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SICK AOS501, AOS502, AOS Prime, AOS504, AOS101 Operating Instructions Manual

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AOS PRIME
Object Detection Systems
OPERATING INSTRUCTIONS
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OPERATING INSTRUCTIONS | AOS Prime
Subject to change without notice
Product described
Product name: AOS Prime
Document identification
Title: AOS Prime Operating Instructions
Status: 2017-08-15
Manufacturer
SICK AG Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Trademarks
IBM is a trademark of the International Business Machine Corporation.
only used here for identification purposes.
Original documents
The German version 8016731/ZPQ5 of this document is an original SICK AG
In case of doubt, contact SICK AG or your local agency.
Legal notes
Subject to change without notice
© SICK AG. All rights reserved
Part number: 8016800/ZPQ5
MS-DOS is a trademark of the Microsoft Corporation. Windows is a trademark of the Microsoft Corporation. Other product names in this document may also be trademarks and are
document. SICK AG does not assume liability for the correctness of a non-authorized translation.
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Contents
CONTENTS
1 About these operating instructions ..............................................................................6
1.1 Described software versions ............................................................................... 6
1.2 Purpose of this document .................................................................................... 6
1.3 Target group ......................................................................................................... 6
1.4 Information depth ................................................................................................ 7
1.5 Abbreviations used ............................................................................................... 7
1.6 Symbols used ....................................................................................................... 8
2 Safety ..............................................................................................................................9
2.1 Qualified personnel .............................................................................................. 9
2.2 Applications of the system ................................................................................... 9
2.3 Intended use ...................................................................................................... 10
2.4 General safety notes and protective measures .............................................. 11
2.4.1 Safety notes and icons ...................................................................... 11
2.4.2 General safety notes .......................................................................... 12
2.4.3 Potential hazardous points ................................................................ 13
2.5 Protecting the environment .............................................................................. 16
3 Product description .................................................................................................... 17
3.1 Scope of delivery ............................................................................................... 17
3.1.1 Scope of delivery, AOS501-AOS504 ................................................. 17
3.1.2 Scope of delivery, AOS101-AOS104 ................................................. 19
3.2 Components in the system ............................................................................... 21
3.2.1 The LMS511/LMS111 laser scanners ............................................. 21
3.2.2 The Flexi Soft control ......................................................................... 22
3.2.3 The test target .................................................................................... 23
3.2.4 The connection box of the laser scanner.......................................... 24
3.3 Principle of operation ........................................................................................ 25
3.4 Status indicators ............................................................................................... 27
3.4.1 LEDs on the LMS111 / LMS511 laser scanner ............................... 27
3.4.2 LEDs on the Flexi Soft ........................................................................ 28
3.5 Parameter memory ........................................................................................... 29
3.5.1 Parameter set on connector plug of the Flexi Soft control unit ....... 29
3.5.2 Parameter set in the laser scanner .................................................. 29
4 Mounting ..................................................................................................................... 30
4.1 Planning mounting locations ............................................................................ 30
4.2 Mounting the laser scanners ............................................................................ 30
4.2.1 General notes ..................................................................................... 30
4.2.2 Mounting the LMS511 laser scanner ............................................... 31
4.2.3 Mounting the LMS 111 laser scanner .............................................. 32
4.3 Mounting the Flexi Soft control ........................................................................ 33
4.4 Mounting and positioning the test targets ....................................................... 34
5 Electrical installation ................................................................................................. 36
5.1 Connecting Flexi Soft to the power supply ....................................................... 36
5.2 Connecting the LMS511 laser scanner ........................................................... 37
5.2.1 Connecting the connection box to the LMS511 laser scanner ....... 37
5.2.2 Connecting the installation cable in the connection box ................. 38
5.2.3 Wiring the installation cable wires to the Flexi Soft control ............. 39
5.2.4 Connecting additional LMS511 laser scanners to Flexi Soft .......... 40
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5.3 Connecting the LMS111 laser scanner ............................................................41
5.3.1 Using the local connection box ..........................................................41
5.3.2 Using the pre-configured system cables ...........................................46
5.3.3 Connecting additional LMS111 laser scanners to the Flexi
Soft ......................................................................................................49
5.4 Connecting additional I/O modules ..................................................................49
6 Commissioning ............................................................................................................ 50
6.1 Switching on the supply voltage ........................................................................50
6.2 Checking the operating state of the components ............................................50
6.2.1 Checking the operating state of the modular control .......................50
6.2.2 Checking the operating state of the laser scanners .........................51
6.3 Configuring laser scanners using SOPAS .........................................................52
6.3.1 Overview ..............................................................................................52
6.3.2 Preparation work.................................................................................54
6.3.3 Loading laser scanners into the SOPAS project ................................56
6.3.4 Notes on the configuration interface .................................................61
6.3.5 Configuring monitoring fields .............................................................62
6.3.6 Configuring evaluation cases .............................................................73
6.3.7 Testing the infringement of the monitoring fields .............................75
6.3.8 Transferring and saving parameters to the device ...........................76
6.3.9 Exporting the device ...........................................................................77
6.4 Configuring the modular control with Flexi Soft Designer ..............................78
6.4.1 Preparation work.................................................................................79
6.4.2 Opening the project file containing the parameter set .....................81
6.4.3 Transferring the parameter set to the control unit ...........................82
6.4.4 Testing the configuration ....................................................................86
6.4.5 Verifying and saving the configuration ..............................................88
6.4.6 Preventing the configuration from being overwritten .......................89
6.4.7 Final steps ...........................................................................................89
6.5 Check the stopping and warning response of the application ........................90
7 Maintenance ................................................................................................................ 91
7.1 Overview of maintenance tasks ........................................................................91
7.2 Maintenance during operation ..........................................................................91
7.2.1 Visual inspection .................................................................................91
7.2.2 Cleaning the laser scanners ...............................................................92
7.3 Replacing components ......................................................................................92
7.3.1 Replacing a laser scanner ..................................................................93
7.3.2 Replacing Flexi Soft control modules ................................................93
8 Fault diagnosis ............................................................................................................ 95
8.1 Response to faults .............................................................................................95
8.2 SICK Support ......................................................................................................95
8.3 Component fault indicators ...............................................................................95
8.3.1 Fault indicator on the LMS511 / LMS111 laser scanners ..............95
8.3.2 Flexi Soft control fault indicator .........................................................96
8.4 Diagnostics .........................................................................................................98
8.4.1 Laser scanner diagnostics .................................................................98
8.4.2 Flexi Soft diagnostics ..........................................................................99
CONTENTS
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9 Technical specifications ........................................................................................... 101
9.1 AOS101 - AOS104 / AOS104 RTG ................................................................. 101
9.1.1 Features ............................................................................................ 101
9.1.2 Performance ..................................................................................... 101
9.1.3 Interfaces .......................................................................................... 101
9.1.4 Mechanics/electronics .................................................................... 101
9.1.5 Ambient data .................................................................................... 102
9.2 AOS501 - AOS504 / AOS502 STS .................................................................. 103
9.2.1 Features ............................................................................................ 103
9.2.2 Performance ..................................................................................... 103
9.2.3 Interfaces .......................................................................................... 103
9.2.4 Mechanics/electronics .................................................................... 103
9.2.5 Ambient data .................................................................................... 104
9.3 AOS Prime dimensional drawings .................................................................. 105
9.3.1 Dimensional drawing of the LMS511 laser scanner...................... 105
9.3.2 Dimensional drawing of the LMS111 laser scanner...................... 108
9.3.3 Dimensioned drawing of the FX3CPU0 main module with
system plug ...................................................................................... 110
9.3.4 Dimensional drawing of the FX3-XTIO expansion module ............. 110
9.4 Electrical wiring diagrams ............................................................................... 111
9.4.1 Connection tables ............................................................................ 111
9.4.2 AOS501 wiring diagram ................................................................... 113
9.4.3 AOS502 wiring diagram ................................................................... 116
9.4.4 AOS503 wiring diagram ................................................................... 119
9.4.5 AOS504 wiring diagram ................................................................... 122
9.4.6 AOS101 wiring diagram ................................................................... 125
9.4.7 AOS102 wiring diagram ................................................................... 128
9.4.8 AOS103 wiring diagram ................................................................... 131
9.4.9 AOS104 wiring diagram ................................................................... 134
10 Appendix .................................................................................................................... 137
10.1 List of tables .................................................................................................... 137
10.2 List of figures ................................................................................................... 138
10.3 Keywords index ............................................................................................... 140

1 ABOUT THESE OPERATING INSTRUCTIONS

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Subject to change without notice
Software
Function
Status
SOPAS ET
SICK Engineering Tool for the configuration and diagnostics of the AOS Prime
≥ V 3.0 FSD Flexi Soft Designer
Configuration and diagnostic software for the control
≥ V 1.7
1 About these operating instructions
Please read through this chapter carefully before you use the documentation and work with the AOS Prime.

1.1 Described software versions

Tab. 1: Software versions

1.2 Purpose of this document

These operating instructions are designed to give technical personnel instructions on the safe mounting, configuration, electrical installation, commissioning, operation, and maintenance of the AOS Prime object detection systems.
These operating instructions do not provide information on operating the customer system into which the AOS Prime has been or is going to be integrated. Additional information on this can be found in the customer documentation.

1.3 Target group

These operating instructions are intended for persons integrating the AOS Prime into a machine, system or vehicle and performing initial commissioning and operation. They are also intended for the planners, developers and operating entities of machines and systems.
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1.4 Information depth

ABOUT THESE OPERATING INSTRUCTIONS 1
Note
These operating instructions contain information about the AOS Prime object detection system on the following topics:
• Product description
• Mounting
• Electrical installation
• Commissioning and configuration
• Maintenance and care
• Fault diagnosis and troubleshooting
• Technical data and dimensional drawings
When planning and using object detection systems such as the AOS Prime, technical skills are required that are not covered by this document.
The applicable official and legal regulations at the application site must always be complied with when operating the system.
Note
Further information about the device components used in the AOS Prime can be found in the accompanying operating instructions.

1.5 Abbreviations used

AOS
LMS
AWG
SOPAS
FSD
EDM
ESD
PLC
Advanced object detection system
Measurement sensor = laser scanner from SICK AG
American wire gage = standardization and classification of wires and cables according to type, diameter, etc.
SICK Engineering Tool = software for configuring and diagnosing the LMS111 and LMS511 laser scanner
Flexi Soft Designer = software for Flexi Soft safety controller configuration and diagnostics
External device monitoring
Electrostatic discharge
Programmable logic control
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, 

1.6 Symbols used

Recommendation
Note
1. / 2. ...
Step by step
Action
Recommendations are designed to assist you in the decision-making process with respect to the use of a certain function or technical measure.
Notes provide information about the features of a device, application tips, or other useful information.
Instructions that must be carried out in the described order are referred to as step-by-step instructions and are indicated by numbered lists. Carefully read and follow the instructions for action.
Instructions for taking action are indicated by an arrow. Carefully read and follow the instructions for action.
LED icons describe the status of a diagnostics LED.
The LED is illuminated continuously.  The LED is flashing.  The LED is off.
Display symbols show the status of the 7-segment display:
 Constant display of characters, e.g., U Flashing display of characters, e.g., 8  Alternating display of characters, e.g., L and 2
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2 Safety

This chapter concerns your own safety and the safety of the system operator.
Please read through this chapter carefully before using the AOS Prime or the machines /
▸
systems monitored by the AOS Prime.

2.1 Qualified personnel

The AOS Prime must only be mounted, commissioned, and maintained by adequately qualified personnel.
A qualified person
• has sufficient skills in the field of the respective equipment based on their technical
training and experience and
• has been instructed by the manufacturer in system operation and all applicable safety
guidelines and
• is familiar with all relevant country-specific occupational safety regulations, work safety
regulations, guidelines, and generally accepted technical rules and standards (e.g., DIN standards, VDE regulations, country-specific rules) to such an extent that he/ she is able to evaluate the safe condition of the power-driven machinery and he/she
• has access to and has read the operating instructions.
SAFETY 2

2.2 Applications of the system

The AOS Prime (Advanced Object Detection System) is a non-contact, self-testing object detection system that is used to protect against collisions.
The AOS Prime is used in monitoring applications where a stand-alone laser scanner is not sufficient and high operational reliability of the system provides added value.
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2.3 Intended use

AOS Prime may only be used as described in section 2.2 Applications of the system. It may only be used by qualified personnel in the environment in which it was mounted and initially commissioned by qualified safety personnel in accordance with these operating instructions.
Note
Note
The AOS Prime object detection system is not a safety device for human protection and it therefore does not comply with any safety standards. For safety applications, please contact SICK AG.
The AOS does not offer protection from flying parts or against radiation.
The AOS satisfies the requirements of Class A (industrial application) of the generic standard for radiated emission.
In the event of any other usage or of modification to the system – including in the context of mounting and installation – any claims against SICK AG under the warranty will be rendered void.
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2.4 General safety notes and protective measures

HAZARD
WARNING
WARNING
NOTE

2.4.1 Safety notes and icons

The following safety and hazard notes concern your own safety, the safety of third parties, and the safety of the devices. You must therefore observe these symbols at all times.
Denotes an immediate hazard that may result in severe to fatal injuries.
The symbol shown on the left-hand side of the note refers to the type of hazard in question (the example here shows a risk of injury resulting from electrical current).
Denotes a potentially dangerous situation that may result in severe to fatal injuries.
The symbol shown on the left-hand side of the note refers to the type of hazard in question (the example here shows a risk of damage to the eye by laser beams).
SAFETY 2
Denotes a potentially dangerous situation that may result in minor personal injury or possible material damage.
Denotes a potential risk of damage or functional impairment of the device or the devices connected to it.
This icon refers to supplementary technical documentation.
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WARNING
WARNING

2.4.2 General safety notes

The AOS Prime has been designed in a way that allows for safe operation. Protective devices reduce potential risks to the maximum possible extent. However, a certain level of risk will always remain.
Awareness of potential hazardous points in the system will help you to work in a safer manner and thus prevent accidents.
To avoid risks, please also observe the special warnings in each of the individual chapters.
Safety notes
Observe the following to ensure the intended use of the AOS Prime as intended.
• The notes in these operating instructions (e.g. regarding use, mounting, installation, or integration into the machine control) must be observed.
• All official and statutory regulations governing the operation of the system must be complied with.
• The national and international legal specifications apply to the installation and use of the system, to its commissioning, and to recurring technical inspections, in particular:
– Work safety regulations and safety rules
– Any other relevant safety provisions
• The manufacturer and user of the system are responsible for coordinating and complying with all applicable safety specifications and regulations in cooperation with the relevant authorities.
• The checks must be carried out by qualified safety personnel or specially qualified and authorized personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time.
• These operating instructions must be made available to the operator of the system in which the AOS Prime is used. The system operator must be instructed by qualified safety personnel and must read the operating instructions.
• Maintenance and repair work must only be done by trained and authorized SICK AG service technicians or qualified safety personnel of the customer.
The AOS Prime is not suitable for the protection of humans within the meaning of the applicable safety standards for machines. The system therefore does not comply with safety standards.
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2.4.3 Potential hazardous points

WARNING
HAZARD
Laser radiation
Damage to the eye by laser beam
The LMS111 or LMS511 laser scanners used in the AOS Prime conform to laser class 1 (eye-safe) criteria according to IEC 60825-1 (latest version); see laser warning plate on the device for publication date. This ensures compliance with 21 CFR 1040.10 except for the tolerances according to Laser Notice No. 50 of July 26, 2001.
The laser beam operates at a wavelength of γ = 905 nm (invisible infrared light). The laser beam is not visible to the human eye.
The radiation emitted in normal operation is harmless to human skin and eyes.
WARNING
Important
Improper use (e.g., opening the housing and stopping the motor) can result in dangerous exposure to radiation.
Never open the laser scanner housing. Opening the housing does not interrupt the
▸
operation of the laser beam.
Pay attention to the laser safety regulations as per IEC 60 8251 (latest version).
▸
• No maintenance is required to ensure compliance with laser class 1.
• The laser output aperture is the inspection window on the laser scanner.
• The laser warning is located on the right side of the laser scanner.
SAFETY 2
Electrical current
Risk of injury and damage caused by electrical current
Improper handling of live devices may lead to severe personal injury or death by electric shock.
Electrical installation and maintenance work must always be carried out by personnel
▸
authorized to do so.
The power supply must be disconnected when attaching and detaching electrical
▸
connections.
Select and implement wire cross-sections and their correct fuse protection in accordance
▸
with the applicable standards.
Do not touch any live parts.
▸
In the event of danger, immediately disconnect the object detection system from the
▸
power supply.
Always use original fuses with the specified current rating.
▸
Report any damaged cables to the maintenance team without delay.
▸
Observe the up-to-date safety regulations when working on electrical systems.
▸
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HAZARD
HAZARD
WARNING
NOTE
Damaging potential equalization currents due to different ground potentials
The AOS Prime has been designed and tested for electrical safety in accordance with EN 60 950-1 (2006-04) and EN 60 950-1/A11 (2009-03).
The AOS Prime is connected to the peripheral devices (power supply, PLC/host, any other sensors, etc.) via shielded cables. The shield of each cable is connected to the metal housing of the corresponding system components via the system plug.
If the peripheral devices have metal housings and if the cable shields are also connected to these housings, it is assumed that all devices involved in the system have the same ground potential.
This is achieved, for example, by complying with the following conditions:
• Mounting the devices on conductive metal surfaces.
• Correctly grounding the devices and metal surfaces in the system.
• Low-impedance and current-carrying equipotential bonding between areas with
different ground potentials, if necessary.
If these conditions are not met, e.g., on devices in a widely distributed system spanning several buildings, different ground potentials may cause potential equalization currents to flow along the cable shields between the devices, thereby creating hazards.
Risk of injury and damage caused by potential equalization currents
Potential equalization currents between the AOS Prime and the peripheral devices can have the following effects:
• Dangerous voltages on the metal housing, e.g., of the laser scanner.
• Incorrect functioning of or irreparable damage to the devices
• Damage/irreparable damage to the cable shields due to heating and cable fires
Commissioning/operation/maintenance
Risk resulting from incorrect commissioning and configuration
Do not commission without testing by qualified personnel!
Before carrying out initial commissioning of the system, you must have it checked and approved by qualified safety personnel.
Claims under the warranty rendered void
The housings of the devices must not be opened. The devices are sealed.
If the device is opened, any warranty claims against SICK AG will be void.
SAFETY 2
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WARNING
Risk resulting from faults
Cease operation if the cause of the malfunction has not been clearly identified.
Immediately stop system operation if you cannot clearly identify the fault and if you
▸
cannot safely remedy the problem.
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2.5 Protecting the environment

The components of the object detection system have been designed to minimize their impact on the environment. They consume little power and natural resources.
Always act in an environmentally responsible manner at work. For this reason, please note the following information regarding disposal.
Disposal after final decommissioning
Always dispose of unusable or irreparable devices in accordance with the applicable
▸
waste disposal regulations specific to your country.
Remove the plastic parts and recycle the aluminum housing of the laser scanner.
▸
Dispose of all electronic assemblies as hazardous waste. The electronic assemblies are
▸
easy to dismantle.
Note
SICK AG does not take back devices that are unusable or irreparable.
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3 Product description

NOTE
This chapter provides information on the special properties of the AOS Prime object detection system. It describes the construction and operating principle of the system, in particular the interaction of the different components.
Note

3.1 Scope of delivery

Always read this chapter before you mount, install, and commission the system.
The AOS Prime object detection system is available in two configuration groups: AOS10x and AOS50x. Different expansion stages result corresponding to the number of LMS laser scanners and the expansion modules of the control.
Thorough check for completeness
It is recommended that you carefully check for and report transport damage of any kind
▸
as soon as possible after receiving the system.
Also verify that the delivery includes all components listed on the delivery note.
▸
PRODUCT DESCRIPTION 3

3.1.1 Scope of delivery, AOS501-AOS504

The AOS501 configuration consists of a pre-configured LMS511 laser scanner, the Flexi Soft control (comprising the main module and an I/O expansion module) and a connection box for bridging large distances between the laser scanner and the terminal compartment.
Fig. 1: Main components of the AOS Prime AOS501
3 PRODUCT DESCRIPTION
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Part No.
Quantity
Description
1064409
1
AOS501
Consisting of:
1057618
1
Laser scanner LMS511-10100S02
1043783
1
Flexi Soft main module FX3-CPU000000
1043700
1
Flexi Soft system plug FX3-MPL000001
1044125
1
Flexi Soft I/O module FX3-XTIO84002
6034574
1
USB configuration connection DSL-8U04G02M025KM1
2073337
1
USB stick with configuration file (prepared configuration for control and laser scanner) as well as device and system documentation
6030928
1
Ethernet connection cable SSL-2J04-G10ME
1059092
1
LMS511 laser scanner accessory set 1, consisting of:
connection box
Part No.
Quantity
Description
2063050
1
Weather hood 180° LMS511
Part No.
Quantity
Description
1066130
1
AOS502
Consisting of:
1057618
2
Laser scanner LMS511-10100S02
1059092
2
Laser scanner LMS511 accessory set 1
Part No.
Quantity
Description
1066131
1
AOS503
Consisting of:
1057618
3
Laser scanner LMS511-10100S02
1044125
2
Flexi Soft I/O module FX3-XTIO84002
1059092
3
Laser scanner LMS511 accessory set 1
Part No.
Quantity
Description
1066132
1
AOS504
Consisting of:
1057618
4
Laser scanner LMS511-10100S02
1044125
2
Flexi Soft I/O module FX3-XTIO84002
1059092
4
Laser scanner LMS511 accessory set 1
AOS501
The “SOPAS” and Flexi Soft Designer configuration tools can be downloaded at
www.sick.com.
Optional
AOS502
Scope of delivery includes the same items listed for the AOS501, except for the following differences:
Connection box for power, I/O and RS-232/-422 data Mounting kit for mounting the laser scanner and
AOS503
AOS504
Scope of delivery includes the same items listed for the AOS501, except for the following differences:
Scope of delivery includes the same items listed for the AOS501, except for the following differences:
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3.1.2 Scope of delivery, AOS101-AOS104

Part No.
Quantity
Description
1064408
1
AOS101
Consisting of:
1047516
1
Laser scanner LMS111-10100S01
1043783
1
Flexi Soft main module FX3-CPU000000
1043700
1
Flexi Soft system plug FX3-MPL000001
1044125
1
Flexi Soft I/O module FX3-XTIO84002
6034574
1
USB configuration connection DSL-8U04G02M025KM1
operating instructions
2062346
1
Connection box for power, I/O and RS-232/RS-422 data (not Ethernet), with three pre-wired M12 cables, 8-pin
2046025
1
Mounting kit for laser scanner
6030928
1
Ethernet connection cable SSL-2J04-G10ME
Part No.
Quantity
Description
2046458
1
LMS111 weather hood 270°
Part No.
Quantity
Description
1066127
1
AOS102
Consisting of:
1047516
2
Laser scanner LMS111-10100S01
2062346
2
Connection box
2046025
2
Mounting kit for laser scanner
The AOS101 configuration consists of a pre-configured LMS111 laser scanner and the Flexi Soft control, which consists of the main module and an I/O expansion module. The laser scanner is connected to the Flexi Soft control via pre-wired configuration cables.
Fig. 2: Main components of the AOS Prime AOS101
AOS101
PRODUCT DESCRIPTION 3
Optional
AOS102
2073337 1 USB stick with configuration files and “AOS Prime”
The “SOPAS” and Flexi Soft Designer configuration tools can be downloaded at
www.sick.com.
Scope of delivery includes the same items listed for the AOS101, except for the following differences:
3 PRODUCT DESCRIPTION
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Part No.
Quantity
Description
1066128
1
AOS103
Consisting of:
1047516
3
Laser scanner LMS111-10100S01
1044125
2
Flexi Soft I/O module FX3-XTIO84002
2062346
3
Connection box
2046025
3
Mounting kit for laser scanner
Part No.
Quantity
Description
1066129
1
AOS104
Consisting of:
1047516
4
Laser scanner LMS111-10100S01
1044125
2
Flexi Soft I/O module FX3-XTIO84002
2062346
4
Connection box
2046025
4
Mounting kit for laser scanner
AOS103
AOS104
Scope of delivery includes the same items listed for the AOS101, except for the following differences:
Scope of delivery includes the same items listed for the AOS101, except for the following differences:
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3.2 Components in the system

3.2.1 The LMS511/LMS111 laser scanners

The LMS511 or LMS111 laser scanners, whose use depends on the application require­ments, are laser measurement sensors that scan their environment in two dimensions using a time-of-flight method. When a sent laser beam is reflected by a target object, the position of the object is determined as a distance and an angle and output to the data interface and supplied to the internal field evaluation.
The laser output occurs at the front screen. It is indicated by a corresponding mark.
Fig. 3: Laser output aperture on the LMS511 / LMS111 laser scanner
Different monitoring fields are defined within the scanning range of the laser scanners (scanning range). Each monitoring field is linked to at least one evaluation case; the assigned switching output is triggered if the respective field is infringed (object detection in the monitoring field).
The LMS511 laser scanner has a monitoring radius of 80 m / 38 m for black objects with 10% remission and a scanning angle of 190°. The monitoring radius of the LMS111 laser scanner is 20 m / 18 m for black objects with 10% remission. The scanning angle is 270°.
All input and output signals from the laser scanner are directly connected to the central Flexi Soft control, which evaluates the laser scanner information accordingly (see below).
The laser measurement sensors are designed for outdoor use in harsh ambient conditions. In order to withstand such conditions, the devices have various filter technologies and an internal heater. They are also equipped with weather hoods.
Both laser scanners feature automatic contamination measuring for the front screen. The contamination signals can be merged using the central Flexi Soft control and can be output via a shared application diagnostic output.
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Note
The laser scanner can evaluate multiple reflection pulses. Additional reflective pulses occur when the laser beam hits smaller particles such as snowflakes or raindrops. In very harsh environments, the laser scanner can also be switched to evaluate the last echo if necessary.
Fig. 4: Evaluation of reflection pulses by the laser scanner
For detailed information about the operating principle of the LMS laser scanner, please refer to the operating instructions of the respective devices.

3.2.2 The Flexi Soft control

The Flexi Soft control consists of the CPU0 central main module (1) and at least one XTIO I/O expansion module (2).
Note
Fig. 5: Flexi Soft safety control components
• The CPU0 main module is the central logic unit of the control. Here, all signals are analyzed and evaluated within the configured logic. The result of this processing is transmitted to the higher-level machine or system control via the I/O module.
The configuration can be edited and adapted to the requirements of the individual application. For this purpose, the main module has an M8 configuration connection.
• The XTIO I/O expansion module provides the I/O input and output signals from the AOS Prime. The communication with the connected laser scanners and with the downstream machine control occurs via the switching signals of the AOS Prime.
One XTIO I/O expansion module is necessary for every two laser scanners. One laser scanner uses three switching inputs in the basic version. Signals are communicated to the upper-level system control via switching outputs.
It is possible to attach additional XTIO modules according to the expansion desired.
In total, the control can be used to operate up to 12 modules (144 I/O signals).
Different configurations are supplied for the Flexi Soft control. The appropriate control configuration for the system can be carried out by downloading a file. This file already contains all AOS functions necessary for checking both the object detection system and the internal self-test of the sensors.
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3.2.3 The test target

No.
Meaning
1
Monitoring field
2
Test target
The self-diagnosis of the object detection system occurs via the continuous detection of an external test target. During this process, the corresponding scanner monitoring field is infringed by the test target. Only by using external test targets can the full functional range of the AOS Prime object detection system be ensured.
At least one external test target is required for each laser scanner. It is also possible to use a shared test target for multiple laser scanners.
A stationary body located outside the actual object detection monitoring area can be used as a test target.
PRODUCT DESCRIPTION 3
Note
Fig. 6: Detection of a test target
Tab. 2: Status indicators on the Flexi Soft main module
The surface of the test target should be flat. For example, sheets, panels or even a suitable part of the monitored machine are appropriate test targets. In order to avoid reflections on the surface of the external test target, the area of the test target must not be covered with a glossy coating. The color of the test target should be consistent with the color of the objects that are to be detected.
The width of the test target must be at least 30 mm. The following applies to the minimum width of the test target as a rule of thumb at distances > 1.5 m to the test target:
Width of test target [mm] = target scanning range [mm] / 50.
To determine the exact diameter of the light spot, please consult the operating instructions for the corresponding laser scanner.
Alternatively, it is possible to use a stationary machine or system part as a test target.
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3.2.4 The connection box of the laser scanner

Using the connection box, connecting the laser scanner and the control cabinet to the Flexi Soft control is easy. The connection box is delivered with the AOS Prime systems by default.
Separate installation cables are routed from the Flexi Soft to the connection box on-site to produce the connection. The connection box is connected to the laser scanner via the pre-configured cables (see chapter 5.1 Connecting the LMS511 laser scanner).
When using the AOS Prime in the AOS10x configuration, the LMS111 laser scanners are also connected to the Flexi Soft using the configured connection box or using system cables (max. 20 m) (see chapter 5.2 Connecting the LMS111 laser scanner).
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3.3 Principle of operation

The AOS Prime is a self-testing object detection system whose functionality as a whole is monitored by the Flexi Soft safety control.
Monitoring fields and evaluation cases
The monitored area scanned by the laser scanners is divided into different fields. The size and geometry of the monitoring fields can vary and must be configured on-site.
Fig. 7: Predefined monitoring fields in the AOS Prime
In the AOS Prime, the following standard monitoring fields are available:
• Stopping field (1) e.g., for stopping the system or a movement direction on a mobile
system.
• Warning field (2) e.g., for advance warning or reduction of speed on a mobile system.
• Test field (3) for detecting an external test target.
Switching signals in object detection
The laser scanners operate internally with so-called evaluation cases that are assigned to the monitoring fields. If a monitoring field is infringed, this will be signaled by the corresponding switching output on the laser scanner.
The Flexi Soft analyzes the information from the laser scanner and transmits the corresponding results, such as “Warning field infringed” or “Stopping field infringed”, to the upper-level system control.
PRODUCT DESCRIPTION 3
Note
Fig. 8: Switching signals for object detection
Additional control tasks, such as an emergency stop or the evaluation of, for example, limit switches, are also possible with the Flexi Soft. However, they are not the primary feature of the AOS Prime object detection system!
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Switching signals in self-diagnostics
The Flexi Soft control also handles the internal self-testing of the laser scanners. For this purpose, the control cyclically sends a changeover signal to the laser scanner to switch the assignment of the monitoring and test fields to the switching output (= switching evaluation fields).
Fig. 9: Switching signals for the internal self-testing of the AOS Prime
The change in the assignment of stopping and warning fields causes the switching outputs to respond with a signal change from High to Low or, conversely, from Low to High. The control performs the safety-related plausibility check of the individual changes expected in the laser scanner switching signals.
In the example below, output Out 1 reports an intact stopping field prior to the changeover signal (test command) by sending a High signal, and output Out 2 reports the detected test target by sending a Low signal.
After the changeover signal, output Out 1 reports the detected test target (Low signal) and output Out 2 reports the intact stopping field (High signal).
Note
Fig. 10: Switching signals of the self-test
The test response from the laser scanner (on/off switching operation at the outputs) occurs once the response time set on the laser scanner has expired, e.g., after 180 msec.
The Flexi Soft wait time for the test response from the laser scanner must always be longer than the actual response time of the laser scanner (e.g. wait time = 1 sec., laser scanner response time = 500 msec.).
In exceptional cases, the predefined wait time must be adjusted via the Flexi Soft parameters.
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What errors can be detected?
Display
Meaning
Laser scanner in operation, no evaluation cases are reporting an event
Optics cover is dirty
Switching output switched
Laser scanner is in teach-in mode
The internal self-test ensures that the test target is continuously detected by the laser scanner. If a correct response is not given, the control is locked and sends a stop signal to the upper-level machine control.
Incorrect responses can, for example, have the following causes:
• Defective laser scanner
• Missing test target
• Improper laser scanner adjustment (mechanical error or manipulation)
• Physically defective switching output on the laser scanner or short-circuit to VDC,
cross-talk or short to ground
• Cable break

3.4 Status indicators

Status indicators are located on the laser scanners and the Flexi Soft control.

3.4.1 LEDs on the LMS111 / LMS511 laser scanner

PRODUCT DESCRIPTION 3
In normal operation, the laser scanner is fully automatic—no operator intervention is required. The LEDs and 7-segment display signal the operational status of the LMS111 and LMS511 laser scanner.
Fig. 11: Laser scanner status indicators (pictured: the LMS511 laser scanner)
Laser scanner in operation, at least one evaluation case reports an event
Tab. 3: Status indicators on the laser scanner
The 7-segment display is used for diagnostics when errors or faults occur (see chapter 8.3
Fault indicator on the LMS511 / LMS111 laser scanners).
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LED
Display
Meaning
MS  Green
Module status, illuminated green during proper control operation.
MS  Green (1 Hz)
System in stopped status. Start application in Flexi Soft Designer. CV 
Configuration in process.
CV  Yellow (2 Hz)
The configuration is being permanently saved. Do not disconnect from power supply until save process has been completed.
CV  Yellow (1 Hz)
Unverified configuration. The configuration must be verified by the Flexi Soft Designer.
CV  Yellow
Verified configuration, illuminated yellow once configuration has been verified.
LED
Display
Meaning
MS
Module status, illuminated green during proper operation of expansion module.
MS
System in stopped status. Start application in Flexi Soft Designer.
I/O  Input/output is deactivated.
CV
Input/output is deactivated.

3.4.2 LEDs on the Flexi Soft

Main module
CPU0
Fig. 12: Status indicators on the Flexi Soft main module
I/O module
Tab. 4: Status indicators on the Flexi Soft main module
Fig. 13: Status indicators on the Flexi Soft expansion module
Green
Green
Green
Tab. 5: Status indicators on the Flexi Soft expansion module
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3.5 Parameter memory

3.5.1 Parameter set on connector plug of the Flexi Soft control unit

The system configuration parameters are saved on the connector plug of the Flexi Soft CPU0 main module. This allows the main or expansion modules to be replaced without having to reconfigure the Flexi Soft control (see chapter 7.3.2 Replacing Flexi Soft
safety control modules).

3.5.2 Parameter set in the laser scanner

All monitoring field with the basic field geometries as well as the necessary evaluation cases are already pre-configured and permanently saved (factory settings) in this laser scanner. Changes to the configuration (e.g. field geometries) are done using SOPAS configuration software. The configuration can be saved in a file and transferred to the replacement device when a laser scanner is replaced (see chapter 7.3.1 Replacing a
laser scanner).
PRODUCT DESCRIPTION 3

4 MOUNTING

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WARNING
4 Mounting

4.1 Planning mounting locations

The reliable and problem-free operation of the AOS Prime depends primarily on the proper planning and mounting of the laser scanners.
Laser scanner
• The laser scanners must have sufficient mechanical protection. Only with optimal positioning is it possible to adequately protect the system against collisions.
• Always be sure that the laser scanner has an unobstructed view of the areas that are to be monitored.
• The laser scanners must be mounted in such a manner that they can detect objects that penetrate the monitored area.
Test target
The test target must be mounted in such a way that the laser beam impinges on the surface of the test target as vertically as possible.
Notes on the scanning field
When planning to mount the laser scanners, be sure to consider the fact that the laser beam widens as the distance from the laser to mount the laser scanner increases. As a result, the ground or a wall panel within the scanned area could end up being permanently detected under unfavorable conditions because it is being hit by the laser beam.
Recommendation
Detailed information on the operating principle of the laser measurement sensors can be found in the operating instructions for the LMS511 and LMS111 laser scanners.

4.2 Mounting the laser scanners

4.2.1 General notes

Mount the laser scanners at the designated locations. Be sure to observe the detailed drawings and information in the operating instructions for the LMS511 or LMS111 laser scanner.
Be sure to closely observe the following notes during mounting:
Mount the laser scanner so that it is protected from dirt and damage.
▸
Ensure that the field of view of the entire front screen is not restricted.
▸
Always mount the laser scanner such that you are able to insert and remove the
▸
connector plug.
Avoid excessive shock and vibration exposure of the laser scanner.
▸
For systems that vibrate heavily, use shock absorbers to prevent the possibility of
▸
fixing screws coming loose unintentionally.
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