectors beyond the protective field boundaries;

REFL

=100mm

The additional distanceZSM is always required. Its size depends on the biggest radius RG from the safety sensor mirror's rotary axis to the protective field boundary without Z

. The position of the rotary mirror axis

Tot

depends on the installation situation.

Leuze electronic RSL 440 69

Mounting

100

120

100

120

140

160

GES

The additional distanceZF is required if the vehicle does not have enough free floor spaceHF and there is therefore no space under the vehicle or the safety sensor for the tips of the feet. You determine the additional distanceZF according to the following diagram:

7.5.2

Fig.7.15: Diagram for determining the additional distanceZF with lack of floor spaceH

If wheels are mounted near the side wall, always add an additional distanceZF > 150mm.

Protective field dimensions

D Minimum distance, vehicle front (danger) to protective field front edge D

TOT

Fig.7.16: Mobile danger zone guarding, dimensions for horizontal protective field

Ä Select 70mm resolution.

Stopping distance

Total required additional distances to the front and for both sides

Distance from safety sensor center to left vehicle edge

Distance from safety sensor center to right vehicle edge

Biggest radius in the protective field without Z

for determining the additional distance Z

TOT

Ä Set the protective field length so that the response time until braking and the braking distance, including

factors for wear and tear and floor conditions, and any necessary additional distances are taken into account.

Ä Arrange the protective field symmetrically with reference to the vehicle width, even if the safety sensor

is not arranged centered.

Ä Configure an upstream warning field that reduces the vehicle's speed.

A full brake with a subsequent interruption of the protective field is then executed moderately and is less demanding on the vehicle's drives. Dimension the minimum distance D for the maximum speed as if the speed reduction initiated by the warning field had not happened.

Leuze electronic RSL 440 70

Ä Take the required free space for lateral protrude protective fields under the roller conveyors along the

transportation path into account.

Ä If you have to expect angular deviations of the vehicle during the travel, plan an additional tolerance

area to guarantee undisturbed travel operation.

7.6 Mobile side guarding on DTSs

WARNING

Danger of injury because of insufficient vehicle stopping distance

Ä The operator of the machine must use organizing measures to ensure that people cannot

enter the vehicle's protective field from the side.

Ä For mobile vertical protective fields use a resolution of at least 150mm. Ä Position the protective field edges in the travel direction in accordance with the front protective field

edge of the horizontal protective field.

Ä Ensure that the response times of all components of the switch-off circuit are the same or balance the

response times with different protective field dimensioning.

Ä Set the vertical protective fields at a slight angle so that the lower protective field edges protrude over

the vehicle width by the amount of the additional distances, ZSM, ZF and Z ter 7.5.2 "Protective field dimensions".

Mounting

where required; see chap-

REFL

7.7 Mounting accessories

7.7.1

Mounting system

Using the mounting system you can adjust the safety sensor horizontally and vertically by ±10degrees when mounting.

Fig.7.17: BTU800M mounting system

NOTICE

Floor mounting only with mounting system BTU800M

Ä The mounting system BTU800M must be used in the case of installation using the mounting

bracket for floor mounting.

Ä Install the wall mount or mounting bracket for floor mounting on the system side. Ä Mount the mounting system on the wall mount or on the mounting bracket for floor mounting. Ä Attach the safety sensor to the mounting system.

Tightening the screws fixes the safety sensor in position.

Ä Align the safety sensor using the integrated electronic spirit level.

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Mounting

3 3

7.7.2

Loop guard

The loop guard for the optics cover prevents damage to the safety sensor caused by light contact with foreign objects.

NOTICE

The loop guard can only be used together with the mounting system BTU800M.

1 BTF815M mounting bracket for floor mounting (only with BTU800M mounting system) 2 BTU800M mounting system 3 Loop guard 4 Safety sensor

Fig.7.18: Loop guard

Ä Attach the safety sensor to the mounting system. Ä Engage the loop guard for the optics cover from above into the mounting system.

Leuze electronic RSL 440 72

8 Electrical connection

WARNING

Faulty electrical connection or improper function selection may result in serious injury!

Ä Only allow competent persons to perform the electrical connection. Ä For access guarding, activate the start/restart interlock and make certain that it cannot be

unlocked from within the danger zone.

Ä Select the functions so that the safety sensor can be used as intended (see chapter 2.1 "In-

tended use").

Ä Select the safety-relevant functions for the safety sensor (see chapter 5.2 "Function modes

of safety sensor").

Ä Always loop both safety-related switching outputs OSSD1 and OSSD2 into the work circuit

of the machine.

Ä Signal outputs must not be used for switching safety-relevant signals.

NOTICE

Laying cables!

Ä Lay all connection cables and signal lines within the electrical installation space or perma-

nently in cable ducts.

Ä Lay the cables and lines so that they are protected against external damages. Ä For further information: see EN ISO 13849-2, Table D.4.

Electrical connection

NOTICE

Observe the maximum cable length!

Observe the maximum cable lengths as a function of operating voltage and load current (see chapter 8.3 "Connection unit CU429").

NOTICE

Observe when wiring with terminals and connectors!

In the case of wiring that continues beyond the device or during repairs to connectors, the user must ensure that cables or conductors that have defectively disconnected cannot result in contact with other signals.

Ä Use suitable terminals. Ä Use heat-shrink tubing, wire-end sleeves or similar.

8.1 Electrical supply

see chapter 15.1 "General specifications".

Functional earth

NOTICE

Always connect the housing of the safety sensor to functional earth or ground!

Ä The housing of the safety sensor must always be connected to earth (functional earth) or

machine/vehicle ground.

Ä If the safety sensor is attached to a non-conductive material (e.g. a concrete wall), the hous-

ing of the safety sensor must be earthed.

• Factory recommendation: Functional earth via a ground strap/braid (low impedance for RF). Connection points for self-tapping screws used for the ground connection are provided and labeled on the bottom of the connection unit (see chapter 8.3 "Connection unit CU429").

Leuze electronic RSL 440 73

• Functional grounding via the shield of the connection cable. For grounding, the shield of the connection cable in the switch cabinet must be connected to earth or machine/vehicle ground.

8.2 Interfaces

The safety sensor has two interfaces:

• Interface for connection with the control system

• Interface for communication with PC or laptop

Tab.8.1: Interfaces

Interface Type Function

Control Connection cable, 29-wire • Power supply

Electrical connection

NOTICE

Make sure that potential equalization is provided!

Ä If the housing of the safety sensor or the mounting bracket – despite being mounted on a

non-conductive material – is connected to metallic parts (even temporarily), you must ensure that the appropriate potential equalization is provided between the switch cabinet and housing potential; e.g. by grounding the Ethernet connection.

• Switching lines and signal lines

8.2.1

Communication M12 – RJ45 Configuration interface and data interface:

• Parameter configuration

• Protective field definition and warning field definition

• Data transmission and measurement value transmission

• Diagnosis

The control cable is permanently attached to the connection unit. A protection cap on the connection unit protects the communication interface when no PC is connected.

Connection cable, control

The safety sensor is equipped with a 29-wire connection cable.

Tab.8.2: Connection cable, control

Core color Signal Description

White RES1 Start/restart input, protective functionA

Acknowledgment

Brown 24V Supply voltage

Green EA1 Contactor monitoring OSSDA

Alternatively: State signaling, configurable

Yellow A1 Output signal

State signaling, configurable

Gray OSSDA1 Safety-related switching output, protective functionA

Pink OSSDA2 Safety-related switching output, protective functionA

Blue 0V (GND) Supply voltage ground

Red MELD Output signal

State signaling, configurable

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Electrical connection

Core color Signal Description

Black F1 5 function inputs for field pair changeover, protective functionA

Violet F2

Gray/pink F3

Red/blue F4

White/Green F5

Brown/Green SE1 Linkage input (E-Stop, OSSD – external device)

White/Yellow SE2 Linkage input (E-Stop, OSSD – external device)

Yellow/Brown A2 Output signal

White/Gray A3 Output signal

Gray/Brown A4 Output signal

White/Pink EA2 Contactor monitoring OSSDB

Field pair changeover with 100 field pairs (A1.x) – 2nd position

Field pair changeover with multi configuration (A1.x) within one bank

State signaling, configurable

Alternatively: State signaling, configurable

8.2.2

Pink/Brown EA3 Input/output signal, configurable

White/Blue EA4 Input/output signal, configurable

Brown/Blue F6 5 function inputs for field pair changeover, protective functionB

White/Red F7

Brown/Red F8

White/Black F9

Brown/Black F10

Gray/Green RES2 Start/restart input, protective functionB

Yellow/Gray OSSDB1 Safety-related switching output, protective functionB

Pink/Green OSSDB2 Safety-related switching output, protective functionB

Connection cable with M30 connector

The safety sensor is equipped with a 30-pin M30 connector.

Field pair changeover with 100 field pairs (Ay.1) – 1st position

Bank changeover with multi configuration (Ay.1)

Acknowledgment

Fig.8.1: Pin assignment for M30 connector, 30-pin

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Electrical connection

Tab.8.3: Pin assignment

Pin Core color Signal Description

1 White RES1 Start/restart input

protective functionA acknowledgment

2 Brown 24V Supply voltage

3 Green EA1 Contactor monitoring OSSDA

Alternatively: State signaling, configurable

4 Gray OSSDA1 Safety-related switching output

protective functionA

5 Pink OSSDA2 Safety-related switching output

protective functionA

6 Red MELD Output signal

state signaling, configurable

7 Yellow A1 Output signal

state signaling, configurable

8 Black F1 5 function inputs for field pair changeover

9 Violet F2

protective functionA

Field pair changeover with 100 field pairs (A1.x) –

10 Gray/pink F3

11 Blue/red F4

12 White/Green F5

2nd position

Field pair changeover with multi configuration (A1.x) within one bank

13 Brown/Green SE1 Linkage input

(E-Stop, OSSD – external device)

14 White/Yellow SE2 Linkage input

(E-Stop, OSSD – external device)

15 Yellow/Brown A2 Output signal

state signaling, configurable

16 White/Gray A3 Output signal

state signaling, configurable

17 Gray/Brown A4 Output signal

state signaling, configurable

18 White/Pink EA2 Contactor monitoring OSSDB

Alternatively: State signaling, configurable

19 Pink/Brown EA3 Input/output signal, configurable

20 White/Blue EA4 Input/output signal, configurable

21 Brown/Blue F6 5 function inputs for field pair changeover

22 White/Red F7

protective functionB

Field pair changeover with 100 field pairs (Ay.1) –

23 Brown/Red F8

24 White/Black F9

1st position

Bank changeover with multi configuration (Ay.1)

25 Brown/Black F10

26 Yellow/Gray OSSDB1 Safety-related switching output

protective functionB

27 Pink/Green OSSDB2 Safety-related switching output

protective functionB

28 --- --- ---

29 Blue 0V (GND) Supply voltage ground

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Pin Core color Signal Description

M5 2x

30 Gray/Green RES2 Start/restart input

protective functionB acknowledgment

Electrical connection

8.2.3

Connector

Shield FE Functional earth, connection cable shield

housing

Pin assignment of M12 Ethernet interface (communication) ( D-coded)

The safety sensor is equipped with a 4-pin M12 connector.

Fig.8.2: Pin assignment of the Ethernet interface

Tab.8.4: Pin assignment of the Ethernet interface

PIN Signal Description

1 TD+ Data communication, transmission

2 RD+ Data communication, transmission

3 TD- Data communication, reception

4 RD- Data communication, reception

FE GND/shield Functional earth, communication cable shield. The shield of the inter-

connection cable is on the thread of the M12 plug. The thread is part of the metallic housing. The housing is at the same potential as functional earth.

8.3 Connection unit CU429

Fig.8.3: Connection unit CU429

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Electrical connection

Cable lengths as a function of operating voltage and load current

The maximum cable length is determined by voltage drops on the supply and signal lines.

The following conditions apply for the necessary operating voltage UB at the input terminals of the connection unit:

• UB must be greater than the permissible nominal voltage limit of 16.8V.

NOTICE

The recommended operating voltage is 19V!

Leuzeelectronic recommends an operating voltage UB of 19V at the input terminals of the connection unit.

Ä The operating voltage should not be allowed to drop below the recommended value if possi-

ble.

• The necessary operating voltage UB must also ensure the function of the downstream devices.

• Once the operating voltage UB has been determined, check whether the resulting signal voltages are sufficient for the downstream devices.

• Take into account the voltage drops in the safety sensor – up to 3.2V – and on the signal wiring.

1 Operating voltage [V] 2 Cable length [m] 3 ILoad = 0A 4 ILoad = 250mA 5 ILoad = 500mA 6 ILoad = 750mA 7 ILoad = 1A 8 ILoad = 1.25A 9 ILoad = 1.5A

10 ILoad = 1.65A

Fig.8.4: Diagram for estimating the voltage drop on the supply line

• Maximum load current: 1.65A with RSL400 cable 1mm2/AWG18 for supply and 0.14mm2/AWG26 for signals

NOTICE

Cable length and cable resistance with OSSD linkage!

When using the OSSD linkage function, observe the specifications of the upstream device for the cable length and for the maximum permissible cable resistance (see chapter 5.13.2 "Linkage of electronic safety-related switching outputs").

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Electrical connection

PNP/NPN changeover

The PNP/NPN changeover for signal inputs F1…F10, RES1, RES2 is performed via a jumper on the connection unit. The reference potential for the signal inputs is set via the jumper:

• P: reference potential +24V

• N: reference potential 0V (GND)

1 Jumper 2 Connection unit

Fig.8.5: Jumper for PNP/NPN changeover

NOTICE

PNP/NPN changeover occurs simultaneously for signals F1…F10, RES1, RES2.

8.4 Circuit diagram example

* Spark extinction circuit, suitable spark extinction provided

Fig.8.6: RSL440 with MSI-SR4B safety relay

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9 Configuring the safety sensor

To start up the safety sensor in your application, the safety sensor must be individually adapted using the software. All configuration data is defined using the configuration and diagnostics software.

General procedure for configuring safety sensor

Ä Assessing the risk

• The system has been determined and its boundaries defined.

• The safety sensor has been selected as the safety component.

• The type of guarding has been determined (danger zone guarding, point of operation guarding, access guarding).

Ä Calculating safety distance

Shape and size of the protective and warning fields

Ä Configuring the safety sensor

• Configuration and diagnostics software (see chapter 4 "Configuration and diagnostic software SensorStudio")

• Determine the configuration project (see chapter 9.3 "Determine the configuration project")

• Configure the protective function (see chapter 9.4 "Configuring protective function")

Ä Checking function (see chapter 11 "Testing")

Configuring the safety sensor

9.1 Defining safety configuration

WARNING

Serious accidents caused by incorrect safety configuration!

The protective function of the safety sensor is only ensured if the safety sensor is correctly configured for the intended application.

Ä Allow only competent persons to perform safety configuration. Ä Select the safety configuration so that the safety sensor can be used as intended (see chap-

ter 2.1 "Intended use").

Ä Select the protective field dimensions and contours according to the safety distance calcu-

lated for the application (see chapter 7.1.1 "Calculation of safety distanceS").

Ä Select the parameters of the safety configuration according to your risk analysis. Ä After start-up, check the function of the safety sensor (see chapter 11.1 "Before the initial

start-up and following modifications").

WARNING

Additional protection against manipulation when the monitoring time is increased!

If the monitoring time is increased to above 5s or if manipulation protection is deactivated, the system operator must introduce other measures to prevent manipulation.

Ä For example, make sure that the distance range in which manipulation is possible cannot be

accessed by personnel under normal operating conditions.

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Configuring the safety sensor

NOTICE

OSSDs will switch off if no reflection signals are being measured!

If the safety sensor is unable to measure any reflection signals in a continuous scanning angle of ≥90° for a long period of time, the safety-related switching outputs switch off. In certain application types (e.g. in buildings with extremely large distances), the safety sensor may not be able to measure any reflection signals. For such application types, it is possible to set or deactivate the monitoring times.

Ä In the CONFIGURATION menu, click the Other option.

ð The OTHER dialog box opens.

Ä In the PROTECTION AGAINST MANIPULATION dialog box, define the monitoring time ac-

cording to your specific conditions.

ð If the parking position is active, there will be no manipulation monitoring.

Prerequisites:

• The safety sensor is mounted (see chapter 7 "Mounting") and connected (see chapter 8 "Electrical connection") correctly.

• Dangerous process is switched off, outputs of the safety sensor are disconnected, and the system is protected against being switched back on.

• The size of the protective field is determined on the basis of the mounting location, the calculated safety distances and additional distances.

• The start/restart operating mode required by the application has been determined.

• The conditions for field pair changeover, if required, have been determined.

• The configuration and diagnostics software for the safety sensor is installed on the PC (see chapter 4.2 "Installing software").

NOTICE

Many safety-relevant parameters are preset for each application in the configuration and diagnostics software. Use these preset values where possible.

Procedure

All configuration data is defined using the configuration and diagnostics software.

To configure the safety sensor, proceed as follows:

Ä Connect the PC to the safety sensor Ä Start the software

• Set up communication

• Determine the configuration project

Ä Configure the protective function using the project wizard

• Protective/warning field configuration

• Resolution and response time

• Start-up behavior

• Contactor monitoring

• E-stop linkage

• Field pair changeover

• Configuration of the signal outputs

Ä Save configuration project Ä Transferring a configuration to the safety sensor Ä Create a record document for the device configuration and protective field dimensioning. The document

must be signed by the person responsible for the configuration. To document the configuration, you can create a PDF file of the safety configuration or save the configuration and settings in an *.xml file.

Leuze electronic RSL 440 81

NOTICE

The configuration data is stored in the connection unit of the safety sensor and is therefore also available after replacement or repair of the scanner unit. The configuration data only needs to be transferred again if changes are made to the configuration.

9.2 Connecting safety sensor to PC

Configuring the safety sensor

9.2.1

9.2.2

Connection via Ethernet cable

Connect the Ethernet cable to the PC or to the network; see the document "Quick Start Guide RSL400".

NOTICE

The TCP/IP protocol is used for communication via Ethernet.

NOTICE

In addition to configuration, you can also use the Ethernet interface to forward measurement data in real-time (process data) to another computer, e.g. for vehicle navigation. This process data cannot be used for safety-relevant purposes.

Connection via Bluetooth

NOTICE

No process data is transferred in the case of connection via Bluetooth.

Prerequisites: Bluetooth communication of the safety sensor has been activated (see chapter 9.2.3 "Communication between safety sensor and PC")

Ä Activate the Bluetooth interface on the PC. Ä Select the safety sensor as the device for the Bluetooth connection.

9.2.3

NOTICE

Distance between safety sensor and PC

The possible distance between safety sensor and PC depends on the quality of the Bluetooth adapter that is used. USB Bluetooth adapters with external rod antenna enable a larger operating range.

Communication between safety sensor and PC

The following communication settings are active when the safety sensor is delivered:

LAN

• DHCP: Obtain IP address automatically

Bluetooth

• Bluetooth module activated

• Device scan activated

You can change the communication settings on the PC using the configuration and diagnostics software in order to, for example, assign a permanent IP address to the safety sensor in your network.

Ä Start the configuration and diagnostics software on your PC. ð The mode selection of the Project Wizard is displayed.

ð If the mode selection is not shown, click the [Project Wizard] button ( ) in the menu bar of the soft-

ware to start the project wizard.

Leuze electronic RSL 440 82

Configuring the safety sensor

Ä Select the configuration mode and click [Next]. ð The Project Wizard displays the device selection list containing the configurable safety sensors. Ä Select the safety sensor from the device selection list and click [Next]. ð The initial screen for the configuration project is displayed together with information for identification of

the selected safety sensor.

Ä In the initial screen, click the SETTINGS tab. ð The SETTINGS menu opens.

Assign permanent IP address

Ä Select the menu command Communication > LAN. Ä In the DHCP dialog box, deactivate the Obtain IP address automatically checkbox. Ä In the CONNECTION SETTINGS dialog box, enter the IP address information.

Activating/deactivating the Bluetooth interface

Ä Select the menu command Communication > Bluetooth. Ä Activate/deactivate communication with the safety sensor via the Bluetooth interface using the Activate

Bluetooth module checkbox. If the Bluetooth module is deactivated, communication with the safety sensor via the Bluetooth interface is not possible.

Ä Activate/deactivate the Bluetooth device scan using the Activate device scan checkbox. If the device

scan is deactivated, the safety sensor will not be found during the Bluetooth device scan. To allow communication via the Bluetooth interface, you must enter the device identification of the safety sensor manually.

9.3 Determine the configuration project

Ä Start the configuration and diagnostics software on your PC. ð The mode selection of the Project Wizard is displayed.

ð If the mode selection is not shown, click the [Project Wizard] button ( ) in the menu bar of the soft-

ware to start the project wizard.

NOTICE

Ä Select the configuration mode and click [Next]. ð The Project Wizard shows the list of configurable safety sensors.

NOTICE

You can use a prepared configuration project as a template and make changes to it. To do so, select the configuration mode Open a stored project file.

If you want to load the configuration project currently stored in the safety sensor to the PC, select the configuration mode Device selection with device scan and establishment of connection (online).

Ä Select the safety sensor in the Sensor list and click OK.

Alternatively, you can select the safety sensor by entering the part number or by specifying the sensor range and the sensor type.

ð The device manager (DTM) of the safety sensor shows the initial screen for the configuration project.

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Configuring the safety sensor

1 Configuration Wizard

Fig.9.1: Safety configuration using Configuration Wizard

NOTICE

9.4 Configuring protective function

Prerequisites: The safety distance, additional distances and protective field dimensions and contours have been determined according to the mounting position (see chapter 7.1.1 "Calculation of safety distanceS").

Ä In the initial screen, click the CONFIGURATION tab. ð The CONFIGURATION menu opens with the options:

• Administration

• OSSDs If the OSSDs option is selected in the CONFIGURATION menu, the Protective function A option is displayed, if the One protective function function mode is selected. In the Two protective functions function mode, the options Protective function A and Protective function B are displayed.

• Changeover order The Changeover order option is only displayed if more than one protective/warning field pair is created (see chapter 9.4.4 "Creating and configuring protective/warning field pairs").

• Outputs

• Other

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Configuring the safety sensor

9.4.1

9.4.2

9.4.3

Creating simple safety configuration

To create a safety configuration for simple commissioning, you must first perform five configuration steps to access the editor used for defining the contours of the protective and warning fields.

By clicking [Next], you can proceed to the next configuration step without selecting the corresponding option in the CONFIGURATION menu.

If you make changes to the default settings in a configuration step, first click the [Confirm] button and then [Next].

Ä Administration Ä OSSDs Ä Protective function A Ä Bank A1 Ä Outputs

Entering administration parameters

Ä In the CONFIGURATION menu, click the Administration option. ð The ADMINISTRATION dialog box opens. Ä In the input fields, enter the device data and the project data for the configuration project.

Activating protective function and contactor monitoring

Ä In the CONFIGURATION menu, click the OSSDs option. ð The OSSDs dialog box opens. Ä In the FUNCTION MODE list, select the protective function of the safety sensor. ð The Protective functionA option is shown in the CONFIGURATION menu. ð The Protective functionB option is shown in the CONFIGURATION menu if Two protective functions

was selected in the FUNCTION MODE list.

NOTICE

The changeover-capable protective/warning field pairs for the selected protective function are defined in configuration banks.

Ä In the Switch off delay time input field, select the internal safe time delay for switching off the OSSD-B

outputs if One protective function was selected in the FUNCTION MODE list.

Ä In the CONTACTOR MONITORING list, activate the contactor monitoring of the safety sensor:

• EDM OSSD A

• EDM OSSD B

• E-Stop

• OSSD linkage

NOTICE

The activated contactor monitoring (EDM) is assigned to indication signal outputs EA1 and/or EA2. These signal outputs are thus disabled for the configuration of the signal outputs.

Ä Click the [Confirm] button.

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Configuring the safety sensor

9.4.4

Creating and configuring protective/warning field pairs

The changeover-capable protective/warning field pairs for the selected protective function are defined in configuration banks. The configuration banks are shown in the navigation tree of the configuration menu as "Bank", e.g. Bank A1.

Configuring protective/warning field pairs for tow protective functions

NOTICE

Configuration of the protective and warning field pairs is described for the One protective function function mode (Protective functionA). If you have selected Two protective functions as the

function mode, you must also configure the banks and field pairs for Protective functionB following the described procedure.

Creating banks

Ä In the CONFIGURATION menu, click the Protective functionA option. ð The PROTECTIVE FUNCTIONA dialog box opens. Ä Enter the description of the protective function in the input field. Ä In the CONFIGURATION menu, right-click the Protective functionA option.

Select Add configuration bank.

ð The Add bank dialog box opens. Ä In the Bank list, select the number of the bank and click the [Add] button.

When you have added all banks for the protective function, click [Close].

ð The Bank[x] option is shown for each added bank under Protective functionA in the CONFIGURA-

TION menu.

Configuring banks

The resolution for hand, leg or body detection, the response time and start-up behavior of the safety sensor and the field pair changeover for the protective/warning field pairs are configured via the banks.

NOTICE

For resolution, response time and DTS speed, select the values that you used for calculating the safety distances and additional distances for the application assigned to the configuration bank.

Ä In the CONFIGURATION menu, select the bank the configuration of which you want to define. ð The RESOLUTION, RESPONSE TIME, START-UP BEHAVIOR and EXTENDED OUTPUT SIGNALS

dialog boxes are displayed.

Ä In the RESOLUTION dialog box, enter the resolution and, if applicable, the maximum speed of a driver-

less transportation system (DTS) in the input fields.

NOTICE

If in the Resolution and Max. DTS speed input fields you select values >0, the application usually used for the bank is displayed in the Application field, e.g. Point of operation guarding.

For access guarding, point of operation guarding and danger zone guarding, you must select Max. DTS speed=0!

Ä In the RESPONSE TIME dialog box, select the response time of the safety sensor. Ä In the START-UP BEHAVIOR dialog box, select the start-up behavior and the restart time of the safety

sensor.

NOTICE

Configuration of the start-up behavior is only implemented if the corresponding electrical signal connections exist; see chapter 8 "Electrical connection".

Ä In the EXTENDED OUTPUT SIGNALS dialog box, activate the definition of output signals. Ä Click the [Confirm] button. Ä Configure all other banks of the protective function following the described procedure.

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Configuring the safety sensor

Create protective and warning fields

A field pair consists of one protective field and one warning field.

Ä In the CONFIGURATION menu, right-click the Bank1 option under Protective function_A

Select Add field pair.

ð The Add field pair dialog box opens. Ä In the Field pair list, select the number of the field pair and click the [Add] button. When you have

added all field pairs for the bank, click [Close].

ð The added field pairs are shown in the CONFIGURATION menu as an option under Bank1 under Pro-

tective function_A. The Parameters option is displayed for each field pair.

Ä Add the field pairs for the other banks of Protective functionA if one protective function with multiple

configuration banks has been selected.

ð The added field pairs are shown in the CONFIGURATION menu under Bank[x] under Protective func-

tionA.

Configure protective and warning fields

Defining contours and boundaries for protective field and warning field

1 Toolbar of field editor 2 Display of field coordinates 3 Structure of safety configuration

Fig.9.2: Field editor with toolbar for field definition

Ä In the CONFIGURATION menu, click the field pair the protective and warning fields of which you want

to define.

Ä Click the button and define the contours and boundaries of the protective field.

NOTICE

Determine protective field size!

The protective field size is determined by the calculated safety distances and additional distances that you determined for the application assigned to the configuration bank.

Ä Click the button and define the contours and boundaries of the warning field.

NOTICE

By right-clicking the field pair in the CONFIGURATION menu, you can calculate an autocontour for the protective or warning field.

You can determine the display options for the field editor in the menu SETTINGS > Field editor display options (see chapter 4.5.6 "SETTINGS").

Ä Configure all other field pairs of the configuration bank following the described procedure.

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Configuring the safety sensor

9.4.5

Configuring field pair monitoring

Ä In the CONFIGURATION menu, click the Parameters option of the field pair the protective and warning

fields of which you have defined.

Ä Select the monitoring mode for the field pair in the Field pair monitoring list.

9.5 Defining permissible field pair changeovers

If monitoring of field pair changeover is activated, you can define the permissible sequence of field pair changeovers.

Determining changeover mode

Ä In the CONFIGURATION menu, select the protective functionA or protective functionB option. Ä In the dialog box MODE FOR FIELD PAIR ACTIVATION AND CHANGEOVER, select the field pair ac-

tivation, the mode for field pair changeover and, if required, the changeover time.

Field pair activation

Changeover mode

Fixed selection of one field pair

Selection by signal inputs

Fixed changeover moment

Description

Changeover of two field pairs

Changeover of 10 field pairs (see chapter 5.7.3 "Changeover of ten field pairs in changeover mode Fixed changeover moment")

When the changeover time has expired, the system changes over to the field pair which at this time has a permanent and valid assignment. Field pair changeover signals issued during the changeover time are ignored.

The inputs F1 - F5 are active.

The inputs F6 - F10 are active.

Selection by signal inputs

Overlapped monitoring

Ä Click the [Confirm] button.

Determining changeover order

Ä In the CONFIGURATION menu, select the Changeover order option. ð The CHANGEOVER ORDER dialog box opens. Ä In the MONITORING OF FIELD PAIR CHANGEOVER dialog box, activate the Monitoring option. Ä In the MONITORING OF FIELD PAIR CHANGEOVER dialog box, define the sequence of field pair

changeovers according to your conditions.

Ä Click the [Confirm] button.

Changeover of 5 field pairs (see chapter 5.7.2 "Changeover of five field pairs in changeover mode Overlapped monitoring")

Both field pairs are monitored during the changeover time.

The inputs F1 - F5 are active.

The inputs F6 - F10 are active.

9.6 Configuring signal outputs

You can define which indication signals are transmitted to the individual indication signal connections.

Ä In the CONFIGURATION menu, select the Outputs option.

The OUTPUTS dialog box opens.

Ä For each usable connection, select the function group and the function of the indication signal. Ä Click the [Confirm] button.

NOTICE

All signal outputs are high active, i.e. logical 1 or +24V DC with an active signal.

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9.7 Saving configuration

To save the changed configuration loaded in the software, you can transfer the configuration and settings to the safety sensor or save them in a file on the PC.

Saving safety configuration as PDF file

Ä In the CONFIGURATION menu, click the [Create PDF file of safety configuration] button. Ä Determine the storage location and the file name for the safety configuration. Ä Click [Save]. ð The safety configuration is saved as a PDF file.

Saving configuration and settings as file

Ä In the CONFIGURATION menu or in the SETTINGS menu, click the [Save configuration and settings to

file] button.

Ä Determine the storage location and the name of the configuration file. Ä Click [Save]. ð The configuration and settings are saved in the file format *.xml.

Saving configuration project as file

Ä In the menu bar of the FDT frame menu, click the button.

Alternatively, select the menu command File > Save.

Ä Determine the storage location and the name of the configuration project file. Ä Click [Save].

Configuring the safety sensor

9.8 Transferring configuration project to safety sensor

The changes that you have made to the configuration only become effective when the changed configuration project file is transferred to the safety sensor.

Prerequisites:

• The software and safety sensor are connected.

• The changed configuration project has been loaded in the software.

• The individual password for the access level Engineer is available.

• Only users with the access level Engineer can transfer configuration data to the safety sensor. To change the access level, see chapter 9.9 "Selecting access level".

• If no individual password has been defined for the access level Engineer, use the preset default password (safety).

NOTICE

Alternatively, you can transfer a configuration project saved as a file on the PC directly to the safety sensor.

Ä In the menu bar of the FDT frame menu, click the [download arrow] button. Alternatively: In the FDT

menu bar, select Device > Download parameters.

ð The software asks for the access level and the password. Ä Select the access level Engineer and enter the preset default password (safety) or the defined individ-

ual password. Confirm with [OK].

Leuze electronic RSL 440 89

Configuring the safety sensor

Ä Before downloading the safety configuration, check whether you are connected to the correct safety

sensor. Confirm the displayed safety notice with [Yes].

Fig.9.3: Check before safety configuration is downloaded

The software transfers the data of the configuration project to the safety sensor.

After successful transfer, the safety sensor immediately enters safety mode, i.e. the safety-related switching outputs switch on if all conditions are fulfilled.

• The configuration data is saved in the connection unit of the safety sensor.

• A copy of the safety configuration is saved in the scanner unit of the safety sensor. If, due to a device swap-out, the scanner unit is attached to a brand new, unconfigured connection unit, the safety configuration is transferred from the scanner unit to the connection unit.

NOTICE

Observe the safety notices regarding changes to the configuration!

Transferring the safety configuration from the scanner unit to the connection unit corresponds to reconfiguration of the system consisting of scanner unit and connection unit.

Ä Observe the relevant safety notices regarding changes to the configuration (see chapter 9.1

"Defining safety configuration").

Ä Check the displayed signature.

Leuze electronic RSL 440 90

Configuring the safety sensor

Ä Confirm successful transfer of the safety configuration to the safety sensor with [OK].

The safety configuration has only been successfully transferred to the safety sensor when the confirmation dialog is displayed during the download.

Fig.9.4: Confirmation: safety configuration downloaded

NOTICE

The safety-related switching outputs will already have switched on if all conditions are fulfilled.

ð The software has saved the configuration project in the safety sensor.

9.9 Selecting access level

Using the device manager (DTM) you can change the access level of the user, if necessary (see chapter

5.1 "Authorization concept of safety sensor").

Ä Click in the DTM menu bar on the Change access levelbutton ( ). ð The Change access level dialog box opens. Ä In the Authorization list, select the item Engineer, Expert or Observer and enter the default password

or the password defined for the individual user (see chapter 4.5.6 "SETTINGS").

• Default password for Engineer: safety

• Default password for Expert: comdiag

Ä Confirm with [OK].

9.10 Reset safety configuration

The device manager (DTM) can be used to reset the safety configuration to the default configuration (one protective function, no restart).

Ä In the DTM menu bar, click the [Reset safety configuration] button. ð Users with the access level Engineer can additionally transfer the changed safety configuration to the

safety sensor (see chapter 9.8 "Transferring configuration project to safety sensor").

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10 Starting up the device

WARNING

Improper use of the safety sensor may result in serious injury!

Ä Make certain that the entire device and the integration of the optoelectronic protective de-

vice was inspected by competent and instructed persons.

Ä Make certain that a dangerous process can only be started while the safety sensor is

switched on

Prerequisites:

• Safety sensor mounted (see chapter 7 "Mounting") and connected (see chapter 8 "Electrical connection") correctly

• Operating personnel were instructed in proper use

• Dangerous process is switched off, outputs of the safety sensor are disconnected, and the system is protected against being switched back on

Ä After start-up, check the function of the safety sensor (see chapter 11.1 "Before the initial start-up and

following modifications").

10.1 Switching on

Requirements for the supply voltage (power supply unit):

• Reliable mains separation is ensured.

• Current reserve of at least 3A is available.

Ä Switch on the safety sensor.

Starting up the device

10.2 Aligning the safety sensor

NOTICE

Faulty or incorrect alignment may result in an operating fault!

Ä The alignment performed during start-up should only be performed by qualified personnel. Ä Observe the data sheets and mounting instructions of the individual components.

To simplify alignment during start-up, the safety sensors of the RSL400 series have an integrated electronic spirit level.

Ä Align the safety sensor using the integrated electronic spirit level.

10.3 Unlocking start/restart interlock

WARNING

Premature unlocking of the start/restart interlock may result in serious injury!

If the start/restart interlock is unlocked, the system can start up automatically.

Ä Before unlocking the start/restart interlock, make certain that no people are in the danger

zone.

The responsible person can restore the ON state of the safety sensor following process interruptions (due to triggering of protective function, failure of the voltage supply).

Ä Unlock the start/restart interlock using the reset button.

The safety-related switching outputs are only enabled if you hold down the reset button for between

0.12s and 4s.

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10.4 Shutting down

Temporarily shutting down the machine with the safety sensor

When you shut down the machine with the safety sensor temporarily, you do not have to observe any more steps. The safety sensor saves the configuration and starts again with the switch-on with this configuration.

Shutting down safety sensor and removing from machine

When you shut down the safety sensor and store it away for a later use, you must reset the safety sensor to the factory settings.

Ä Reset the safety sensor to the factory settings using the software.

In the device manager (DTM) of the safety sensor, select the CONFIGURATION tab. Click the [Reset safety configuration] button.

10.5 Restarting

Restarting the machine with the safety sensor

If you have only shut down the system with the safety sensor temporarily and are restarting the system without any changes, you can restart the safety sensor with the configuration that applied with the shutdown. The configuration remains saved in the safety sensor.

Ä Perform a function test (see chapter 11.3 "Periodically by the operator").

Starting up the device

Starting up machine with safety sensor after modification or reconfiguration

If you have performed significant changes on the machine or have reconfigured the safety sensor, the safety sensor must be checked as with the initial start-up.

Ä Test the safety sensor (see chapter 11.1 "Before the initial start-up and following modifications").

10.6 Starting up replacement scanner unit

The replacement scanner unit and the original scanner unit must be the same with regard to the following points:

• Scanner unit type in accordance with name plate or downward compatible with previous scanner unit with greater range and greater function range

• Mounting on the existing connection unit

Mounting and aligning replacement scanner unit

Ä Mount the replacement scanner unit on the connection unit instead of the original scanner unit (see

chapter 13.1 "Changing scanner unit").

NOTICE

Realignment of safety sensor not necessary!

Realignment of the safety sensor is not necessary since the replacement scanner unit is mounted on the existing, aligned connection unit.

Transferring configuration to replacement scanner unit

The configuration stored in the connection unit is automatically transferred to the replacement scanner unit.

WARNING

Malfunctioning of safety sensor due to incorrect configuration!

Ä The safety sensor configuration stored in the connection unit can only be adopted without

changes if the replacement scanner unit and the original scanner unit are downward compatible with respect to range and performance class. The replacement scanner unit will reject an invalid configuration.

Ä Change the configuration parameters of the safety sensor using the configuration and diag-

nostic software according to the performance class of the replacement scanner unit.

Ä Change the configuration parameters of the safety sensor using the configuration and diag-

nostic software according to the operating range of the replacement scanner unit.

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Starting up the device

Transferring configuration with the PC

If the range and/or performance class of the replacement scanner unit is not compatible with the original scanner unit, you must adapt the configuration of the safety sensor to the replacement scanner unit.

Ä Connect the safety sensor's Ethernet communication interface with the PC. Ä Configure the safety sensor according to the range and performance class of the replacement scanner

unit (see chapter 9 "Configuring the safety sensor").

Ä Transfer the configuration to the safety sensor with the replacement scanner unit. ð The alphanumerical display confirms successful transfer of the configuration.

The replacement scanner unit is not compatible with the connection unit if the safety sensor displays a fault.

Checking replacement scanner unit

The check performed on the replacement device depends on whether you automatically adopted the configuration from the connection unit or whether you transferred the changed configuration to the safety sensor.

Ä If you adopted the configuration from the connection unit, check the safety sensor using the checklist

for the daily test.

Ä If you transferred a new configuration to the safety sensor, check the safety sensor according to the

routine for initial start-up (see chapter 11.1.1 "Checklist for integrator – to be performed prior to the initial start-up and following modifications").

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11 Testing

NOTICE

Ä Safety sensors must be replaced at the end of their mission time (see chapter 15 "Technical

data").

Ä Always exchange entire safety sensors. Ä For the tests, observe, if necessary, nationally applicable regulations. Ä Document all tests in a comprehensible manner and include the configuration of the safety

sensor along with the data for the safety- and minimum distances in the documentation.

11.1 Before the initial start-up and following modifications

WARNING

Unpredictable machine behavior during initial start-up may result in serious injury!

Ä Make certain that there are no people in the danger zone.

Ä Before they begin work, train the operators on their respective tasks. The training is the responsibility of

the operating company.

Ä Attach notes regarding daily testing in the respective national language of the operator on the machine

in a highly visible location, e.g. by printing out the corresponding chapter (see chapter 11.3 "Periodically by the operator").

Ä Test the electrical function and installation according to this document.

Acc. to IECTS62046 and national regulations (e.g. EU directive2009/104/EC), tests are to be performed by competent persons in the following situations:

• Prior to initial commissioning

• Following modifications to the machine

• After longer machine downtime

• Following retrofitting or new configuration of the machine

Ä As preparation, check the most important criteria for the safety sensor according to the following check-

list (see chapter 11.1.1 "Checklist for integrator – to be performed prior to the initial start-up and following modifications"). Completing the checklist does not replace testing by a competent person!

Not until proper function of the safety sensor is ascertained may it be integrated in the control circuit of the system.

Testing

11.1.1

Leuze electronic RSL 440 95

Checklist for integrator – to be performed prior to the initial start-up and following modifications

NOTICE

Completing the checklist does not replace testing by a competent person!

Ä If you answer one of the items on the check list with no, the machine must no longer be op-

erated (see table below).

Ä IEC/TS62046 contains additional recommendations on testing protective devices.

Tab.11.1: Checklist for integrator – to be performed prior to the initial start-up and following modifications

Check: Yes No n.a.

not applicable

Is the safety sensor operated acc. to the specific environmental conditions that are to be maintained (see chapter 15 "Technical data")?

Is the safety sensor correctly aligned and are all fastening screws and connectors secure?

Are safety sensor, connection cables, connectors, protection caps and command devices undamaged and without any sign of manipulation?

Testing

Check: Yes No n.a.

not applicable

Does the safety sensor satisfy the required safety level (PL, SIL, category)?

Are the safety-related switching outputs (OSSDs) integrated in the downstream machine control acc. to the required safety category?

Are switching elements that are controlled by the safety sensor monitored according to the required safety level (PL, SIL, category) (e.g., contactors through EDM)?

Are all points of operation near the safety sensor accessible only through the protective field of the safety sensor?

Are the necessary additional protective devices in the immediate surroundings (e.g., safety guard) properly mounted and secured against tampering?

If it is possible to be present undetected between the safety sensor and point of operation: is an assigned start/restart interlock functional?

Is the command device for unlocking the start/restart interlock mounted in such a way that it cannot be reached from within the danger zone and so that the complete danger zone can be seen from the installation location?

Has the maximum stopping time of the machine been measured and documented?

Is the required safety distance maintained?

Does interruption with a test object intended for this purpose cause the dangerous movement(s) to stop?

Is the safety sensor effective during the entire dangerous movement(s)?

Is the safety sensor effective in all relevant operating modes of the machine?

Is start-up of dangerous movements reliably prevented if the protective field is interrupted with a test object intended for this purpose?

Was the sensor detection capacity successfully tested (see chapter 11.3.1 "Checklist – periodically by the operator")?

Were distances to reflective surfaces taken into account during configuration and no reflection bypasses subsequently detected?

Are notices for regular testing of the safety sensor legible to the operator and are they located in a highly visible location?

Are changes to the safety function (e.g. protective field changeover) not easy to achieve through tampering?

Are settings that could result in an unsafe state possible only by means of key, password or tool?

Are there incentives that pose stimulus for tampering?

Were the operators instructed prior to starting work?

11.2 To be performed periodically by competent persons

The reliable interaction of safety sensor and machine must be periodically tested by competent persons in order to detect changes to the machine or impermissible tampering with the safety sensor.

Acc. to IEC/TS 62046 and national regulations (e.g., EU directive 2009/104/EC), tests of elements which are subject to wear must be performed by competent persons at regular intervals. Testing intervals may be regulated by nationally applicable regulations (recommendation acc. to IEC/TS62046: 6months).

Ä Have all tests performed by competent persons. Ä Observe the nationally applicable regulations and the time periods specified therein. Ä As preparation, observe the checklist (see chapter 11.1 "Before the initial start-up and following modifi-

cations").

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11.3 Periodically by the operator

The function of the safety sensor must be checked regularly (e.g., daily, on shift change, monthly or in an even longer cycle) according to the following checklist. The frequency of the checks is determined by means of the risk analysis performed by the operating company.

Due to complex machines and processes, it may be necessary under certain circumstances to check some points at longer time intervals. Observe the classification in "Test at least" and "Test when possible".

WARNING

Unpredictable machine behavior during the test may result in serious injury!

Ä Make certain that there are no people in the danger zone. Ä Before they begin work, train the operators on their respective tasks and provide suitable

test objects and an appropriate test instruction.

Testing

11.3.1

Checklist – periodically by the operator

NOTICE

Ä If you answer one of the items on the check list with no, the machine must no longer be op-

erated (see chapter 11.1.1 "Checklist for integrator – to be performed prior to the initial startup and following modifications").

Tab.11.2: Checklist – regular function test by trained operators/persons

Test at least: Yes No

Are safety sensor and connectors securely mounted and free of obvious signs of damage, changes or tampering?

Were obvious changes made to access or entry possibilities?

Test the effectiveness of the safety sensor:

1. The LED1 and LED6 on the safety sensor must illuminate green (see chapter 3.3

"Display elements").

2. Interrupt the protective field using a suitable opaque test object (see figure).

Checking the protective field function with test rod

Do the LED1 and LED6 on the safety sensor illuminate constantly red while the protective field is interrupted?

Tab.11.3: Checklist – regular function test by trained operators/persons

When possible, test during running operation: Yes No

Protective device with approach function: during machine operation, the protective field is interrupted with the test object – are the obviously dangerous machine parts stopped without noticeable delay?

Protective device with presence detection: the protective field is interrupted with the test object – does this prevent operation of the obviously dangerous machine parts?

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12 Diagnostics and troubleshooting

12.1 What to do in case of failure?

After switching the safety sensor on, the display elements assist in checking the correct functionality and in faultfinding (see chapter 3.3 "Display elements").

In case of failure, you can determine the fault from the LED displays and read a message from the display. With the error message you can determine the cause of the error and initiate measures to rectify it.

NOTICE

If the safety sensor responds with an error display, you will often be able to eliminate the cause yourself!

Ä Switch off the machine and leave it switched off. Ä Analyze the cause of the fault using the diagnostics displays and rectify the fault. Ä If you are unable to rectify the fault, contact the Leuzeelectronic branch responsible for you

or call the Leuzeelectronic customer service (see chapter 14 "Service and support").

12.2 Diagnostics displays

The diagnostics displays consist of one letter plus four numbers, divided into classes consisting of letters and the first number.

Diagnostics classes:

• I (Information)

• No OSSD switch-off

• Unhindered operation possible

Diagnostics and troubleshooting

• U (Usage) Application error

• E (External) External fault

• F (Failure) internal device error

• OSSD switch-off

• Self test unsuccessful

• Hardware error

• P (Parameter) Inconsistency in configuration

Tab.12.1: Diagnostics displays in order of ascending ID number

DiagnosticIDDiagnostic message Measure

U0370 Input level at the electrical inputs is unclear. Check the wiring of the safety sensor.

P0409 Safety configuration is not compatible: un-

known bank switchover.

P0410 Safety configuration is not compatible: un-

known output signals.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

P0413 Safety configuration is not compatible: un-

known inputs SE1 and SE2.

Leuze electronic RSL 440 98

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

DiagnosticIDDiagnostic message Measure

Diagnostics and troubleshooting

P0414 Safety configuration is not compatible: un-

known EDM inputs.

P0415 Safety configuration is not compatible: un-

known field pair monitoring mode.

P0416 Safety configuration is not compatible: un-

known field pair monitoring parameters.

P0417 Safety configuration is not compatible: un-

known field pair monitoring mode.

P0419 Safety configuration is not compatible: un-

known monitoring parameter for the changeover order.

P0420 Safety configuration is not compatible: un-

known monitoring mode of the field pair changeover.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

P0421 Safety configuration is not compatible: un-

known parameter for field pair changeover monitoring.

P0422 Safety configuration is not compatible: un-

known field pair selection mode.

P0423 Safety configuration is not compatible: un-

known field pair selection parameter.

P0424 Safety configuration is not compatible: un-

known parameter for manipulation monitoring.

P0425 Safety configuration is not compatible: un-

known configuration of the output signals.

P0426 Safety configuration is not compatible: un-

known resolution.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

P0427 Safety configuration is not compatible: un-

known parameter.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

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DiagnosticIDDiagnostic message Measure

Diagnostics and troubleshooting

P0429 Safety configuration is not compatible: un-

known start/restart mode.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

P0430 Safety configuration is not compatible: un-

known start mode.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

P0431 Safety configuration is not compatible: un-

known restart mode.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

P0432 Safety configuration is not compatible: un-

known OSSD stop mode.

Swap out the safety sensor or change the configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the Sensor Studio software.

U0573 EDM fault at system start. Check the wiring of the downstream relays

and that they are functioning correctly.

U0574 Switching fault, EDM at OSSDA: external

relay does not switch off.

U0575 Switching fault, EDM at OSSDA: external

relay does not switch on.

Check the wiring of the downstream relays and that they are functioning correctly.

U0576 Switching fault, EDM at OSSDB: external

relay does not switch off.

U0577 Switching fault, EDM at OSSDB: external

relay does not switch on.

U0580 Switching fault at inputs SE1 and SE2; ex-

ternal safety device does not switch in accordance with the specifications.

U0582 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: overlap time too long.

U0583 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: no signal for field pair activation.

U0584 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: changeover time exceeded.

U0585 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: changeover order not observed.

Check the wiring of the downstream relays and that they are functioning correctly.

Check the wiring of the external safety device and that the parameter settings in the configuration are correct.

Check the changeover times of function inputs F1toF10 or the parameter settings in the configuration.

Check the wiring and the changeover times of function inputs F1toF10.

Check the changeover times of function inputs F1toF10 or the parameter settings in the configuration.

Check the wiring of function inputs F1toF10 and that the parameter settings in the configuration are correct.

U0792 Field pair changeover without release. Check the release signal for field pair

changeover or change the safety configuration.

U0793 Field pair changeover without request. Check the request signal for field pair

changeover or change the safety configuration.

U0849 Field pair changeover not permitted. Check the wiring of the field pair inputs.

Leuze electronic RSL 440 100

Leuze RSL 440, RSL 445 Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

1 About this document

1.1 Other applicable documents

1.2 Downloading configuration software from the Internet

1.3 Used symbols and signal words

1.4 Checklists

2 Safety

2.1 Intended use

Vapors, smoke, dust, particles

Stray light

Obstructions in the protective field

2.2 Foreseeable misuse

2.3 Competent persons

2.4 Disclaimer

2.6 Responsibility for safety

3 Device description

3.1 Device overview

Parameters for protective function

Device and monitoring functions

3.2 Connection unit

3.3 Display elements

LED indicator

Alphanumerical display

Field-of-view display

3.4 Mounting system (optional)

3.5 Loop guard (optional)

4.1 System requirements

4.2 Installing software

4.3 User interface

4.4 FDT frame menu

Project wizard

DTM change

User management

4.5 Using configuration projects

Selecting access level

IDENTIFICATION

PROCESS

CONFIGURATION

DIAGNOSIS

SETTINGS

5 Functions

5.1 Authorization concept of safety sensor

5.2 Function modes of safety sensor

One protective function

One protective function – 100 field pairs

Two protective functions

One protective function – four field mode

Two protective functions – four field mode

One protective function – multi configuration

Two protective functions - multi configuration

5.3 Selectable resolution for hand, leg and body detection

5.4 Speed-dependent protective function for vehicles

5.5 Response time

5.6 Configurable start-up behavior

Automatic start/restart

Start interlock/automatic restart

Start/restart interlock (RES)

5.7 Field pair changeover

Fixed selection of one field pair

Changeover of five field pairs in changeover mode Overlapped monitoring

Changeover of ten field pairs in changeover mode Fixed changeover moment

Changeover of 100 field pairs

Changeover of 2x ten field pairs

Changeover of 10x ten field pairs

5.8 Monitoring of field pair changeover

5.9 Reference contour monitoring

5.10 Field pair monitoring

5.11 Internal safe time delay

5.12 EDM contactor monitoring

5.13 E-Stop linkage

Contact-based safety circuit

Linkage of electronic safety-related switching outputs

5.14 Signaling functions

6 Applications

6.1 Stationary danger zone guarding

6.2 Stationary point of operation guarding