Leuze electronic RSL 410 Operating Instructions Manual

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EN 2015/11 - 50128230 We reserve the right to make technical changes

SAFE IMPLEMENTATION AND OPERATION

Original operating instructions

RSL 410

Safety Laser Scanner

Leuze electronic RSL 410 2

1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1 Other applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2 Downloading configuration software from Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.3 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Approved purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1.1 Vapors, smoke, dust, particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1.2 Stray light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1.3 Obstructions in the protective field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.4 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.5 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.6 Laser safety notices – Laser class 1 for wavelength range outside 400 - 700 nm . . . . . . 11

3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1 Device overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1.1 Protective function of RSL 400 safety sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.1.2 Parameters for protective function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2 Connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.3 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3.1 LED indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3.2 Alphanumerical display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.3.3 Field-of-view display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4 Mounting system (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.5 Loop guard (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Configuration and diagnostic software

4.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.2 Installing software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

4.3 User interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

4.4 FDT frame menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.4.1 Project Wizard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.4.2 DTM Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.4.3 User management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.4.4 Exiting

4.5 Using configuration projects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.5.1 Selecting access level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.5.2 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.5.3 PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.5.4 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.5.5 DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.5.6 SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Sensor Studio

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Sensor Studio

. . . . . . . . . . . . . . . . . . . . 18

5 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.1 Authorization concept of safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.2 Function modes of safety sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2.1 One protective function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.2.2 One protective function - four field mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.3 Selectable resolution for hand, leg and body detection. . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.4 Speed-dependent protective function for vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Leuze electronic RSL 410 3

5.5 Response time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.6 Configurable start-up behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.6.1 Automatic start/restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.6.2 Start interlock/automatic restart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.6.3 Start/restart interlock (RES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.7 Reference contour monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.8 EDM contactor monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.1 Stationary danger zone guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.2 Stationary point of operation guarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.3 Stationary access guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.4 Mobile danger zone guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.5 Danger zone guarding on side-tracking skates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.1 Basic infos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.1.1 Calculation of safety distance S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.1.2 Suitable mounting locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1.3 Mounting the safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1.4 Mounting examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.1.5 Information on protective field dimensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2 Stationary danger zone guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.3 Stationary point of operation guarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.4 Stationary access guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.5 Mobile danger zone guarding on DTSs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.5.1 Minimum distance D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7.5.2 Protective field dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.6 Mobile side guarding on DTSs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

7.7 Mounting accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.7.1 Mounting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.7.2 Loop guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.1 Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.2 Interfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

8.2.1 Pin assignment for control M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8.2.2 Pin assignment of M12 Ethernet interface (communication) ( D-coded). . . . . . . . . . . . . . 59

8.3 Connection unit CU408-M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.4 Circuit diagram example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9 Configuring the safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.1 Defining safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

9.2 Connecting safety sensor to PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

9.2.1 Connection via Ethernet cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

9.2.2 Connection via Bluetooth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

9.2.3 Communication between safety sensor and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

9.3 Determining configuration project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

9.4 Configuring protective function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

9.4.1 Creating simple safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

9.4.2 Entering administration parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9.4.3 Activating protective function and contactor monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9.4.4 Creating and configuring protective/warning field pairs. . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9.5 Saving configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Leuze electronic RSL 410 4

9.6 Transferring configuration project to safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

9.7 Selecting access level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

9.8 Reset safety configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

10 Starting up the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10.2 Aligning the safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10.3 Unlocking start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10.4 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

10.5 Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

10.6 Starting up replacement scanner unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

11 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

11.1 Before the initial start-up and following modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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

modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

11.2 To be performed periodically by competent persons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

11.3 Periodically by the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

11.3.1Checklist – periodically by the operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

12 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

12.1 What to do in case of failure? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

12.2 Diagnostics displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

13 Care, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

13.1 Changing scanner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

13.2 Cleaning the optics cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

13.3 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

13.4 Disposing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

14 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

15 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

15.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

15.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

15.3 Dimensioned drawings: Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

15.4 Representation of safety sensor status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

16 Standards and legal regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

17 Ordering information and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

18 EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

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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

Software for users of the machine

for safety sensor diagnostics if a fault occurs and for machine design engineers

Notes for the machine design engineer

for configuring the safety sensor

for config-

uring the safety sensor (software instructions)

Notices regarding mounting, alignment and connection of the safety sensor.

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

1.2 Downloading configuration software from Internet

 Call up the Leuze home page: www.leuze.com.

 Enter the type designation or part number of the device as the search term.

 The configuration software can be found on the product page for the device under the

title

Sensor Studio RSL 400 DTM

Safe implementation and operation (this document)

Online help for software

Quick Start Guide RSL 400

Source

Supplied with the safety sensor on data carrier

PDF, supplied with the safety sensor on data carrier

Supplied with the safety sensor on data carrier

Print document, supplied with the safety sensor

Downloads

tab.

1.3 Used symbols and signal words

Table 1.1: Warning symbols and signal words

Symbol indicating dangers to persons

Symbol indicating dangers from harmful laser radiation

NOTICE 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 injury

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 410 6

Table 1.2: Other symbols

Symbol for tips Text passages with this symbol provide you with further information.

About this document



Symbols for action steps Text passages with this symbol instruct you to perform actions.

Table 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)

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

PL Performance Level

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

TSS

RES Start/REStart interlock

SIL

State ON: device intact, OSSDs switched on

1.4 Checklists

The checklists serve as a reference for the machine manufacturer or supplier (see chapter 11). 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.

Probability of dangerous Failure per Hour

Transverse Side-tracking Skate

Safety Integrity Level

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

Leuze electronic RSL 410 7

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 table 15.1). 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.

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

task.

The following national and international legal regulations in particular apply for start-up, technical tests and handling of 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

• Betriebssicherheitsverordnung (Ordinance on Industrial Safety and Health) and employment protection act

• Product Safety Law (ProdSG)

Safety

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

2.1 Approved purpose

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

WARNING

A running machine may result in serious injury!

 Make certain that the safety sensor is correctly connected and that the protective function of the pro-

tective device is ensured.

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

shut down and protected against being restarted.

• 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

• When selecting the safety sensor it must be ensured that its safety-related capability meets or exceeds the required performance level PL

• 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.

• The safety sensor must be inspected regularly by a competent person to ensure proper integration and mounting (see chapter 2.4).

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

competent person (see chapter 2.4).

ascertained in the risk assessment (see table 15.1).

Leuze electronic RSL 410 8

CAUTION

Observe intended use!

 Only operate the device in accordance with its 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.

Leuze electronic GmbH + Co. KG is not liable for damages caused by improper use.

 Read these original operating instructions before commissioning the device.

Knowledge of the original operating instructions is an element of proper use.

NOTICE

Comply with conditions and regulations!

 Observe the locally applicable legal regulations and the rules of the employer's liability insurance asso-

ciation.

2.1.1 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.

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

ticles occur at the beam level.

Safety

2.1.2 Stray light

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

• Infrared light

• Fluorescent light

• Strobe light

 Ensure that there are no interfering light sources at beam level.

 Prevent reflective surfaces at beam level.

 Where applicable, take protective field addition distances into account.

 Implement all additional measures to ensure that any special application of any effected beam types

does not impair the safety sensor's operation.

2.1.3 Obstructions in the protective field

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

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

• 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.

not suitable as a protective device for use in the following cases:

Leuze electronic RSL 410 9

NOTICE

Do not modify or otherwise interfere with the device!

 Do not carry out modifications or otherwise interfere with the safety sensor.

The safety sensor must not be tampered with and must not be changed in any way.

The safety sensor must not be opened. There are no user-serviceable parts inside.

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.

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

2.3 Responsibility for safety

Manufacturer and operating company 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 operator

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

Safety

The operator of the machine is responsible for:

• Instructing the operator

• Maintaining the safe operation of the machine

• Adhering to all regulations and directives on industrial safety and safety at work

• Regular testing by competent persons

2.4 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 stan-

dards 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 BGV A3 (e.g. electrician foreman). In other countries, there are respective regulations that must be observed.

Leuze electronic RSL 410 10

2.5 Exemption of liability

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).

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

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

ATTENTION, INVISIBLE LASER RADIATION – LASER CLASS 1

The device fulfills the IEC 60825-1:2007 (EN 60825-1:2007) requirements for a product in as well as the U.S. 21 CFR 1040.10 regulations with deviations corresponding to Laser Notice No. 50 from June 24th, 2007.

 Observe the applicable statutory and local laser protection regulations.

 The device must not be tampered with and must not be changed in any way.

There are no user-serviceable parts inside the device.

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

Safety

laser class 1

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

Leuze electronic RSL 410 11

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 13849-1d

Device description

RSL 400

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

Figure 3.1: Device overview of safety laser scanner RSL 400

Leuze electronic RSL 410 12

All safety sensors of the RSL 410 series are equipped as follows:

Device description

• Laser scanner with the range class

Range class Operating range [m]

S3.00

M4.5

L 6.25

XL 8.25

• 24-digit alphanumerical display

• Integrated electronic spirit level for aligning the safety sensor

• LED indicators

• Connection unit:

• Configuration memory

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

• Electrical connection to the machine via M12 plug

3.1 Device overview

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

Table 3.1: Device overview

S, M, L or XL:

RSL 410 RSL 420 RSL 430 RSL 440

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

x x

2 OSSD pairs

x x

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

1 10 10 + 10 100

protective/warning field pairs

E-Stop linkage - x x x

Four field mode (quads) x x x x

Internal safe time delay - - x x

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 410 13

Only when the protective field is free again does the safety sensor reset the safety-related switching func-

M5 2x

tion, 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

Device description

Additional functions of the protective function

• Warning field evaluation

• Selectable dynamic contactor monitoring (EDM)

3.2 Connection unit

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

1 M12 socket, A-coded, connection to the control 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

Figure 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 M12 plug

Safety sensor Connection unit Connection

RSL 410 CU408-M12 M12 plug, 8-pin

Leuze electronic RSL 410 14

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

2 3 4 5 6

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 indicators

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

• Protective function A: LEDs 1, 2, 3

Device description

1 LED 1, red/green 2LED 2, yellow 3 LED 3, blue 4 No function 5 No function 6 No function

Figure 3.3: LED indicators

Table 3.2: Meaning of the LEDs

LED Color State Description

1 Red/green OFF Device switched off

Red OSSD off

Red, flashing Error

Green OSSD on

2 Yellow OFF RES deactivated

RES activated and enabled

Blinking Protective field occupied

ON RES activated and blocked but ready to be

unlocked Protective field free and linked sensor enabled (if applicable)

3 Blue OFF No internal function call active (e.g. warning field

free)

ON Internal function call (e.g. warning field occupied)

Leuze electronic RSL 410 15

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 fault diagnosis (see chapter 12).

Table 3.3: Alphanumerical displays

Display Description Example

Upon startup without configuration/upon initial commissioning

Sensor type Sensor type 420M

Sensor serial number Serial number of the sensor SN: 21513123456

Device description

Sensor name / Network name

Configuration necessary Configuration required CONFIG REQUESTED

Name of the sensor / network A123456789

Repeated until end of booting phase / start phase, then

Spirit level permanent Horizontal alignment in degrees: H

Vertical alignment in degrees: V

Upon startup with configuration

Sensor type Sensor type 410XL

Sensor serial number Serial number of the sensor SN: 21513123456

Sensor name / Network name

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

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

Name of the sensor / network A123456789

H -3° V +9°

10.25.45.2

Spirit level Horizontal alignment in degrees: H

Vertical alignment in degrees: V

H-3° V+9°

Repeated until end of booting phase / start phase, then

Display following configuration of normal operation e.g. display of active field pair A1.1

Transfer of the configuration data

AWAITING CONFIG Until downloading of configuration data is confirmed

DOWNLOAD CONFIG During transfer of configuration data

Spirit level

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

Vertical alignment in degrees: V

Sensor detection

PING received Display for identification by device name PING received

H -3° V +9°

Device

name

Message

Leuze electronic RSL 410 16

Display Description Example

Message via a signal output or diagnosis ID ProtF A: E123

Device: P007 - wrong Config

Fault diagnosis

F… Failure, internal device error

E… Error, external error

Device description

U…

I… Information

P…

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).

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

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.

3.3.3 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.

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

NOTICE

Always check the protective field configuration!

 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.

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

Usage info, application error

Parameter, inconsistency in the configuration

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 table 17.3).

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 table 17.3).

Leuze electronic RSL 410 17

Configuration and diagnostic software Sensor Studio

4 Configuration and diagnostic software

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.

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

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

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

Operating system Microsoft

Sensor Studio

® Windows 7 and Windows 8.1

Only the term PC is used below.

4.2 Installing software

Prerequisites:

• You do

• All Windows applications are closed.

Installing the Sensor Studio software

not need the safety sensor to install the software on the PC.

The software is installed in two steps:

- Install the

If FDT frame software is already installed on your PC, you do not need the lation.

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

Sensor Studio

FDT frame.

LeSafetyCollection

device manager (DTM).

Sensor Studio

instal-

Leuze electronic RSL 410 18

Configuration and diagnostic software Sensor Studio

 Insert the data carrier.

The installation will start automatically.

 If installation does not start automatically, double-click the file

 If you want to call up the menu of the CD, double-click the file

 Select a language for the interface text in the installation wizard and software and confirm with [OK].

The installation wizard starts.

 Click [Next].

The installation wizard opens the software license agreement.

 If you want to accept the license agreement, select the appropriate option field and click [Next].

 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].

 Click the [Install] button to start installation

The wizard installs the software and places a shortcut on the desktop ( ).

 Click the [Finish] button to complete installation.

SensorStudioSetup.exe

start.exe

Installing

Prerequisites:

•The

• Data carrier inserted.

 Double-click the file

 Select a language for the interface text in the installation wizard and software and confirm with [OK].

The installation wizard starts.

 Click [Next].

The installation wizard opens the software license agreement.

 If you want to accept the license agreement, select the appropriate option field and click [Next].

 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].

 Click the [Install] button to start installation.

The wizard installs the software.

 Click the [Finish] button to complete installation.

LeSafetyCollection

Sensor Studio

During installation of the software, a user can start the software without user identification. If other users are registered (Tools > User man- agement in the FDT frame menu), you must log in at the software with a user name and pass- word.

device manager (DTM)

software is installed on the PC.

LeSafetyCollectionSetup.exe

admin

(without password query) is created so that you

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).

Leuze electronic RSL 410 19

4.3 User interface

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 bar 7 Navigation area

Figure 4.1: User interface of the software

2 3

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 410 20

Project tree view

Configuration and diagnostic software Sensor Studio

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

Figure 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

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").

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

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

4.4.2 DTM Change

DTM Change

The

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

from device DTM to communication DTM.

 Start the

DTM change

Information on

function in the FDT frame menu by clicking the button.

DTM change

can be found in the online help for the FDT frame menu under

Sensor Studio Options.

Leuze electronic RSL 410 21

4.4.3 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

select the access level for the user. For information on access permissions and access levels (see chapter 5.1 "Authorization concept of safety sensor").

 In the FDT frame menu, click

Logging users in/out Prerequisites:

• Users have been created

 In the FDT frame menu, click

Managing passwords Prerequisites:

• Users have been created

 In the FDT frame menu, click

Configuration and diagnostic software Sensor Studio

Tools > User management in the software frame menu,

Tools > User management > Create user.

Tools > Log in/log out.

Tools > Change password.

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

4.4.4 Exiting

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

 Exit the program via

 Save the configuration settings as a configuration project on the PC.

You can open the configuration project again at later time via Wizard ( ).

access level ( (SETTINGS > Passwords) independently of the password management via the FDT frame menu.

Sensor Studio

Engineer, Expert

File > Exit.

4.5 Using configuration projects

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

During installation of the software, a user can start the software without user identification. If other users are registered ( agement in the FDT frame menu), you must log in at the software with a user name and pass- word.

) and the password defined via the device manager (DTM)

Fil e > Open or with the

admin

(without password query) is created so that you

Sensor Studio

Tools > User man-

Project

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).

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

mode selection of the Project Wizard is displayed.

•The

• If the mode selection is not shown, start the Project Wizard in the FDT frame menu by clicking the [Project Wizard] button ( ).

Leuze electronic RSL 410 22

Configuration and diagnostic software Sensor Studio

Figure 4.3: Project Wizard

 Select the configuration mode and click [Next].

• Automatic connection to a connected safety sensor (

Online)

• Device selection without communication connection (Offline)

• Load a saved project again

The project wizard displays the

SEARCH DEVICES dialog box.

 Select the interface and click the [Start] button.

 Find the safety sensor for your configuration project using the search function of the communication

DTM.

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

Figure 4.4: Communication DTM with search function

Leuze electronic RSL 410 23

Configuration and diagnostic software Sensor Studio

The project wizard displays the device list of configurable safety sensors in the SEARCH DEVICES dialog box.

Figure 4.5: Device selection in project wizard

 Select the safety sensor from the device selection list and click [Next].

The device manager (DTM) of the safety sensor shows the initial screen for the configuration project.

Figure 4.6: Initial screen for safety configuration

The device manager (DTM) starts without querying the access level of the user. During commu- nication 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").

Leuze electronic RSL 410 24

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 menu item in the menu [?].

4.5.1 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 5.1 "Authorization concept of safety sensor".

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

Change access level dialog box opens.

The

 In the

The following access levels are available:

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

 Confirm with [OK].

Access level

the password defined for the individual user.

•

Observer

•

Expert

•

Engineer

can read everything (no password)

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

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

list, select the item

Configuration and diagnostic software Sensor Studio

Expert, Engineer

Observer

Help

and enter the default password or

4.5.2 IDENTIFICATION

Detailed information on the menu items and setting parameters can be found in the information area and in the online help. Select the

• Safety laser scanner RSL 400

• Sensor and configuration data

• Technical data

4.5.3 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

Help menu item in the menu [?].

Engineer

• Measurement contour

• Inputs / outputs

4.5.4 CONFIGURATION

see chapter 9 "Configuring the safety sensor"

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

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Engineer

4.5.5 DIAGNOSIS

Adjustment / Alignment Display of safety sensor alignment using the integrated electronic spirit level Prerequisites: The software and safety sensor are connected.

 In the

DIAGNOSIS menu, click the [Align sensor mechanically] button ( ).

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.

 In the DIAGNOSIS menu, click the [Visually identify sensor] button ( ).

In the display of the safety sensor connected to the device manager (DTM), the message PING received flashes for ten seconds.

Reset sensor Acknowledge messages and faults Set safety sensor to safety mode

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

Configuration and diagnostic software Sensor Studio

• SENSOR DISPLAY

• STATE OF THE ACTIVE PROTECTIVE AND WARNING FIELDS

• SENSOR DATA

Diagnostics list Access list EventLog

4.5.6 SETTINGS

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

Communication

•LAN

•DHCP

• CONNECTION SETTINGS

•MAC address

• Bluetooth

• Activate Bluetooth module

• Activate device scan

• Bluetooth address

Engineer

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.

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Configuration and diagnostic software Sensor Studio

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

Help menu item in the menu [?].

the

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

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 one-time password and have it confirmed by the manufacturer.

CHANGE PASSWORD

 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).

One-time password

Prerequisites:

• The software is connected to the safety sensor.

 Generate a one-time password.

Note down the generated one-time password.

 Send the one-time 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.

 Enter the confirmed 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 [?].

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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 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

access level of the user. For information

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Table 5.1: Access levels and functions available

Access level Functions

Functions

Observer

Expert In addition to the functions of the

Engineer In addition to the functions of the

• 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

• 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

functions 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

Observer

Expert

, full access to all user-relevant

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

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").

• 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 CONFIGURATION > 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.

Tools > User management in the FDT frame menu,

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Overview of the function modes

A1.1P

B1.1P

A1.1W

B1.1W

Table 5.2: Function modes

Functions

Function mode Field pairs (FP)

Protective field (PF) Warning field (WF)

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

One protective function - four field mode

5.2.1 One protective function

A fixed field pair for safety-related switching outputs OSSD-A.

5.2.2 One protective function - four field mode

The safety sensor monitors one protection 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 FP / 1 PF + 3 WF Fixed selection of a field pair

Field pair activation

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

Figure 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

CONFIGURATION > Outputs; see chapter 9 "Configuring the safety sensor").

(

Table 5.3: Example: Assignment of signals to switching outputs

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Logic signal Electrical switching output Description

Functions

OSSD A Safety-related switching outputs

OSSD A

Protective function A: Violation of protective field

B-CLEAR Switching output MELD – not safe Protective function B: Violation of protec-

tive field

A-WF-VIO Switching output A1 Protective function A: Violation of warn-

ing field

B-WF-VIO Switching output EA1 Protective function B: Violation of warn-

ing field

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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.

Table 5.4: Resolution of the safety sensor depending on the function

Functions

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

150 Body detection Access guarding

Function Application(s)

Danger zone guarding

mounted close to floor level

Danger zone guarding

• Mounting height 150 mm

• Mounting height = Height of the scan level above floor level

• Leg detection with the safety sensor mounted at a height of 300 mm

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

Stationary danger zone guarding Mobile danger zone guarding

Mobile side guarding

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 ( protective/warning field pairs of a configuration bank.

Max. DTS speed

) is selected in the configuration project together for all

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.

5.6.1 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

start/restart interlock

•The machine control system. or

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

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automatic start/restart

function is taken over by a downstream safety-related component of the

function under the following prerequisites:

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

Automatic start-up The

automatic start-up

Automatic restart The

automatic restart

5.6.2 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

• Start interlock

• Automatic restart

Using start interlock/automatic restart

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

machine with this reset button.

 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.

 Identify the area to be released on the reset button so that its meaning is clear and easy to understand.

 Ensure that nobody is in the danger zone

 Hold down the reset button for between 0.12 s and 4 s to enable the safety-related switching outputs.

function starts the machine automatically as soon as the supply voltage is present.

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

has two functions:

Functions

before pressing the reset button.

DANGER

Risk of death if start-up is operated unintentionally!

 Ensure that the reset button for unlocking the start interlock cannot be reached from the danger zone.

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

Start interlock The

start interlock

supply voltage returns. The machine only starts when you press the reset button.

Automatic restart The

automatic restart

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

• Start interlock

• Restart interlock

function prevents the machine from starting automatically after switching on or after the

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

has two functions:

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

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

machine with this reset button.

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Functions

 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.

 Identify the area to be released on the reset button so that its meaning is clear and easy to understand.

 Ensure that nobody is in the danger zone

 Hold down the reset button for between 0.12 s and 4 s to enable the safety-related switching outputs.

DANGER

Risk of death if start/restart is operated unintentionally!

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

zone.

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

Start interlock The

start interlock

supply voltage returns. The machine only starts when you press the reset button.

Restart interlock The

restart interlock

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

function prevents the machine from starting automatically after switching on or after the

function prevents the machine from starting automatically, as soon as the protective

restart interlock

before pressing the reset button.

function always includes the

start interlock

function.

5.7 Reference contour monitoring

The

reference contour monitoring

tion 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

Activation of the function

 Activate the

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

Standby request

off

Reference contour monitoring

5.8 EDM contactor monitoring

The

EDM contactor monitoring

downstream of the safety sensor. Prerequisites for this are switching elements with positive-guided feedback contacts (normally closed contact).

Activation of the function

 Activate the contactor monitoring function using the configuration and diagnostics software (see

chapter 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:

function dynamically monitors the contactors, relays or valves connected

function prevents unintentional misalignment and deliberate manipula-

function together with the definition of the protective field

• 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).

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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

Figure 6.1: Stationary danger zone guarding

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").

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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

lock

function is vital for access guarding.

Applications

start/restart inter

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

Figure 6.2: Stationary access guarding

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.

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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

Figure 6.3: Mobile danger zone guarding

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Applications

Figure 6.4: Mobile danger zone guarding

6.5 Danger zone guarding 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.

Leuze electronic RSL 410 38

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

Figure 6.5: Mobile side guarding on side-tracking skates

Leuze electronic RSL 410 39

7 Mounting

SKTC+=

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.

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

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

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

WARNING

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.

 Only allow competent persons to install the safety sensor.

 Maintain the necessary safety distances (see chapter 7.1.1 "Calculation of safety distance S").

 Make sure that stepping behind, crawling under or stepping over the protective device is reliably ruled

out and reaching under, over or around is taken into account in the safety distance, if applicable with additional distance C

 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.

 Observe the relevant standards, regulations and these instructions.

 After mounting, check the safety sensor for proper function.

 Clean the safety sensor at regular intervals.

Environmental conditions: see chapter 15 "Technical data"

Care: see chapter 13 "Care, maintenance and disposal"

corresponding to EN ISO 13855.

Mounting

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 (t t

[s] = Response time of the protective device

[s] = Response time of the safety relay

[s] = Machine stopping time

C [mm] = Additional distance to the safety distance

+ ti + tm)

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

Leuze electronic RSL 410 40

7.1.2 Suitable mounting locations

Area of application: Mounting Tester: technician who mounts the safety sensor

Table 7.1: Checklist for mounting preparations

Check: Yes No

Is the safety distance to the point of operation 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?

Mounting

Is the safety sensor accessible for testing and replacing?

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

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

If you answer one of the items on the checklist (see table 7.1) with no, the mounting location must be changed.

7.1.3 Mounting the safety sensor

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

Proceed as follows:

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

cation.

 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 410 41

Mounting

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

Figure 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)

Figure 7.2: Mounting: area with unobstructed view

 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.

 Have the appropriate tools at the ready and mount the safety sensor.

 Install protective enclosures or safety bars if the safety sensor is in an exposed position.

Leuze electronic RSL 410 42

Mounting

 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.

 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 diagnostics software: Diagnosis > [Align sensor mechanically] button ( )

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

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

tents).

 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.

• 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.

 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.

 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 check (see chapter 11 "Testing") the safety sensor.

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7.1.4 Mounting examples

54,6

Mounting

, 4 5

all dimensions in mm 1 Safety sensor 2Post 3 Mounting bracket BT856M

Figure 7.3: Example: mounting on a post

all dimensions in mm 1 Safety sensor 2 Mounting bracket BT840M

Figure 7.4: Example: mounting on a chamfered corner

Leuze electronic RSL 410 44

1 Mounting bracket BTF815M (only in combination with the mounting system BTU800M)

2 3

2 Mounting system BTU800M 3 Safety sensor

Figure 7.5: Example: mounting on floor

Mounting

7.1.5 Information on protective field dimensioning

 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.

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

guards.

 Ensure that the protective field cannot be walked behind in the direction of the danger zone.

 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).

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

account.

 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.

 Observe the lateral tolerance when dimensioning the protective fields (see chapter 15 "Technical data").

 Do not use cone-shaped protective field contours, as these do not guarantee any protective function.

 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 410 45

1 Safety sensor

2 3

4 5 4 53

2Protective field 3 Unmonitored area; optimum availability at a distance of 50 mm to fixed contours

Figure 7.6: Unmonitored area

Mounting

 Prevent access to an unmonitored area with screens.

 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 3Protective field 4 Safety sensor 5 Machine 6 Angled physical cover

Figure 7.7: Stepping behind protection by countersinking into the machine contour

 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.

Leuze electronic RSL 410 46

Mounting

2 23

4 4

1 1

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.

 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

Figure 7.8: Shielding prevents reciprocal influencing of safety sensors set up beside one another

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

1 Minimum distance, min. 100 mm

Figure 7.9: Height offset mounting, parallel alignment

2 Scan level

 Install the safety sensors with crossed alignment.

Leuze electronic RSL 410 47

1 Scan level

SKTC+=

Figure 7.10: Mounting beside one another, without height offset, crossed alignment

1 Scan level

Figure 7.11: Mutually opposing mounting, without height offset, crossed alignment

Mounting

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 [mm] = Safety distance K [mm/s] = Approach speed for danger zone guarding with approach direction parallel to the pro-

tective field (resolution up to 90 mm): 1600 mm/s T [s] = Total time of the delay, sum from (t t

[s] = Response time of the protective device

[s] = Response time of the safety relay

[s] = Machine stopping time

C [mm] = Additional distance for danger zone guarding with approach reaction H = height of the

protective field, H

d = resolution of the protective device C = 1200 mm - 0.4  H; H

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 t 64 mm per additional scan.

 Select a response time t

 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".

 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 t

increases by 40 ms. With K = 1600 mm/s the safety distance increases by

of at least 120 ms or higher.

+ ti + tm)

= minimum installation height permitted, but no smaller than 0,

min

= 15  (d - 50)

min

Leuze electronic RSL 410 48

Additional distance C for danger zone guarding with approach reaction

C120004H–=

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

[mm] = 850 mm

MIN

[mm] = 1000 mm

MAX

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

Table 7.2: Additional distance C depending on the resolution of the safety sensor

Mounting

Safety sensor resolution (mm) Minimum permissible installa-

Additional distance C (mm)

tion height (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

+ Z

D Minimum distance D (= safety distance S + additional distance Z RG Largest protective field radius without additional distances, measured from the rotation axis of the

rotary mirror

, where required)

REFL

Figure 7.12: Defining the protective field contour for a stationary, horizontal protective field

 Define the limits of the protective field using the safety distance S without an additional distance.

 Determine the biggest protective field radius R

Leuze electronic RSL 410 49

for this protective field.

Mounting

DSZSMZ

REFL

++=

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.

Table 7.3: Additional distance Z

Biggest protective field radius RG without additional distances

for the protective field contour because of measurement error

Additional distance Z

< 6.25 m 100 mm

> 6.25 m 120 mm

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

add another additional distance

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

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

[mm] = Additional distance for retro-reflectors

REFL

 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 Z

, and Z

REFL

where required, into account. With the protective field contour under these conditions, stay about 50 mm away from the machine surface.

 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.

 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. The protective field reaching to under the hard guards takes over the protective function of preventing an adult from crawling under in this case.

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

 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.

7.3 Stationary point of operation guarding

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

Leuze electronic RSL 410 50

Mounting

KT C

+=

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

[mm] = Safety distance

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

approach direction to the protective field (resolution 14 to 40 mm): 2000 mm/s

or 1600 mm/s, when S T [s] = Total time of the delay, sum from (t t

[s] = Response time of the protective device

[s] = Response time of the safety relay

[s] = Machine stopping time

[mm] = Additional distance in which a body part can move towards the protective device before

> 500 mm

+ ti + tm)

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 t

increases by 40 ms. With K = 2000 mm/s approach speed this corre-

sponds with an increase in the safety distance of 80 mm per additional scan. With K = 1600 mm/s it is 64 mm.

 Select a response time t

 Determine the machine/system's stopping time t

of at least 80 ms or higher.

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

 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 t

Additional distance C

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 C

: 128 mm

• Arm detection:

• Resolution: 40 mm

• Additional distance C

: 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 refer-

ence 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 410 51

Mounting

KT C

+=

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

Figure 7.13: Defining the protective field contour and reference contour, stationary point of operation

guarding, vertical 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.

Calculation of safety distance S

[mm] = Safety distance

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

T [s] = Total time of the delay, sum from (t

[s] = Response time of the protective device, max. 80 ms

[s] = Response time of the safety relay

[s] = Machine stopping time

[mm] = Additional distance for access guarding with approach reaction with resolutions of

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.

 Select a response time t

Never define a value higher than 80 ms for t ues it can happen that a person might not be detected when passing through the protective field with an approach speed of 1600 mm/s.

 Determine the machine/system's stopping time t

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

for access guarding

tive field: 2000 mm/s or 1600 mm/s, if SRT > 500 mm

+ ti + tm)

14 to 40 mm, d = resolution of protective device CRT = 8  (d - 14) mm. Additional dis-

tance for access guarding for resolutions > 40 mm: C

= 850 mm (standard value for

arm length)

of 80 ms or higher.

for access guarding or passage controls. With higher val-

Leuze electronic RSL 410 52

Mounting

DDAZ

Ges

 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 t

Additional distance C

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 C

: 128 mm

• Arm detection:

• Resolution: 40 mm

• Additional distance C

: 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 refer-

 When defining the protective field ensure that there are no gaps bigger than 150 mm.

 When defining the protective field boundaries,

specify the sectors that monitor the position of the protective 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

 The operator of the machine must use organizing measures to prevent people from entering the pro-

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

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

devices.

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

If you must also guard the rever se t rav el, you mus t al so install a safety sensor on the rear of the vehicle.

 Mount the safety sensor on the vehicle so that there are no unmonitored areas

protective field and vehicle front.

 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".

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

7.5.1 Minimum distance D

≥ 70 mm between the

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

[mm] = Stopping distance

[mm] = Total required additional distances

TOT

Leuze electronic RSL 410 53

Figure 7.14: Mobile danger zone guarding, calculation of required minimum distance D

D · L · L

V · (T +T )

max

GES

200

DAv

maxT1T2

+DBL1L

+=

TotZSMZFZREFL

++=

Mounting

Stopping distance D

max

[mm] = Stopping distance [mm/s] = Maximum vehicle speed [s] = Safety sensor response time [s] = DTS response time [mm] = Braking distance with v

and maximum vehicle load

max

[---] = Factor for brake wear and tear [---] = Factor for problematic floor conditions, e.g. dirt, wet conditions

Additional distances Z

[mm] = Total of the required additional distances

Tot

[mm] = Additional distance for system-related measurement error, see table 7.3

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

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

REFL

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

ies; Z

= 100 mm

REFL

. The position of the rotary mirror axis

Tot

depends on the installation situation.

additional distance Z

The

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 Z

according to the following diagram:

120

100

Figure 7.15: Diagram for determining the additional distance ZF with lack of floor space H

Leuze electronic RSL 410 54

100

120

140

160

If wheels are mounted near the side wall, always add an additional distance ZF  150 mm.

7.5.2 Protective field dimensions

Mounting

GES

D Minimum distance, vehicle front (danger) to protective field front edge D

Stopping distance

Total required additional distances to the front and for both sides

Tot

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 ZSM

TOT

Figure 7.16: Mobile danger zone guarding, dimensions for horizontal protective field

 Select 70 mm resolution.

 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.

 Arrange the protective field symmetrically with reference to the vehicle width, even if the safety sensor

is not arranged centered.

 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.

 Take the required free space for lateral protrude protective fields under the roller conveyors along the

transportation path into account.

 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

 The operator of the machine must use organizing measures to ensure that people cannot enter the

vehicle's protective field from the side.

 For mobile vertical protective fields use a resolution of at least 150 mm.

 Position the protective field edges in the travel direction in accordance with the front protective field edge

of the horizontal protective field.

Leuze electronic RSL 410 55

 Ensure that the response time of all components of the switch-off circuit are the same or balance the

response times with different protective field dimensioning.

 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, Z figure 7.16.

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.

, ZF and Z

where required; see

REFL

Mounting

Figure 7.17: Mounting system BTU800M

NOTICE

Floor mounting only with mounting system BTU800M

 The mounting system BTU800M must be used in the case of installation using the mounting bracket

for floor mounting.

 Install the wall mount or mounting bracket for floor mounting on the system side.

 Mount the mounting system on the wall mount or on the mounting bracket for floor mounting.

 Attach the safety sensor to the mounting system.

Tightening the screws fixes the safety sensor in position.

 Align the safety sensor using the integrated electronic spirit level.

Leuze electronic RSL 410 56

7.7.2 Loop guard

3 3

The loop guard for the optics cover prevents damage to the safety sensor caused by light contact with foreign objects.

The loop guard can only be used together with the mounting system BTU800M.

Mounting

1 Mounting bracket for floor mounting BTF815M (only with mounting system BTU800M) 2 Mounting system BTU800M 3 Loop guard 4 Safety sensor

Figure 7.18: Loop guard

 Attach the safety sensor to the mounting system.

 Engage the loop guard for the optics cover from above into the mounting system.

Leuze electronic RSL 410 57

8 Electrical connection

WARNING

Faulty electrical connection or improper function selection may result in serious injury!

 Only allow competent persons to perform the electrical connection.

 For access guarding, activate the start/restart interlock and make certain that it cannot be unlocked

from within the danger zone.

 Select the functions so that the safety sensor can be used as intended (see chapter 2.1 "Approved

purpose").

 Select the safety-relevant functions for the safety sensor (see chapter 5.2 "Function modes of safety

sensor").

 Always loop both safety-related switching outputs OSSD1 and OSSD2 into the work circuit of the

machine.

 Signal outputs must not be used for switching safety-relevant signals.

NOTICE

Laying cables!

 Lay all connection cables and signal lines within the electrical installation space or permanently in

cable ducts.

 Lay the cables and lines so that they are protected against external damages.

 For further information: see EN ISO 13849-2, Table D.4.

Electrical connection

8.1 Electrical supply

see table 15.7.

Functional earth

NOTICE

Always connect the housing of the safety sensor to functional earth or ground!

 The housing of the safety sensor must always be connected to earth (functional earth) or machine/

vehicle ground.

 If the safety sensor is attached to a non-conductive material (e.g. a concrete wall), the housing 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 figure 8.3).

• 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.

NOTICE

Make sure that potential equalization is provided!

 If the housing of the safety sensor or the mounting bracket – despite being mounted on a non-conduc-

tive 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.

8.2 Interfaces

The safety sensor has two interfaces:

• Interface for connection with the control system

• Interface for communication with PC or laptop

Leuze electronic RSL 410 58

Table 8.1: Interfaces

Interface Type Function

Electrical connection

Control M12 connec-

tor, 8-pin

Communica-

M12 – RJ 45 Configuration interface and data interface:

tion

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.

8.2.1 Pin assignment for control M12

The safety sensor is equipped with a connection cable with a 8-pin M12 connector.

Figure 8.1: Pin assignment of safety sensor

Table 8.2: Pin assignment

• Power supply

• Switching lines and signal lines

• Parameter configuration

• Protective field definition and warning field definition

• Data transmission and measurement value transmission

• Diagnosis

Pin Core color Signal Description

1 White RES1 Start/restart input, protective function A

Acknowledgement

2 Brown UB Supply voltage

3 Green EA1 Contactor monitoring OSSD A

State signaling, configurable

4 Yellow A1 State signaling

5 Gray OSSDA1 Safety-related switching output, protective

function A

6 Pink OSSDA2 Safety-related switching output, protective

function A

7 Blue GND / Ground Supply voltage ground

8 Red MELD Output signal

State signaling, configurable

M12 thread FE Functional earth, connection cable shield.

The shield of the connection cable is on the thread of the M12 plug. The thread is part of the metallic housing.

8.2.2 Pin assignment of M12 Ethernet interface (communication) ( D-coded)

The safety sensor is equipped with a 4-pin M12 connector.

Leuze electronic RSL 410 59

Electrical connection

M5 2x

Figure 8.2: Pin assignment of the Ethernet interface

Table 8.3: Pin assignment of the Ethernet interface

PIN Signal Description

1 TD+ Data communication, transmission

3 TD- Data communication, transmission

4 RD- Data communication, reception

2 RD+ Data communication, reception

FE GND/shield Functional earth, communication cable shield. The shield of the intercon-

nection 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 CU408-M12

strap

Figure 8.3: Connection unit CU408-M12

Leuze electronic RSL 410 60

8.4 Circuit diagram example

Electrical connection

* Spark extinction circuit, suitable spark extinction provided

Figure 8.4: RSL 410 with MSI-SR4B safety relay

Leuze electronic RSL 410 61

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

 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).

 Calculating safety distance

Shape and size of the protective and warning fields

 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 "Determining configuration project")

• Configure the protective function (see chapter 9.4 "Configuring protective function")

 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.

 Allow only competent persons to perform safety configuration.

 Select the safety configuration so that the safety sensor can be used as intended (see chapter 2.1

"Approved purpose").

 Select the protective field dimensions and contours according to the safety distance calculated for the

application (see chapter 7.1.1 "Calculation of safety distance S").

 Select the parameters of the safety configuration according to your risk analysis.

 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.

 For example, make sure that the distance range in which manipulation is possible cannot be accessed

by personnel under normal operating conditions.

Leuze electronic RSL 410 62

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 ≥ 45°

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.

 In the

CONFIGURATION menu, click the

OTHER dialog box opens.

The

Other

option.

PROTECTION AGAINST MANIPULATION dialog box, define the monitoring time according to

your specific conditions.

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").

Many safety-relevant parameters are preset for each application in the configuration and diag- nostics 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:

 Connect the PC to the safety sensor

 Start the software

• Set up communication

• Determine the configuration project

 Configure the protective function using the project wizard

• Protective/warning field configuration

• Resolution and response time

• Start-up behavior

• Contactor monitoring

• Field pair changeover

 Save configuration project

 Transferring a configuration to the safety sensor

 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.

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.

Leuze electronic RSL 410 63

9.2 Connecting safety sensor to PC

9.2.1 Connection via Ethernet cable

Connect the Ethernet cable to the PC or to the network; see the document Quick Start Guide RSL 400.

The TCP/IP protocol is used for communication via Ethernet.

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.

9.2.2 Connection via Bluetooth

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")

 Activate the Bluetooth interface on the PC.

 Select the safety sensor as the device for the Bluetooth connection.

Configuring the safety sensor

9.2.3 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.

 Start the configuration and diagnostics software on your PC.

mode selection of the Project Wizard is displayed.

•The

• If the

 Select the configuration mode and click [Next].

The

 Select the safety sensor from the device selection list and click [Next].

The initial screen for the configuration project is displayed together with information for identification of the selected safety sensor.

 In the initial screen, click the

The

mode selection is not shown, click the [Project Wizard] button ( ) in the menu bar of the

software to start the project wizard.

Project Wizard displays the device selection list containing the configurable safety sensors.

SETTINGS

SETTINGS menu opens.

tab.

Assign permanent IP address

 Select the menu command

 In the

Leuze electronic RSL 410 64

DHCP dialog box, deactivate the

CONNECTION SETTINGS dialog box, enter the IP address information.

Communication > LAN.

Obtain IP address automatically

checkbox.

Activating/deactivating the Bluetooth interface

 Select the menu command

 Activate/deactivate communication with the safety sensor via the Bluetooth interface using the

Bluetooth module

sor via the Bluetooth interface is not possible.

 Activate/deactivate the Bluetooth device scan using the

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.

checkbox. If the Bluetooth module is deactivated, communication with the safety sen-

Communication > Bluetooth.

9.3 Determining configuration project

 Start the configuration and diagnostics software on your PC.

mode selection of the Project Wizard is displayed.

•The

•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.

Configuring the safety sensor

Activate device scan

Activate

checkbox. If the device

 Select the configuration mode and click [Next].

The

Project Wizard shows the list of configurable safety sensors.

You can use a prepared configuration project as a template and make changes to it. To do so, select the configuration mode

If you want to load the configuration project currently stored in the safety sensor to the PC, select the configuration mode

(online)

 Select the safety sensor in the

Alternatively, you can select the safety sensor by entering the part number or by specifying the sensor range and the sensor type.

The device manager (DTM) of the safety sensor shows the initial screen for the configuration project.

Open a stored project file

Device selection with device scan and establishment of connection

Sensor list and click [OK].

admin

(without password query) is created so that you

Tools > User man-

Leuze electronic RSL 410 65

Configuring the safety sensor

1 Configuration Wizard

Figure 9.1: Safety configuration using Configuration Wizard

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").

 In the initial screen, click the

CONFIGURATION menu opens with the options:

The

•

Administration

•

OSSDs

If the displayed.

•

Outputs

•

Other

OSSDs

option is selected in the CONFIGURATION menu, the

CONFIGURATION

tab.

Protective function A

option is

9.4.1 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

If you make changes to the default settings in a configuration step, first click the [Confirm] button and then [Next].



Administration



OSSDs



Protective function A

Leuze electronic RSL 410 66

CONFIGURATION menu.



Bank A1



Outputs

9.4.2 Entering administration parameters

 In the

The

 In the input fields, enter the device data and the project data for the configuration project.

9.4.3 Activating protective function and contactor monitoring

 In the

The

 In the

The

CONFIGURATION menu, click the

ADMINISTRATION dialog box opens.

CONFIGURATION menu, click the

OSSDs dialog box opens.

FUNCTION MODE list, select the protective function of the safety sensor.

Protective function A

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

option is shown in the CONFIGURATION menu.

Administration

OSSDs

option.

Configuring the safety sensor

option.

 In the

 Click the [Confirm] button.

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.

Creating banks

 In the

The

 Enter the description of the protective function in the input field.

 In the

The

 In the

The

CONTACTOR MONITORING list, activate the contactor monitoring of the safety sensor:

• EDM OSSD A

The activated contactor monitoring (EDM) is assigned to indication signal outputs IO1 and/or IO2. These signal outputs are thus disabled for the configuration of the signal outputs.

Bank A1

CONFIGURATION menu, click the

PROTECTIVE FUNCTION A dialog box opens.

CONFIGURATION menu, right-click the

Select

banks for the protective function, click [Close].

Add configuration bank

Add bank dialog box opens.

Bank list, select the number of the bank and click the [Add] button. When you have added all

Bank 1

option is shown under

Protective function A

option.

in the CONFIGURATION 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.

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.

 In the

The RESOLUTION, RESPONSE TIME and START-UP BEHAVIOR dialog boxes are displayed.

 In the

Leuze electronic RSL 410 67

CONFIGURATION menu, select the bank the configuration of which you want to define.

RESOLUTION dialog box, enter the resolution and, if applicable, the maximum speed of a driv-

erless transportation system (DTS) in the input fields.

Configuring the safety sensor

If in the used for the bank is displayed in the

For access guarding, point of operation guarding and danger zone guarding, you must select

Max. DTS speed

 In the RESPONSE TIME dialog box, select the response time of the safety sensor.

 In the

 Click the [Confirm] button.

 Configure all other banks of the protective function following the described procedure.

Create protective and warning fields A field pair consists of one protective field and one warning field.

 In the

The

 In the

The added field pairs are shown in the

START-UP BEHAVIOR dialog box, select the start-up behavior and the restart time of the safety

sensor.

Configuration of the start-up behavior is only implemented if the corresponding electrical signal connections exist; see chapter 8 "Electrical connection".

CONFIGURATION menu, right-click the

Select

all field pairs for the bank, click [Close].

Add field pair

Add field pair dialog box opens.

Field pair list, select the number of the field pair and click the [Add] button. When you have added

tive function_A

Resolution

. The

Parameters

and

Max. DTS speed

input fields you select values >0, the application usually

Application

= 0!

Bank 1

CONFIGURATION menu as an option under

option is displayed for each field pair.

field, e.g.

option under

Point of operation guarding

Protective function_A

Bank 1

under

Protec

Configure protective and warning fields Defining contours and boundaries for protective field and warning field

1 Toolbar of field editor

Figure 9.2: Field editor with toolbar for field definition

2 Display of field coordinates 3 Structure of safety configuration

 In the

 Click the button and define the contours and boundaries of the protective field.

Leuze electronic RSL 410 68

CONFIGURATION menu, click the field pair the protective and warning fields of which you want

to define.

Configuring the safety sensor

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.

 Click the button and define the contours and boundaries of the warning field.

The field pair is fully configured.

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 display options (see chapter 4.5.6 "SETTINGS").

 Configure all other field pairs of the configuration bank following the described procedure.

9.5 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

 In the CONFIGURATION menu, click the [Create PDF file of safety configuration] button.

 Determine the storage location and the file name for the safety configuration.

 Click [Save].

The safety configuration is saved as a PDF file.

Saving configuration and settings as file

 In the

 Determine the storage location and the name of the configuration file.

 Click [Save].

The configuration and settings are saved in the file format *.xml.

Saving configuration project as file

 In the menu bar of the FDT frame menu, click the button.

 Determine the storage location and the name of the configuration project file.

 Click [Save].

CONFIGURATION menu or in the SETTINGS menu, click the [Save configuration and settings

to file] button.

Alternatively, select the menu command

SETTINGS > Field editor

File > Save.

9.6 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

• Only users with the access level

change the access level, see chapter 9.7 "Selecting access level".

• If no individual password has been defined for the access level

password (safety).

Alternatively, you can transfer a configuration project saved as a file on the PC directly to the safety sensor.

Leuze electronic RSL 410 69

Engineer

can transfer configuration data to the safety sensor. To

is available.

Engineer

, use the preset default

Configuring the safety sensor

 In the menu bar of the FDT frame menu, click the [download arrow] button.

Alternatively: In the FDT menu bar, select

Device > Download parameters.

The software asks for the access level and the password.

 Select the access level

Engineer

and enter the preset default password (safety) or the defined individual

password.

Confirm with [OK].

 Before downloading the safety configuration, check whether you are connected to the correct safety

sensor.

Confirm the displayed safety notice with [Yes].

Figure 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 recon-

figuration of the system consisting of scanner unit and connection unit.

 Observe the relevant safety notices regarding changes to the configuration (see chapter 9.1 "Defining

safety configuration").

 Check the displayed signature.

 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.

Leuze electronic RSL 410 70

Configuring the safety sensor

Figure 9.4: Confirmation: safety configuration downloaded

The safety-related switching outputs will already have switched on if all conditions are fulfilled.

The software has saved the configuration project in the safety sensor.

9.7 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".

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

Change access level dialog box opens.

The

 In the

 Confirm with [OK].

Authorization list, select the item

the password defined for the individual user (see chapter 4.5.6 "SETTINGS").

• Default password for

Engineer Expert

9.8 Reset safety configuration

The device manager (DTM) can be used to reset the safety configuration to the default configuration (one protective function, no restart).

 In the DTM menu bar, click the [Reset safety configuration] button.

Users with the access level safety sensor (see chapter 9.6 "Transferring configuration project to safety sensor").

: safety

: comdiag

Engineer

Engineer, Expert

can additionally transfer the changed safety configuration to the

Observer

and enter the default password or

Leuze electronic RSL 410 71

10 Starting up the device

WARNING

Improper use of the safety sensor may result in serious injury!

 Make certain that the entire device and the integration of the optoelectronic protective device was

inspected by competent and instructed persons.

 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

 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

Starting up the device

Requirements for the supply voltage (power supply unit):

• Reliable mains separation is ensured.

• Current reserve of at least 3 A is available.

 Switch on the safety sensor.

10.2 Aligning the safety sensor

NOTICE

Faulty or incorrect alignment may result in an operating fault!

 The alignment performed during start-up should only be performed by qualified personnel.

 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.

 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.

 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).

 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.

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.

Leuze electronic RSL 410 72

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.

 Reset the safety sensor to the factory settings using the software.

In the device manager (DTM) of the safety sensor, select the 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.

 Perform a function test (see chapter 11.3 "Periodically by the operator").

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.

 Test the safety sensor (see chapter 11.1 "Before the initial start-up and following modifications").

CONFIGURATION

Starting up the device

tab. Click the [Reset

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

 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!

 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.

 Change the configuration parameters of the safety sensor using the configuration and diagnostic soft-

ware according to the performance class of the replacement scanner unit.

 Change the configuration parameters of the safety sensor using the configuration and diagnostic soft-

ware according to the operating range of the replacement scanner unit.

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.

 Connect the safety sensor's Ethernet communication interface with the PC.

Leuze electronic RSL 410 73

Starting up the device

 Configure the safety sensor according to the range and performance class of the replacement scanner

unit (see chapter 9 "Configuring the safety sensor").

 Transfer the configuration to the safety sensor with the replacement scanner unit.

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.

 If you adopted the configuration from the connection unit, check the safety sensor using the checklist

for the daily test.

 If you transferred a new configuration to the safety sensor, check the safety sensor according to the rou-

tine for initial start-up (see chapter 11.1.1 "Checklist for integrator – to be performed prior to the initial start-up and following modifications").

Leuze electronic RSL 410 74

11 Testing

NOTICE

 Safety sensors must be replaced at the end of their mission time (see chapter 15 "Technical data").

 Always exchange entire safety sensors.

 For the tests, observe, if necessary, nationally applicable regulations.

 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!

 Make certain that there are no people in the danger zone.

 Before they begin work, train the operators on their respective tasks. The training is the responsibility of

the operating company.

 Attach notices 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").

 Test the electrical function and installation according to this document.

Testing

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 the initial start-up

• Following modifications to the machine

• After longer machine downtime

• Following retrofitting or new configuration of the machine

 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.

11.1.1 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!

 If you answer one of the items on the check list with

, the machine must no longer be operated (see

table 11.1).

 IEC/TS 62046 contains additional recommendations on testing protective devices.

Table 11.1: Checklist for integrator – to be performed prior to the initial start-up and following

modifications

Check: Yes No

n. a.

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?

Leuze electronic RSL 410 75

Testing

Check: Yes No

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?

n. a.

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 table 11.2)?

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?

a) not applicable

Leuze electronic RSL 410 76

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).

 Have all tests performed by competent persons.

 Observe the nationally applicable regulations and the time periods specified therein.

 As preparation, observe the checklist (see chapter 11.1 "Before the initial start-up and following modifi-

cations").

11.3 Periodically by the operator

The function of the safety sensor must be checked periodically depending on the given risk (e.g. daily or on change of shifts) according to the following checklist so that damages or prohibited tampering can be detected.

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!

 Make certain that there are no people in the danger zone.

 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

 If you answer one of the items on the check list with

table 11.1).

, the machine must no longer be operated (see

Leuze electronic RSL 410 77

Testing

Table 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:

• The LED 1 on the safety sensor must illuminate green (see chapter 3.3.1 "LED indicators").

• Interrupt the protective field using a suitable opaque test object (see figure 11.1).

Figure 11.1: Checking the protective field function with test rod

Does the LED 1 on the safety sensor illuminate constantly red while the protective field is interrupted?

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?

Leuze electronic RSL 410 78

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!

 Switch off the machine and leave it switched off.

 Analyze the cause of the fault using the diagnostics displays and rectify the fault.

 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)

Diagnostics and troubleshooting

• No OSSD switch-off

• Unhindered operation possible

• 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

Table 12.1: Diagnostics displays in order of ascending ID number

Diagnostic ID

U0370 Input level at the electrical inputs is unclear. Check the wiring of the safety sensor.

P0409 Safety configuration is not compatible:

Diagnostics message Measure

Swap out the safety sensor or change the

unknown bank switchover.

configuration. The type of safety sensor must be the same as the type stored in the connection unit or in the ware.

Sensor Studio

soft-

P0410 Safety configuration is not compatible:

unknown output signals.

Leuze electronic RSL 410 79

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 ware.

Sensor Studio

soft-

Diagnostics and troubleshooting

Diagnostic ID

P0413 Safety configuration is not compatible:

P0414 Safety configuration is not compatible:

P0415 Safety configuration is not compatible:

P0416 Safety configuration is not compatible:

Diagnostics message Measure

unknown inputs SE1 and SE2.

unknown EDM inputs.

unknown field pair monitoring mode.

unknown field pair monitoring parameters.

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 ware.

Sensor Studio

soft-

P0417 Safety configuration is not compatible:

unknown field pair monitoring mode.

P0419 Safety configuration is not compatible:

unknown monitoring parameter for the changeover order.

P0420 Safety configuration is not compatible:

unknown monitoring mode of the field pair changeover.

P0421 Safety configuration is not compatible:

unknown parameter for field pair changeover monitoring.

P0422 Safety configuration is not compatible:

unknown field pair selection 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 ware.

Sensor Studio

soft-

P0423 Safety configuration is not compatible:

unknown field pair selection parameter.

Leuze electronic RSL 410 80

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 ware.

Sensor Studio

soft-

Diagnostics and troubleshooting

Diagnostic ID

P0424 Safety configuration is not compatible:

P0425 Safety configuration is not compatible:

P0426 Safety configuration is not compatible:

P0427 Safety configuration is not compatible:

Diagnostics message Measure

unknown parameter for manipulation monitoring.

unknown configuration of the output signals.

unknown resolution.

unknown 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 ware.

Sensor Studio

soft-

P0428 Safety configuration is not compatible:

unknown reflector mode.

P0429 Safety configuration is not compatible:

unknown start/restart mode.

P0430 Safety configuration is not compatible:

unknown start mode.

P0431 Safety configuration is not compatible:

unknown restart mode.

P0432 Safety configuration is not compatible:

unknown 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 ware.

Sensor Studio

soft-

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.

Leuze electronic RSL 410 81

Check the wiring of the downstream relays and that they are functioning correctly.

Diagnostics and troubleshooting

Diagnos-

Diagnostics message Measure

tic ID

U0575 Switching fault, EDM at OSSD A: external

relay does not switch on.

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; exter-

nal 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.

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.

U0584 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: changeover time

Check the changeover times of function inputs F1 to F10 or the parameter settings in the configuration.

exceeded.

U0585 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: changeover order

Check the wiring of function inputs F1 to F10 and that the parameter settings in the configuration are correct.

not observed.

E0588 Optics cover is soiled. Clean the optics cover. Restart the safety

sensor.

I0604 Optics cover is soiled. Clean the optics cover as soon as possible.

Sensor is still in safety mode.

P0653 Safety configuration is not compatible: pro-

tective/warning field radius too large.

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

soft-

ware.

P0654 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: field pair not

Check the wiring of function inputs F1 to F10 and that the parameter settings in the configuration are correct.

defined.

I0660 Field pair changeover is not performed in

accordance with the specifications configured in the safety sensor: no field pair acti-

Check the wiring of function inputs F1 to F10 and that the parameter settings in the configuration are correct.

vated at system start.

U0661 Safety-related switching outputs (OSSDs)

Check the wiring of the OSSDs. cannot be switched: short circuit with 0 V, +24 V DC or between OSSDs.

Leuze electronic RSL 410 82

Diagnostics and troubleshooting

Diagnos-

Diagnostics message Measure

tic ID

I0719 Timeout of signals RES1 or RES2 (acknowl-

edgment button, start/restart).

Check the wiring of inputs RES1 and RES2.

The time specifications for start/restart must

be observed.

P0747 Safety configuration is not compatible: pro-

tective/warning field radius too small.

Change the dimensions and contour of the

protection field in the configuration. The min-

imum range of the protection field must be

observed.

I0825 Simulation mode has been activated. The safety-related switching outputs

(OSSDs) have been switched off.

I0826 Simulation mode has been deactivated. The sensor is again in safety mode.

CAUTION!

Be aware of potential hazards which can

occur when the machine is started up!

F.... The monitoring functions have detected an

internal error.

Create the service file (see chapter 4.5.5

"DIAGNOSIS")and contact the

Leuze electronic customer service (see

chapter 14 "Service and support").

Leuze electronic RSL 410 83

13 Care, maintenance and disposal

13.1 Changing scanner unit

If the safety sensor check or an error message indicates a defective scanner unit, change the scanner unit. Only a trained and competent person is permitted to change the scanner unit.

The scanner unit is changed as follows:

• Detach the scanner unit from the connection unit.

• Attach the replacement scanner unit to the connection unit.

NOTICE

Safety sensor malfunction caused by dirt!

 Perform all work in an environment which is as dust-free and dirt-free as possible.

 Do not touch any of the parts inside the device.

WARNING

Malfunctioning of safety sensor due to incompatibility of connection unit and scanner unit! Malfunctioning of safety sensor due to incorrect configuration!

 Wherever possible, replace the scanner unit with a scanner unit with the same range and performance

class (e.g. RSL 420-M with RSL 420-M). The safety sensor configuration stored in the connection unit is only adopted without changes if the new scanner unit supports all configured functions.

 Change the configuration parameters of the safety sensor using the configuration and diagnostic soft-

ware according to the performance class of the scanner unit or of the connection unit.

If a scanner unit is attached to a connection unit with a lower performance class (e.g. a scanner unit RSL 430 to a connection unit CU416), the integrated cable management of the connection unit means that only the functions of the lower performance class (of the connection unit) are available.

If a scanner unit is attached to a connection unit with a higher performance class (e.g. an RSL 420 scanner unit to a CU429 connection unit), the performance of the scanner unit restricts the functions to those of the lower performance class (of the scanner unit).

 Change the configuration parameters of the safety sensor using the configuration and diagnostic soft-

ware according to the operating range of the replaced scanner unit.

If the scanner unit is replaced with a scanner unit with a different range (e.g. RSL 420-L with RSL 420-M), you must check and, if necessary, adapt the configuration of the safety sensor.

Care, maintenance and disposal

Detailed information on attaching the scanner unit can be found in the document Quick Start Guide RSL 400.

 Undo the quick-release fasteners on both sides of the scanner unit.

 Pull the scanner unit off the connection unit.

 Place the new scanner unit on the connection unit.

 Connect and lock the new scanner unit using the quick-release fasteners on both sides.

 Check the configuration of the safety sensor (see chapter 9 "Configuring the safety sensor").

If a preconfigured scanner unit is attached to a brand new, unconfigured connection unit, the safety configuration stored in the scanner unit is transferred to the connection unit and you can use the safety sensor without reconfiguration after a restart.

 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").

Leuze electronic RSL 410 84

13.2 Cleaning the optics cover

Clean the optics cover as required by the application-related load rating. Use the cleaning set consisting of special cleaning agent and cleaning cloths for cleaning (see chapter 17

"Ordering information and accessories"). The procedure for cleaning depends on the kind of contamination:

Soiling Cleaning

Care, maintenance and disposal

Particles, loose, scouring

Particles, loose, non-scouring

Particles, sticking

Particles, statically charged

Particles/drops, smearing

Water drops

Oil drops

Fingerprints

Scratches

NOTICE

The wrong cleaning agents or cloths will damage the optics cover!

 Do not use any scouring cleaning agents or scratching cloths.

 Vacuum without touching or blow away softly, oil-free  Wipe free in one swipe with cleaning cloth  Vacuum without touching or blow away softly, oil-free

Wipe free in one swipe with cleaning cloth

 Wet with cloth soaked in cleaning agent  Wipe free in one swipe with cleaning cloth  Vacuum without touching  Wipe free in one swipe with cleaning cloth soaked with cleaning

agent

 Wet with cloth soaked in cleaning agent  Wipe free in one swipe with cleaning cloth  Wipe free in one swipe with cleaning cloth

 Wet with cloth soaked in cleaning agent  Wipe free in one swipe with cleaning cloth  Wet with cloth soaked in cleaning agent  Wipe free in one swipe with cleaning cloth  Change optics cover

If cleaning takes longer than four seconds, e.g. with fingerprints, the safety sensor displays a fault of optics cover monitoring. After cleaning is complete, the safety sensor resets itself auto- matically.

 Soak cloth with cleaning agent.

 Wipe optics cover free in one swipe.

13.3 Servicing

The device does not normally require any maintenance by the operator. Repairs to the device must only be performed by the manufacturer.

 For repairs, contact your responsible Leuze electronic subsidiary or Leuze electronic customer service

(see chapter 14 "Service and support").

13.4 Disposing

 For disposal observe the applicable national regulations regarding electronic components.

Leuze electronic RSL 410 85

14 Service and support

24-hour on-call service at: +49 (0) 7021 573-0

Service hotline: +49 (0) 8141 5350-111 Monday to Thursday, from 8.00 a.m. to 5.00 p.m. (UTC+1) Friday, 8.00 a.m. to 4.00 p.m. (UTC+1)

E-mail: service.protect@leuze.de

Return address for repairs: Service center Leuze electronic GmbH + Co. KG In der Braike 1 D-73277 Owen / Germany

Service and support

Leuze electronic RSL 410 86

15 Technical data

15.1 General specifications

Table 15.1: Safety-relevant technical data

Type in accordance with IEC/EN 61496 Type 3

SIL in accordance with IEC 61508 SIL 2

SILCL in accordance with IEC/EN 62061 SILCL 2

Technical data

Performance Level (PL) in accordance with

PL d

EN ISO 13849-1

Category acc. to EN ISO 13849-1 Cat. 3

Average probability of a failure to danger per hour (PFH

)

Mission time (T

) 20 years

9x10-8 1/h

Table 15.2: Optics

Laser protection class in accordance with

Class 1

EN 60825-1

Wavelength 905 nm (infrared)

Impulse duration 2.5 ns

Maximum output power (peak) 35 W

Pulse frequency of laser transmitter 90 kHz

Scanning rate 25 scans/s, equal to 40 ms/scan

Scanning angle Max. 270 °

Angular resolution 0.1 °

Tolerance field of reference contour + 200 mm

Table 15.3: Protective field data

Safety sensor RSL 410 RSL 420 RSL 430 RSL 440

Number of field pairs 1 10 10 + 10 100

Reference contour selectable x x x x

Minimum adjustable range 200 mm

Detection range of the test object from the housing edge

The detection capability is limited in the 0 mm to 50 mm range to increase availability.

Diffuse reflectance PF minimum 1.8 %

Leuze electronic RSL 410 87

Technical data

Table 15.4: Protective field range

Device range S M L XL

Resolution [mm] Protective field range [m]

150 3.00 4.50 6.25 8.25

70 3.00 4.50 6.25 8.25

60 3.00 4.50 6.25 8.25

50 3.00 4.50 6.25 6.25

40 3.00 4.50 4.50 4.50

30 3.00 3.50 3.50 3.50

Table 15.5: Warning field data

Number of field pairs 1, 10, 10 + 10, 100

Warning field range 0 - 20 m

Object size 150 mm x 150 mm

Diffuse reflectance WF minimum Min. 10 %

Table 15.6: Measurement field data

Detection range 0 - 50 m

Diffuse reflectance 20 %

Radial resolution 5 mm

Lateral resolution 0.1 °

Table 15.7: Electrical supply

Voltage supply Power supply unit

24 V DC (+20 % / -30 %) Supply acc. to IEC 742 with secure mains supply isolation and equalization for voltage dips of up to 20 ms acc. to EN 61496-1.

Voltage supply Battery

24 V DC (+20 % / -30 %) (performance data may differ)

Overcurrent protection Via 2 A semi-time-lag fuse in the cabinet

Notice: With high external loads at the switching outputs (total current > 700 mA), the fuse rating must be adjusted to 2.5 A.

Current consumption Approx. 700 mA (use power supply unit with 3 A)

Power consumption 17 W with 24 V plus output capability

Overvoltage protection Overvoltage protection with protected limit stop

Protective conductor Connection required

Device connection Connection cable, M12-8 connector

Connection socket for Ethernet/communication M12-4 connector, D-coded

Leuze electronic RSL 410 88

Technical data

Table 15.8: Inputs

Reset +24 V, dynamically monitored (0.12 s to 4 s)

Signal definition:

High/logical 1 16 - 30 V

Low/logical 0 < 3 V

Table 15.9: Safety-related switching outputs

OSSD transistor safety-related switching outputs 2 safe PNP semiconductor outputs

Short-circuit proof, cross circuit monitored

Minimum Typical Maximum

Response time 80 ms

(2 scans)

Switching voltage high active U

– 3.2 V

1000 ms (25 scans)

Switching voltage low 2.0 V

Switching current 300 mA

Cut-off frequency f

Load capacity C

load

Cable length between safety sensor and load with cross section 0.25 mm

Permitted wire cross section 0.25 mm

1 kHz

100 nF

25 m

Test pulse width 60 µs 110 µs

Test pulse distance 35 ms 40 ms 40 ms

The safety-related transistor outputs perform the spark extinction. With transistor outputs, it is therefore neither necessary nor permitted to use the spark extinction circuits recommended by contactor or valve manufacturers (RC elements, varistors or recovery diodes), since these con- siderably extend the decay times of inductive switching elements.

Table 15.10: Inputs and outputs

Features Max. output cur-

rent I

EX/A=changeover-capable (EA1)

20 mA (-20 mA)

Min. input current I

10 mA (-10 mA)

Typical connection components

Auxiliary contact of power contactor (EDM)

AX=output Current limited, short-circuit proof (A1, MELD)

100 mA (-20 mA)

--- Lamp (PNP only) Control input (PNP/ NPN)

Signal definition:

High/logical 1 16 - 30 V

Low/logical 0 < 3 V

Leuze electronic RSL 410 89

Technical data

Table 15.11: Software

Configuration and diagnostics software Sensor Studio for Windows 7 and Windows 8.1

Table 15.12: General system data

Degree of protection IP 65 in acc. with IEC 60529

Safety class III

Ambient temperature, operation 0 ... +50 °C

Ambient temperature, storage -20 ... +60 °C

Humidity DIN 40040, table 10, code letter E (reasonably

dry)

Interference rejection In acc. with DIN EN 61496-1 (type 4), also in acc.

with DIN 40839-1/3 test pulses 1, 2, 3a, 3b and 5

Vibration stress over 3 axes In acc. with IEC 60068 part 2 - 6, 10 - 150 Hz

max 5 G

Continuous shock over 3 axes In acc. with IEC 60068 part 2 - 29, 10 G, 16 ms

Disposal Specialist disposal required

Housing Diecast zinc, plastic

Standard version dimensions (ensure free space for

140 x 149 x 140 (W x H x D) in mm

plug with fixing and connection cable)

Weight of standard version incl. connection unit Approx. 3 kg

Distance, beam level center to bottom housing edge 104 mm

Leuze electronic RSL 410 90

15.2 Dimensions

140,2

140,3



M5 2x

61,3

Technical data

all dimensions in mm

1 Scan level

Figure 15.1: Dimensions safety laser scanner with connection unit

Leuze electronic RSL 410 91

all dimensions in mm

125

4 (

)

Figure 15.2: Mounting dimensions safety laser scanner with connection unit

Technical data

all dimensions in mm

Figure 15.3: Minimum space requirements for installation and replacement of scanner unit

all dimensions in mm

1 Reference point for distance measurement and protective field radius

Leuze electronic RSL 410 92

Figure 15.4: Dimensions of scanning range

15.3 Dimensioned drawings: Accessories

192

166,3

157,5

Technical data

all dimensions in mm

Figure 15.5: Mounting system BTU800M

Leuze electronic RSL 410 93

Technical data

162

6 0 2 1

6 8 1

0 2 1

5 1

all dimensions in mm

Figure 15.6: Mounting bracket BTF815M

258

288

Leuze electronic RSL 410 94

Technical data

258

288

162

all dimensions in mm

Figure 15.7: Mounting bracket BTF830M

Leuze electronic RSL 410 95

Technical data

160

11,8

151

205,2

all dimensions in mm

Figure 15.8: Loop guard BTP800M

all dimensions in mm

Figure 15.9: Mounting bracket BT840M

Leuze electronic RSL 410 96

7 0 ,

all dimensions in mm

Figure 15.10: Mounting bracket BT840M, view A

Technical data

151

140,8

233,5

all dimensions in mm

Figure 15.11: Mounting bracket BT856M

9 1 1

Leuze electronic RSL 410 97

Technical data

7 0 ,

all dimensions in mm

Figure 15.12: Mounting bracket BT856M, view A

Leuze electronic RSL 410 98

Technical data

122

120,4

130

142

all dimensions in mm

Figure 15.13: Drilling template for adapter plate, RS4/ROD4 BT800MA

Leuze electronic RSL 410 99

Technical data

192

166,3

157,5

all dimensions in mm The mounting plate BTU804MA supplements the old mounting system of the RS4/ROD4 for the mounting system BTU800M.

Figure 15.14: Mounting plate BTU804MA

15.4 Representation of safety sensor status

The table lists all logic and electrical signals that are present in the safety sensor. The signal names are used consistently throughout the configuration and diagnostics software (device DTM), in the event log and in the data telegram.

Table 15.13: Representation of status

Byte Bit Signal Description Value 0 Value T Default

0 --- --- Type (variant) of status profile.

Extensions require new type of status profile

1 --- OP-MODE Operating mode:

Messages and OSSDs

• 1: Safety mode

• 2: Simulation mode

--- --- 1

Leuze electronic RSL 410 100

Leuze electronic RSL 410 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 About this document

1.1 Other applicable documents

1.2 Downloading configuration software from Internet

1.3 Used symbols and signal words

1.4 Checklists

2 Safety

2.1 Approved purpose

2.1.1 Vapors, smoke, dust, particles

2.1.2 Stray light

2.1.3 Obstructions in the protective field

2.2 Foreseeable misuse

2.3 Responsibility for safety

2.4 Competent persons

2.5 Exemption of liability

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

3 Device description

3.1 Device overview

3.1.1 Protective function of RSL 400 safety sensors

3.1.2 Parameters for protective function

3.2 Connection unit

3.3 Display elements

3.3.1 LED indicators

3.3.2 Alphanumerical display

3.3.3 Field-of-view display

3.4 Mounting system (optional)

3.5 Loop guard (optional)

Configuration and diagnostic software Sensor Studio

4.1 System requirements

4.2 Installing software

4.3 User interface

4.4 FDT frame menu

4.4.1 Project Wizard

4.4.2 DTM Change

4.4.3 User management

4.5 Using configuration projects

4.5.1 Selecting access level

4.5.2 IDENTIFICATION

4.5.3 PROCESS

4.5.4 CONFIGURATION

4.5.5 DIAGNOSIS

4.5.6 SETTINGS

5 Functions

5.1 Authorization concept of safety sensor

5.2 Function modes of safety sensor

5.2.1 One protective function

5.2.2 One protective function - four field mode

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

5.6.1 Automatic start/restart

5.6.2 Start interlock/automatic restart

5.6.3 Start/restart interlock (RES)

5.7 Reference contour monitoring

5.8 EDM contactor monitoring

6 Applications

6.1 Stationary danger zone guarding

6.2 Stationary point of operation guarding

6.3 Stationary access guarding

6.4 Mobile danger zone guarding

6.5 Danger zone guarding on side-tracking skates

7 Mounting

7.1 Basic infos

7.1.1 Calculation of safety distance S

7.1.2 Suitable mounting locations

7.1.3 Mounting the safety sensor

7.1.4 Mounting examples

7.1.5 Information on protective field dimensioning

7.2 Stationary danger zone guarding

7.3 Stationary point of operation guarding

7.4 Stationary access guarding

7.5 Mobile danger zone guarding on DTSs

7.5.1 Minimum distance D

7.5.2 Protective field dimensions

7.6 Mobile side guarding on DTSs

7.7 Mounting accessories