Siemens SIMATIC FS600 Instruction Manual

SIMATIC FS600 Laser Scanner
Laser Scanner for Personal Protection and Measurement Tasks
Instruction Manual
600672
Warning
Important
This instruction manual must accompany the product throughout its working life. Those persons responsible for the product must ensure that all persons involved in the installation, commissioning, operation, maintenance and servic­ing on the product have access to all the information supplied by the manufacturers of the machine and its safety system.
3
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.
4
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the tech­nical description and only in connection with devices or components from other ma­nufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
5
About this Instruction Manual
This instruction manual contains information on the proper use and effective applica­tion of the SIMATIC FS600 Laser Scanner.
WARNING
All the information contained herein, in particular the safety notes, need to be carefully observed.
Notes regarding safety and warnings are marked by this symbol .
Notes regarding important pieces of information are marked by the symbol .
References to the safety of laser devices are identified with the symbol .
This instruction manual must be stored carefully. It must be available for the entire operating time.
SIEMENS AG is not liable for damages caused by improper use. Knowledge of this instruction manual is an element of proper use.
Warning
Dangerous electric voltage! Electric voltage can cause elec­tric shock and burns. Before commencement of work you therefore need to turn the system/device power off.
Important note
Safe device operation can only be guaranteed when certified components are used! The products described herein were developed to take over safety-related functions as part of a turn key system or machine. A complete safety-related system is usually equipped with sensors, evaluation units, status controls and incorporates concepts for safe switch-off procedures. It is the responsibility of the manufacturer of a system or a machine to ensure its correct overall operation. SIEMENS AG, its local offices and associated companies (hereafter referred to as “SIEMENS”) cannot guarantee for all features of a turn key system or a machine that was not designed by SIEMENS. Neither does SIEMENS assume liability for recommendations given in or implied in the following instruction manual. The following instruction manual shall not be construed as a new guarantee, warranty or liability claim beyond the general terms and conditions of SIEMENS.
Copyright © SIEMENS AG 2007 All rights reserved Reprints and reproduction of this instruction manual as well as communication and
utilization of its content is not permitted without express permission. Noncompliance will entail compensation for damages. All rights reserved, in particular for the grant of patents or design registrations.
Technical Support: Telephone:+49 (0) 180 50 50 222 Internet:www.siemens.com/automation/service&support
Subject to change without prior notice.
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CONTENTS
1 Approvals and Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Approval and Declaration of EC Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Specialized Technical Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Guidelines and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Brief Description and Functional Principle of the SIMATIC FS600 Laser
Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Special Features of the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Safety notes and usage in accordance with intended purpose . . . . . . . . . . . . . . . . . . . . . . 17
3.1 General safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Usage requirements and usage in accordance with intended purpose . . . . . . . . . . . . . . 17
3.3 Restrictions for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Information Related to Detection Zone Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 General information related to determining detection zone contours . . . . . . . . . . . . . . . 20
3.6 Additional Safety Notes for Stationary Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.7 Additional Safety Notes for Mobile Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Applications for the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Stationary Safeguarding of the Danger Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Access guarding by passage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Safeguarding of danger points based on hand and arm detection . . . . . . . . . . . . . . . . . 25
4.4 Mobile Safeguarding of Automatic Guided Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 Protecting Transporter Trolleys against Collisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Guarding the sides on AGVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7 Other possible applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5 Information for Planning and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 Attachment and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 Installing adjacent laser scanners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.2 Adjusting adjacent laser scanners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.3 Information on Setting the Dimensions of Detection Zones . . . . . . . . . . . . . . . . . . . . . . 32
5.3.1 Methods of Configuring Detection Zones using the PC . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3.2 Range of the Detection Zone, Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3.3 Range of the Warning Zone, Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.3.4 Range of the measurement field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3.5 Required Detection Zone Additions Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.4 Safeguarding Stationary Danger Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.1 The Purpose of Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.2 Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.4.3 Mounting Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.4.4 Recommendations for Mounting to Prevent Unmonitored Zones . . . . . . . . . . . . . . . . . . 36
5.4.5 Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4.6 System Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4.7 Restart Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4.8 Calculating the Detection Zone Dimensions for Safeguarding an Area . . . . . . . . . . . . . 42
5.5 Access protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5.1 Object of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5.2 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5.3 Safety-relevant settings, and calculation of the safety distance . . . . . . . . . . . . . . . . . . . 47
5.5.4 Definition of the reference boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7
5.6 Protecting danger points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6.1 Object of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6.2 Installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.6.3 Safety-related settings, and calculation of the safety distance . . . . . . . . . . . . . . . . . . . . 49
5.6.4 Defining the reference boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Safeguarding Mobile Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7.1 The Purpose of Safeguarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7.2 Installing adjacent laser scanners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7.3 Mounting Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7.4 Mounting Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.7.5 Recommendations for Mounting to Prevent Unmonitored Zones . . . . . . . . . . . . . . . . . . 53
5.7.6 Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.7.7 System Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.7.8 Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.7.9 Calculating the Dimensions of the Detection Zone of an AGV Application . . . . . . . . . . . 57
5.7.10 Side guarding configuration on AGVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6 Details on switching over detection and warning zones . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1 Sequence of zone pair switchovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Practical AGV Application (Example) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7 Functions of the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.1 Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2 Channels for Zone Pair Changeovers, FP 1 to FP 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.3 Alarm 1 (X1-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.4 Alarm 2 (X1-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.5 OSSD 1 (X1-12) and OSSD 2 (X1-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.6 Data Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 Integrating the SIMATIC FS600 Laser Scanner into Machine Controls . . . . . . . . . . . . . . . . 68
8.1 Integrating the SIMATIC FS600 Laser Scanner with External Wiring with Relays
and Quadruple Zone Pair Changeover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.2 Connecting the SIMATIC FS600 Laser Scanner to a Safety Sequence Circuit
with Manual Restart, Relay Monitoring, without Zone Pair Changeover . . . . . . . . . . . . . 71
8.3 Connecting the SIMATIC FS600 Laser Scanner to a PLC with Corresponding
Safety Level (Cat. 3 or higher, EN 954) and Zone Pair Changeover . . . . . . . . . . . . . . . 72
9 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.1 Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.2 Connecting the PC and Control Cables to the Scanner . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.3 Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.4 Points to Consider When Preparing and Laying the Cables . . . . . . . . . . . . . . . . . . . . . . 74
9.5 Interface Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.1 Hardware and Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.2 Installing “SIMATIC FS600 Parameterization Software LS4soft” and Starting Up
the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.3 SIMATIC FS600 Laser Scanner status indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.4 Status information of the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . 81
10.5 Restart and device swap-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8
11 Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.1 Test before First Startup by Person Qualified and Authorized to Perform the
Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.2 Extended Shutdown of the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . . . . 83
11.3 Regular Tests by a Person Qualified and Authorized to Perform the Task . . . . . . . . . . . 84
11.4 Daily Test by with Test Piece Performed by Responsible Operating Personnel . . . . . . . 84
11.4.1 Checklist for Daily Test of Stationary Applications by Responsible Operating
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
11.4.2 Checklist for Daily Test of Mobile Applications by Responsible Operating
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
11.5 Checklist for Testing Stationary Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11.6 Checklist for Testing Mobile Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
11.7 Replacing the Optical Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.7.1 General information: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
11.7.2 Initial Measurement of the New Optical Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.7.3 Procedure when Using the SIMATIC FS600 Parameterization Software LS4soft
User Software Version 1.09 or later . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
11.8 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.8.1 Cleaning the Optical Window when Dirty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
11.8.2 Cleaning the Optical Window; Cleaning Diffusing Light Panes . . . . . . . . . . . . . . . . . . . . 96
12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13 Delivery Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
13.1 Coding of the Control Cable X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
14 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
14.1 Test Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
14.2 Detection zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
14.3 Detection Zone Additions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14.4 Warning zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14.5 Contour Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
14.6 Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
14.7 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
14.8 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
14.9 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
14.10 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
14.11 Optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
14.12 Environment and Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
14.13 Dimensional drawings of the SIMATIC FS600 Laser Scanner . . . . . . . . . . . . . . . . . . . 104
14.14 Dimensional drawings of the mounting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
15 Diagnostic Codes and Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9

1 Approvals and Certificates

1.1 Approval and Declaration of EC Conformity

EC prototype testing in accordance with DIN EN 61496 - 1 and IEC 61496 - 3
TÜV PRODUCT SERVICE GMBH IQSE Ridlerstr. 65 80339 Munich
10

1.2 Specialized Technical Terms and Abbreviations

AGV Automatic Guided Vehicle (FTS in German)
AOPD Active Optoelectronic Protective Device
AOPDDR Active Optoelectronic Protective Device responsive to Diffuse
BWS See ESPE
EDM External Device Monitoring
ESPE Electro-Sensitive Protecting Equipment
FTS Automatic Guided Vehicle (see AGV)
N.O. Normal open contact
OSSD Output Signal Switching Device
PC Personal Computer
DZ Detection Zone, German SF
Reset Defined Reset
RS 232 RS 232 interface
RS 422 RS 422 interface
ZP Zone pair (contains 1 x detection zone and 1 x warning zone),
WZ Warning Zone, German WF
Reflection
Monitoring of external control parts (relay monitoring)
Safety-relevant switch output
of SIMATIC FS600 Laser Scanner
German FP
Table 1.2-1: Specialized Technical Terms and Abbreviations
11

1.3 Guidelines and Standards

The following guidelines and standards are of critical importance for the implementation of laser scanners. Guidelines providing particularly relevant information for users of such systems are marked with an asterisk (
Guideline/Standard Designation
European Guidelines
98 / 37 / EG Machine guideline
73 / 23 / EWG Low voltage guideline
89 / 336 / EWG EMC guideline
A Standards
DIN EN 292 1 and 2 Safety of machinery, basic concepts
DIN EN 1050 Principles of risk assessment
B1 Standards
).
*
*
DIN EN 294 Safety distances
DIN EN 954 -1 Safety-related parts of controls
DIN EN 999 Approach speeds of body parts
B2 Standards
DIN EN 60204 -1 Electrical equipment of machines
DIN EN 60825 -1 Safety of machines with laser components
DIN EN 61496 -1
IEC 61496-3 AOPDs responsive to diffuse reflection
C Standards
DIN EN 775 Industrial robots; safety
DIN EN 1525 Automatic guided vehicles (AGV) and their
DIN EN 12895 Floor conveyor vehicles, electromagnetic
Electro-sensitive protecting equipment
(AOPDDR)
systems
compatibility
*
*
* *
* *
12
Guideline/Standard Designation
National Standards
DIN 15185-2 Warehousing systems using rail-guided aisle
conveyance vehicles
Table 1.3-1: Guidelines and Standards
This list does not claim to be complete. In certain cases, the concrete requirements of the application will necessitate the application of additional guidelines and standards! Copies of safety standards can be purchased from the Beuth Publishing Company in Berlin, Germany.
*

2 System Overview

2.1 Brief Description and Functional Principle of the SIMATIC FS600 Laser Scanner

The SIMATIC FS600 Laser Scanner is an optical distance sensor that takes two­dimensional measurements. It could also be referred to as an optical area radar device. The sensor uses a rotating deflecting unit to periodically emit light pulses within a working range of 190°.
If these pulses strike a person or an obstacle, the reflected light is received and evaluated by the SIMATIC FS600 Laser Scanner. The scanner calculates the precise coordinates of the person or object based on the travel time of the reflected light and the current angle of the deflecting unit. If the person or obstacle is within the bounds of a previously defined area called a detection zone, a safety-oriented switching function is performed. This switching function causes the semiconductor outputs to be switched off. The safety-oriented switching function cannot be reset until the detection zone is clear. Depending on the operating mode, the reset can be initiated either automatically or manually.
13
DZ = Detection zone, max. 2,15 m / 4 m WF = Warning zone, max. 15 m a = Maximum registration of measurement values,
max. 50 m
b = Detection zone programmed
in the SIMATIC FS600 Laser Scanner (example)
c = Warning zone programmed
in the SIMATIC FS600 Laser Scanner (example)
d = Configurable detection
zone and warning zone expansion (-5 °)
d
cb
e = Configurable detection
zone and warning zone expansion (+5 °)
f = Object in the detection zone
Fig. 2.1-1: The 190° angle range of the SIMATIC FS600 Laser Scanner is divided
into 0.36° angle segments.
A laser diode coupled with transmitter optics produces focused light pulses. These pulses are projected across the monitored surface by a rotating mirror in such a way that a light pulse is triggered in each of the angle segments within 40 ms (scanning rate: 25 scans/s).
SF
WF
f
a
e
14
Fig. 2.1-2: Functional principle of the SIMATIC FS600 Laser Scanner
The SIMATIC FS600 Laser Scanner can detect people up to a distance of 4.0 m e.g.
2.15 m – even if they are wearing very dark clothing or exhibit a low degree of reflectance. Dangerous movements are brought to a standstill by two failsafe semiconductor outputs.
Objects (min. 150 x 150 mm) are detected up to a distance of 15 m (corresponds to the warning zone) and signaled by way of a non-safety-related semiconductor output.
Four programmable zone pairs (each of which consists of one detection zone and one warning zone) enable the scanner to be optimally adapted to the needs of each particular application.
The SIMATIC FS600 Laser Scanner can be implemented not only on machines and systems (stationary safeguarding of danger zones), but also on vehicles (mobile safeguarding of transport vehicles).
Due to its wide range of measurement and its non-contact, electro-sensitive measurement principle, the SIMATIC FS600 Laser Scanner can be effectively used as a protective device for virtually any application.

2.2 Special Features of the SIMATIC FS600 Laser Scanner

Four / eight freely programmable detection zones (up to a maximum of 4 m)
Four / eight freely programmable warning zones (up to a maximum of 15 m)
Expanded monitoring range of up to 190 °
ConfigPlug see Chapter 10.5 for easy device swap-out without configuration
expense
Compact design (W x D x H: 140 mm x 135 mm x 155 mm)
Low weight (2 kg)
Low power requirements (300 mA, plus the load at the outputs)
Two types of interfaces at one Sub-D jack (RS232 and RS422)
User-friendly software
15
Status displays on the SIMATIC FS600 Laser Scanner
Protective caps
Assignment of interface X1
FP 4
8
FP 3
7
FP 2
FP 1
UB
GND
6
5
4
3
2
1
Alarm 1
Restart
LEDs
Assignment of interface X2 as RS232 port
Alarm 2
15
Reserved
14
Reserved
13
OSSD2
12
OSSD1
11
Reserved
10
Reserved
9
16
1a
2a
1b
2b 2c
5a 5b 5c
1a= Sensor function 1b= Errors on the zone pair control inputs,
Light flashing at 2 Hz 2a= Warning field is occupied 2b= Optical window is dirty,
Light flashing at 2 Hz 2c = Confi gPlug configuration see Chapter 10.5 no t
compatible, Light flashing at 4 Hz 3 = OSSDs are turned off 4 = OSSDs are turned on 5a= Restart inhibit locked,
Continuous light 5b= Optical window is dirty,
Light flashing at 2 Hz 5c = Fault, light flashing at 4 Hz
Reserved
Reserved
GND/shield
TxD
RxD
1
2
3
4
5
RS232 detection
6
Reserved
7
Reserved
8
Reserved
9
Assignment of interface X2 as RS422 port
Tx +
Tx -
Rx -
Rx +
GND/shield
1
2
3
4
5
RS422 detection
6
Reserved
7
Reserved
8
Reserved
9
Connection Pin 5 to Pin 6

3 Safety notes and usage in accordance with intended purpose

3.1 General safety notes

SIEMENS products are developed and manufactured with careful application of standard rules of the industry. The protective function of the devices can be negatively affected, however, if they are used improperly or not in accordance with their intended purposes. If this occurs, it may not be possibly to safeguard danger areas completely or at all, which may result in danger to life and limb for persons who are in the general area of the machines or systems.
CAUTION – LASER RADIATION!
The SIMATIC FS600 Laser Scanner is a laser device belonging to laser class 1. The valid legal and local regulations for operating laser systems must be complied with. Avoid positioning the scanner at eye level.

3.2 Usage requirements and usage in accordance with intended purpose

The relevant regulations for machine safety apply for the use of the SIMATIC FS600 Laser Scanner. Responsible authorities (for example professional trade unions, OSHA) are also available for questions related to safety. In general, the following usage requirements must be observed:
If the scanner is enclosed in a protective housing, additional window material, such
as plastic or glass must not be used as it may impair the detection.
Avoid touching the scanner optical window and the six diffusing light screens.
The SIMATIC FS600 Laser Scanner is not suitable for use as a protective device:
- if it is possible that dangerous fluids will be spewed out or objects will be
- ejected. for machines with long braking times (max. depth of the detection zone: 4 m) For these cases, SIEMENS offers suitable safety interlocking devices (safety switches) with and without guard locking.
The SIMATIC FS600 Laser Scanner corresponds to Type 3 in accordance with IEC 61496-1 and –3A safety category of 3 in accordance with EN 954-can be achieved with the SIMATIC FS600 Laser Scanner if all other elements in the safety chain are set up to stop the dangerous motion in accordance with that safety category.
The electrical connection of the SIMATIC FS600 Laser Scanner to the control system must only be made by an electrician.
The 24-V DC power supply (+20 %, -30 %) must be ensured by a safe network disconnect in accordance with IEC 742. The same requirements apply to all connected input and output circuits..
17
The 24-V DC power supply must be fed to the scanner through a separate branch with a 1.25 Amp delayed action fuse in the control cabinet.
Guard operation is only permitted with the control cable (X1) of the dummy connector . This also applies for transport and storage.
The safety output has a double design. The two OSSDs must always be included in the shut-off circuit of the machine in such a manner that either of the two is completely sufficient by itself to turn off the motion that presents a danger.
The alarm output 1 (Pin 5 on X1) must not be used to switch safety-related signals.
System tests (of the scanner, machine, control components and switch components) may only be performed when they do not result in potential hazards for people.
Tampering with or making changes to the SIMATIC FS600 Laser Scanner can result in the loss of the safety function.
Only expert trained personnel is allowed to perform startup, maintenance, parameter settings or detection zone configurations. Familiarity with the safety notes in this Connecting and Operating Instruction and in the operating instructions for the “SIMATIC FS600 Parameterization Software LS4soft” program constitutes part of this expert knowledge.
The password required for configuring safety-relevant parameters must be kept in a secure location by the safety official. Information about password levels can be found in the “SIMATIC FS600 Parameterization Software LS4soft” user's manual.
If the machine is designed for start interlock /manual restart, all detection zones must be checked before enable - no one is permitted in the danger area.

3.3 Restrictions for Use

Glass, highly reflective materials such as mirrors (reflectance > 10,000 %), or objects that do not reflect any light back to the sensor can falsify the measurement result. More information is available in Chapter 5.3.5.
Do not expose the SIMATIC FS600 Laser Scanner to flying sparks (for example a welding flash). Doing so may cause damage to the optical window.
Vapor, smoke, dust and all particles visible in the air have a significant negative effect on measurement values and will result in the semiconductor outputs being turned off.
Avoid extreme variations in temperature.
18
Make sure that the following types of light sources are not present on the scanning plane:
- Laser light from one or more other scanners or sensors
- Infrared light
- Fluorescent light
- Stroboscopic light Please consider as well Chapter 5.2.
It must not be used with internal combustion engines.
The SIMATIC FS600 Laser Scanner is conceived for use inside enclosed spaces and with the operating parameters listed in the technical specifications (temperature, humidity, shock, vibration, etc.). Please refer to the list of parameters in Chapter 14.
Avoid having reflective surfaces (such as glass, mirrors, retro-reflectors, etc.) at fixed contours in the scanning plane. If this is not possible, an additional detection zone must be provided.

3.4 Information Related to Detection Zone Changeover

If alternating operation is included in the design, and thus detection zone changeover, the activation and effect of the detection zone in question must match the alternating operating mode.
The new detection zone must be activated before turning off the previous detection zone. The time at which the changeover is made must be based on a risk analysis.
Braking paths, response and coast-down times must be taken into consideration (for example overlapping detection zones).
A “Start interlock” function is provided.
If the machine has a restart key, it must not be possible to operate it from inside the detection zones. All danger areas must be visible from the position of the button. Before releasing the start/restart interlock, all detection zones must be tested. No one is permitted inside the danger areas.
There must be no unmonitored zones inside the danger areas.
There must be no possibility for direct access to the danger area that shortens the necessary safety distance (use a protective grid, for example).
The information on required detection zone additions in Chapter 5 must be observed.
19

3.5 General information related to determining detection zone contours

Shadow effects (e.g. surfaces or areas located behind stationary objects) must be considered. As a rule, insufficient safeguarding must be adequately supplemented by further safety measures such as guard fences, light curtains, and the like!
Access to the detection zone in the dangerous area is not permitted.
When setting the dimensions of the detection zone, you must comply with the formulas cited in Chapters 5.4.8 and 5.7.9 ! Be sure to comply with higher-level machine standards (e.g. DIN EN 1525) if applicable. These contain individual specifications, for example, on points of access to the danger zone and, if applicable, detection zone additions that must be given special consideration. They also provide information on how to measure safety distances at machines.
Detection zones with a radius smaller than 20 cm (at or close to the scanner) are not admissible. 20 cm is the preset minimum contour.
When setting the dimensions of the detection zones, please comply with the maximum angle error stated in the technical specifications (Chapter 14.11).
Needle-shaped detection zone contours are not permitted, since they do not ensure any protective effect. For additional information, please refer to the SIMATIC FS600 Parameterization Software LS4soft user software (Chapter entitled “Definition of Detection Zones”).
Due to possible measurement errors, every detection zone has an additions area in which detection is not guaranteed under all conditions. Please consider as well Chapter 5.3.5. Read Chapter 5.4.6 and 5.7.7 for information on optimizing system availability.
The required safety distances must be taken into account when making detection zone configurations. Safety distances are calculated according to formulas found in either the machine-specific C standards or the general B standards IEC 61496-3 in combination with DIN EN 999 (see Section 2 and 5 of the standard). Tolerance fields and/or additions (make sure to consider Chapter 5.4 and 5.7).
After the detection zones have been set, make a printout of the following information:
- Detection zone contour with the X and Y coordinates
-Date
- Serial number of the scanner
- Name of the safety official
When calculating the additions, be sure to consider whether the dust algorithm is deactivated or activated (see Chapter 5.3.5).
20
When calculating the safety distances, be sure to consider all delay times, such as the response time of the scanner, response time of the control elements, and braking times and/or stopping times of the machine/system or AGV! Variations in delay time caused by factors such as reduced braking power must also be taken into consideration.
The effectiveness of the switch-off function must be tested along the defined contour of the detection zone during the initial startup and subsequent to any changes made to a machine or system.
The effectiveness of the switch-off function must be tested for the detection zone contours along the entire driving route during the initial startup and following any changes made to an AGV.
In the event that there is insufficient room available to allow the full dimensions of a detection zone, for example because of the position of the scanner, additional safety measures (e.g. safety grids) must be installed.
Following each definition of and change to the detection zones, the configuration must be checked to see whether the possibility of people standing in the danger zone as well as any barriers provided have been considered by an appropriate layout of the detection zone(s).

3.6 Additional Safety Notes for Stationary Use

If the danger zone can be accessed from the side, and if the detection zone cannot be extended sufficiently in this direction, additional safety measures (e.g. safety fences) must be installed.
We recommended marking the contour of the detection zone on the floor by painting a colored line or applying colored adhesive tape.
Check the mounting regularly (in particular, the angle of inclination) in order to guarantee the reliability of detection.
21

3.7 Additional Safety Notes for Mobile Use

There are additional requirements for the use of scanners on automatic guided vehicles (AGV) and transporter trolleys according to DIN EN 1525.
If possible, expanded detection zones to each side should be provided in order to safeguard access from the side and directly in front of the vehicle.
If is it not possible to completely safeguard the contour of the vehicle including its trailer and the dimensions of its load while making curves, additional protective devices such as switch strips must be attached to the side of the vehicle.
There must be a minimum safety distance S on both sides. A one-sided minimum safety distance is admissible in certain exceptional cases. The specifications of DIN EN 1525 must be complied with.
The basic value of the detection zone width for an AGV corresponds to the maximum vehicle width including the trailer and the dimensions of the load plus the detection zone additions Z AGV while making curves must be considered when defining detection zones.
If the SIMATIC FS600 Laser Scanner is mounted on vehicles, the mounting (especially the angle of inclination), the vehicles' braking power, and if applicable, play in the vehicle guidance (the difference between the optimum and actual line of guidance) must be regularly checked in order to guarantee the reliability of detection.
. Furthermore, the greatest possible lateral shift of the
S
of 500 mm to the side of the vehicle
AB
22

4 Applications for the SIMATIC FS600 Laser Scanner

Due to its continuous coverage of the area, its wide range, and the ability to select among four / eight zone pairs, the SIMATIC FS600 Laser Scanner is able to handle even complex applications

4.1 Stationary Safeguarding of the Danger Area

The SIMATIC FS600 Laser Scanner is used to safeguard dangerous working areas at machines and systems where both constant and variable demands are placed on the geometrical shape of the detection zone. The aim is to prevent people from entering the danger zone or reaching the danger point with their upper and/or lower extremities, at the same time without impeding the production process. The SIMATIC FS600 Laser Scanner can be mounted directly at the machine table or on the side or in front of the machine.
b
WF2
SF2
SF1
a
WF1
SF1= Detection zone 1, activated a = Emergency stop and
manual restart interlock SF2= Detection zone 2, deactivated b = SIMATIC FS600 Laser Scanner WF1= Warning zone 1, activated WF2= Warning zone 2, deactivated
Fig. 4.1-1: Danger area guarding at stationary machinery with two alternating work
Please comply with the safety notes in Chapter 3 and Chapter 5.4.7. For an example of how to calculate detection zone measures, please refer to Chapter 5.4.8.
areas
23

4.2 Access guarding by passage monitoring

Access guarding by passage monitoring (whole body trip control) is a suitable method when the access to a machine or to a hazardous zone can be precisely defined in structural terms, and there is no other unprotected access to the area. It is best to mount the laser scanner above the passage in question, in vertical alignment. In order to secure the protective equipment, laser scanner and fence against inadvertent misadjustment and manipulation, the detection zones of the SIMATIC FS660I Laser Scanner must be defined on the basis of a reference boundary. In this operating mode, the scanner will use the polled environment as a reference and so check for changes in the layout of the protective equipment, as well as checking every one of the individual measurements it carries out with a view to detecting an intrusion. An example of the configuration of the SIMATIC FS660I Laser Scanner to give access protection by passage monitoring will be found in Chapter 5.5.
a
c
SF1
b
24
a = SIMATIC FS660I Laser Scanner SF1 = b=Reference boundary of the detection zone c=Emergency stop and triggering of the manual restart interlock
Fig. 4.2-1: Access guarding by whole body trip control with system check of a
reference boundary
Detection zone 1, enabled

4.3 Safeguarding of danger points based on hand and arm detection

If the machine operator, in close proximity to the danger zone, needs to halt the hazardous movement of the machine or to coordinate the handling of workpieces or their removal from the machine, the machine must be provided with protection at the danger point. To safeguard danger points in this way a protective system needs to be installed. The SIMATIC FS660I Laser Scanner is certified as a system providing hand and arm protection, and is able in such a situation to guarantee flexible safety conditions in the workplace. This may be combined with alternation of the detection zones. In order to safeguard the protective equipment, laser scanner and side-mounted panels (which serve as a reference and provide additional access protection) against inadvertent misadjustment or manipulation, the detection zones of the SIMATIC FS660I Laser Scanner must be defined on the basis of a reference boundary. An example of the configuration of the SIMATIC FS660I Laser Scanner for the protection of danger points based on hand and arm protection may be found in Chapter 5.6.
a
SF2
SF1
b
a = SIMATIC FS660I Laser
Scanner SF1= Detection zone 1, enabled SF2 = Detection zone 2, disabled c=Emergency stop and manual triggering of restart interlock, acknowledgement for
switchove
Fig. 4.3-1: Safeguarding of danger points based on hand and arm detection with
r
alternation of detection zones
c
b=
Reference boundarys of the detection zones
25

4.4 Mobile Safeguarding of Automatic Guided Vehicles

For this application, the SIMATIC FS600 Laser Scanner is installed on automatic guided vehicles in order to monitor the vehicle path. The aim is to detect people or objects in the path of the vehicle and to automatically bring the vehicle to a halt. Safety systems available up to now, such as bumpers or safety bars, have allowed only very low driving speeds to be maintained. In contrast, using the SIMATIC FS600 Laser Scanner as a non-contact “advance bumper” results in the creation of a substantially larger safety zone. The vehicles can move faster, and down times are reduced to the necessary minimum.
SF3
SF1
WF1
SF4
a
SF1= Detection zone 1 for slow speed SF3= Detection zone 3 for a route
WF1= Detection zone 2 for high speed SF4= Detection zone 4 for a route
a = Traveling straight ahead
Fig. 4.4-1: Safeguarding an automatic guided vehicle
Please comply with the safety notes in Chapter 3. For an example of how to calculate detection zone measures, please refer to Chapter 5.7.9.
curving to the left
curving to the right

4.5 Protecting Transporter Trolleys against Collisions

Transporter trolleys are generally guided along a system of rails or grooves in the floor. Hence the vehicle paths are usually just slightly wider than the trolleys themselves. This represents an increased hazard for people, since it is impossible to get out of the way of the trolley. For this reason, transporter trolley are used in enclosed areas equipped with suitable access safeguarding.
26
SF1
SF2
SF1= Detection zone 1 for slow speed SF2= Detection zone 2 for high
speed
Fig. 4.5-1: Safeguarding a transporter trolley
Please comply with the safety notes in Chapter 3 and Chapter 5.7.8. In these cases, the SIMATIC FS600 Laser Scanner is used to detect people or objects in the vehicle path and then automatically bring the vehicle to a halt. Select “Manual restart” mode.
The demands placed on the geometrical shape of the detection zone are determined by the vehicle width, speed, stopping distance and response time. Here as well, factors such as additions in the direction of travel for tolerances in the measurement value and reduced braking power due to wear and tear must be taken into consideration.

4.6 Guarding the sides on AGVs

In addition to the danger area guarding of the path of an AGV application, in some cases it is also necessary to set up a side guarding. This side guarding detects people in the space between vehicle and conveyor, or detects people that stand on the conveyor edge in the vehicle area. Furthermore, the side guarding also enables the correct position of the load to be monitored, so that a transport with overhanging load is not initiated.
27
Fig. 4.6-1: Bild 6.3-1 Guarding the sides on AGVs
Please observe the safety notes in Chapter 3. An example for the side guarding configuration on AGVs can be found inChapter 5.7.9 and 5.7.10.

4.7 Other possible applications

Object and contour measurement
Logistics (counting, measuring, controlling)
Projection control (e.g. in fully automatic parking ramps or lots)
Safeguarding or monitoring enclosed spaces
and many more
28

5 Information for Planning and Mounting

It is essential that the following key points be complied with so that the SIMATIC FS600 Laser Scanner can provide optimum performance:
The SIMATIC FS600 Laser Scanner must be placed so that areas of access to the danger zone being monitored are completely covered by the detection zone.
The mounting position of the scanner should provide protection from humidity, dirt and extreme temperatures below 0° C or over 50° C.
The mounting position must be selected in such a way as to minimize the possibility of mechanical damage. Additional protective cover panels or safety bars must be installed at exposed positions.
Reinforcements, cover panels, mounting niches, and other machine elements may not in any way impair the field of view of the scanner.
If there are areas of shadow caused by fixed obstacles that were defined as part of the detection zone boundary, these should be safeguarded (e.g. by safety grids) in order to prevent people standing in them from being able to suddenly enter the detection zone. This point must be taken into account in the hazard analysis of the machine or system.
Be sure that there are no retro-reflectors or highly reflective surfaces made of metal or ceramic in the area of the detection zone and at the height of the scanning plane. Such objects can cause measurement errors.
In order to ensure a consistent detection height at every point of the detection zone, the scanner – and hence the scanning plane – must be placed parallel to reference section.
If the “Restart interlock” function is included, the restart button must ne located outsidethe detection zone in a place that is visible from the entire danger area .
If the scanner is used without a start interlock or startup test with automatic start/ restart, a startup warning (visual or acoustic) must be provided.
The scanner must not be used as an aid for climbing. If there is is any risk, a suitable diagonal protection (45°) should be set up.
Please comply with the safety notes in Chapter 3, Chapter 5.4.7 and 5.7.8.
29

5.1 Attachment and Dimensions

For attaching the SIMATIC FS600 Laser Scanner, four drill holes are located at the back of the unit. Any laser scanner installation point is possible with mounting. The SIMATIC FS600 Laser Scanner can, for example, also be mounted on the head or inclined facing down. The mounting set 3RG7838-1AA is available as an accessory offering following advantages:
Speeds up the mounting process by providing screws that are accessible from the front.
Allows vertical inclinations of up to 9°, either up or down, infinitely adjustable within this range.
Allows lateral tilting of up to approx. 9° to either side from the midpoint setting, infinitely adjustable within this range.
Enables quick replacement of the scanner without requiring realignment.
For information on which parts and dimensions are required for mounting, please refer to Chapter 14.13 and 14.14.

5.2 Installing adjacent laser scanners

The SIMATIC FS600 Laser Scanner has been developed in a way that prevents several laser scanners from interfering with one other as much as possible.
WARNING
An increase in the response time can, however, be caused by the installation of several adjacent laser scanners. If in the following sections or the specific adjustment (section 5.2.2) are implemented,
then the SIMATIC FS600 Laser Scanner response time set and shown in the configuration and diagnosis software (SIMATIC FS600 Parameterization Software LS4soft) is extended by 40 ms.
be taken into account when calculating the safety distance!
none
of the constructive measures (section 5.2.1) described
This extension in the response time MUST
5.2.1 Constructive measures
The direct external light irradiation from laser scanners of the same kind (905 nm laser light wavelength) in a line and at the same installation height can be prevented with shielding plates at scan level. Shielding, as high as the scanner front screen and flush with the front housing edge, is sufficient. The same also applies with installation in vertical alignment and overlapping of the scan levels
30
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