SunX SD3-A1 User guide

About the instruction manual (connection and operation) of the SD3-A1 and the SD3SOFT instruction manual (software operation)

The instruction manual (conn ection and operati on) for the SD3-A1 contains important information on proper usage of laser scanner and usage in accordance with intend ed purpose. F or additional inform ation on the configuration of the SD3-A1, please refer to the SD3SOFT instructi on manual (software operation).

It is essential to observe all in formation in the instructi on manual (connecti on and operation) and in the instruction m anual (softw are operation), especially the safety notes.

The instruction manual (connection and operation) and the instruction manual (software operation) must be kept in a safe place. They must be available during the entire period when the SD3-A1 i s in use. Documents ar e also aut omatically inst all ed on the PC wh en SD3SOFT is installed and can be viewed at any time with the Help menu.

Safety and warning notices are identified by the symbol .

References to important information are identified by the symb ol .

References to the safety of laser devices are identified with the symbol .

SUNX Limited is not liable for damage caused by improper usage. The user must also be familiar with all the SD3-A1 m anuals t o be able t o u se th e sy st em pr operl y.

Version: V5.5

 Reprinting and duplic ation is prohibited in whole or in part without prior approval of

SUNX Limited.

Contents

1 Approvals .........................................................................................................................................6

2 System Overview .............................................................................................................................9

3 Safety Notes and Usage in Accordance with Intended Purpose ............................................. 13

4 Applications for the SD3-A1 .........................................................................................................19

5 Information for Planning and Mounting...................................................................................... 25

1.1 Approval and declaration of EC conformity............................................................................6

1.2 Specialized technical terms and abbreviations ......................................................................7

1.3 Guidelines and standards ....................................................................................................... 8

2.1 Brief description and functional principle of the SD3- A1........................................................ 9

2.2 Special features of the SD3-A1............................................................................................ 11

3.1 General safety notes ............................................................................................................13

3.2 Usage requirements and usage in accordance with intended purpose ............................... 13

3.3 Restrictions for use ............................................................................................................... 14

3.4 Information related to detection zone cha ngeover ............................................................... 15

3.5 General information related to determining detection zone contours ..................................16

3.6 Additional safety notes for stationary use ............................................................................17

3.7 Additional safety notes for mobile use ................................................................................. 18

4.1 Stationary safeguarding of the danger area.........................................................................19

4.2 Access guarding by passage monitoring .............................................................................20

4.3 Safeguarding of danger points based on hand and arm protection.....................................21

4.4 Mobile safeguarding of automatic guided vehicles ..............................................................22

4.5 Protecting transporter trolleys against collisions .................................................................. 22

4.6 Guarding the sides on AGVs ................................................................................................ 23

4.7 Other possible applications ..................................................................................................24

5.1 Attachment and dimensions .................................................................................................26

5.2 Installing adjacent laser scanners ........................................................................................26

5.2.1 Constructive measures......................................................................................................... 26

5.2.2 Adjusting adjacent laser scanners........................................................................................ 27

5.3 Information on setting the dimensions of detection zones ...................................................28

5.3.1 Methods of configuring detection zones using the PC ......................................................... 28

5.3.2 Range of the detection zone, resolution ............................................................................... 28

5.3.3 Range of the warning zone, resolution.................................................................................29

5.3.4 Range of the measurement field ..........................................................................................30

5.3.5 Required detection zone additions Z....................................................................................30

5.4 Safeguarding stationary danger zones ................................................................................ 31

5.4.1 The purpose of safeguarding ............................................................................................... 31

5.4.2 Mounting position .................................................................................................................31

5.4.3 Mounting height ....................................................................................................................32

5.4.4 Recommendations for mounting to prevent unmonitored zon es .........................................32

5.4.5 Additions ...............................................................................................................................36

5.4.6 System availability ................................................................................................................36

5.4.7 Restart interlock....................................................................................................................37

5.4.8 Calculating the detection zone dimensions for safeguard ing an area .................................38

5.5 Access protection ................................................................................................................. 43

5.5.1 Object of protection .............................................................................................................. 43

5.5.2 Installation position ...............................................................................................................43

5.5.3 Safety-relevant settings, and calculation of the safety distance .......................................... 43

5.5.4 Definition of the reference bo undary ....................................................................................44

5.6 Protecting danger points.......................................................................................................45

5.6.1 Object of protection .............................................................................................................. 45

5.6.2 Installation position ...............................................................................................................45

5.6.3 Safety-related settings, and calculation of the safety distance ............................................ 45

5.6.4 Defining the reference boundary ..........................................................................................47

5.7 Safeguarding mobile machines ............................................................................................ 48

5.7.1 The purpose of safeguarding ............................................................................................... 48

5.7.2 Installing adjacent laser scanners ........................................................................................48

5.7.3 Mounting position .................................................................................................................48

5.7.4 Mounting height ....................................................................................................................48

5.7.5 Recommendations for mounting to prevent unmonitored zon es .........................................49

5.7.6 Additions ...............................................................................................................................51

5.7.7 System availability ................................................................................................................52

5.7.8 Restart ..................................................................................................................................52

5.7.9 Calculating the dimensions of the detection zone of an AGV application ........................... 53

5.7.10 Side guarding configuration on AGVs ..................................................................................56

6 Details on Switching Over Detection and Warning Zones........................................................57

7 Functions of the SD3-A1............................................................................................................... 62

8 Integrating the SD3- A1 into Machine Controls ..........................................................................64

9 Electrical Connection....................................................................................................................69

10 Commissioning..............................................................................................................................73

6.1 Sequence of zone pair switchovers...................................................................................... 57

6.2 Practical AGV applicat ion (example) .................................................................................... 59

7.1 Restart ..................................................................................................................................62

7.2 Channels for zone pair changeovers, FP 1 to FP 4 .............................................................62

7.3 Alarm 1 (X1-5) ...................................................................................................................... 63

7.4 Alarm 2 (X1-15) .................................................................................................................... 63

7.5 OSSD 1 (X1-12) and OSSD 2 (X1-11) .................................................................................64

7.6 Data communication .............................................................................................................64

8.1 Integrating the SD3-A1 with external wiring with re lays and

eightfold zone pair changeover ............................................................................................65

8.2 Connecting the SD3-A1 to a safety sequence circuit with manual restart,

relay monitoring, without zone pair changeover .................................................................. 67

8.3 Connecting the SD3-A1 to a PLC with corresponding safety level

(Category 3 or higher, EN 954) and zone pair changeover .................................................68

9.1 Electrical power supply......................................................................................................... 69

9.2 Connecting the PC and control cables to the scanner ......................................................... 69

9.3 Connector assembly .............................................................................................................70

9.4 Points to consider when preparing and laying the cables .................................................... 70

9.5 Interface pin assignments.....................................................................................................71

10.1 Hardware and software requirements ..................................................................................73

10.2 Installing “SD3SOFT” and starting up the SD3-A1 ..............................................................73

10.3 SD3-A1 status indicator........................................................................................................ 75

10.4 Status information of the SD3- A1......................................................................................... 77

10.5 Restart and device swap-out ................................................................................................78

11 Maintenance and Testing..............................................................................................................79

12 Delivery Package ...........................................................................................................................93

13 Technical Data ...............................................................................................................................96

14 Diagnostic Codes and Causes...................................................................................................103

11.1 Test before first startup by person qualified and authorized to perform the task ................ 79

11.2 Extended shutdown of the SD3- A1 ...................................................................................... 79

11.3 Regular tests by a person qualified and authorized to perform the task .............................80

11.4 Daily test by with test piece performed by responsible operating personnel ....................... 80

11.4.1 Checklist for daily test of stationary applications by responsible operating personnel ........81

11.4.2 Checklist for daily test of mobile applications by responsible operating personnel ............. 82

11.5 Checklist for testing stationary applications .........................................................................83

11.6 Checklist for testing mobile applications ..............................................................................85

11.7 Replacing the optical window ............................................................................................... 87

11.7.1 General information: .............................................................................................................87

11.7.2 Initial measurement of the new optical window.................................................................... 89

11.7.3 Procedure when using the SD3SOFT user software version 1.09 or later .......................... 90

11.8 Cleaning................................................................................................................................91

11.8.1 Cleaning the optical window when dirty ...............................................................................91

11.8.2 Cleaning the optical window; cleaning diffusing light panes ................................................ 92

12.1 Disposal ................................................................................................................................93

12.2 Accessories and spare parts ................................................................................................ 94

12.3 Coding of the control cable X1 .............................................................................................95

13.1 Test pieces ...........................................................................................................................96

13.2 Detection zone...................................................................................................................... 96

13.3 Detection zone additions ......................................................................................................97

13.4 Warning zone........................................................................................................................97

13.5 Contour measurement .......................................................................................................... 97

13.6 Electrical power supply......................................................................................................... 98

13.7 Inputs ....................................................................................................................................98

13.8 Outputs .................................................................................................................................98

13.9 Software................................................................................................................................99

13.10 Interfaces ..............................................................................................................................99

13.11 Optics....................................................................................................................................99

13.12 Environment and material................................................................................................... 100

13.13 Dimensional drawings of the SD3-A1 ................................................................................ 101

13.14 Dimensional drawings of the mount ing system.................................................................. 102

1 Approvals

1.1 Approval and declaration of EC conformit

EC t yp e examin ation in accor d anc e with DIN EN 61496 - 1 and IEC 6149 6 - 3

TUV PRODUCT SERVICE GMBH IQSE Ridlerstr. 65 80339 Munich

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

EDM External Devic e Monitoring

ESPE Electro-Sensitive Protecting Equipment (BWS in German)

N.O. N orm al open cont ac t

OSSD Output Signal Switching Device Safety-relevant switch output

PC Personal Computer

DZ Detecti on Zone (SF in German)

Reset Defined Reset or SD3-A1

RS-232 RS-232 interface

RS-422 RS-422 interface

ZP Zone Pair (contains 1 × detection zone and 1 × warning zone)

WZ Warning Zone (WF in German)

Table 1.2-1: Specialized technic al terms and abbreviations

Reflection

Monitoring of external control parts (relay monitoring)

(FP in German)

1.3 Guidelines and standards

The following guidelines and standards are of critical importance for the implementation of laser scanner. Guidelines providing particularly relevant information for users of such systems are marked with an asterisk (

Guideline / Standard Designation

European Gu idelines

98 / 37 / EG Machine guideline

73 / 23 / EWG Low voltage guideline

89 / 336 / EW G EMC guideline

A Standards

ISO 12100-1 and 2 Safety of machi nery - basic concepts

ISO 14121 Safety of machi nery - principles for risk assessment

B1 Standards

ISO 13852 Safety of m achinery - safety di stances to prevent danger

ISO 13849-1 Safety of machi nery - Safety related parts of control

ISO 13855 Safety of machinery. The positioning of protective

B2 Standards

IEC 60204-1 Safety of m achinery - Electric al equipm ent of machines -

IEC 60825-1 Safety of laser products - Part 1: Equipm ent classification

IEC 61496-1 Safety of machinery. Electro-sensitive prot ective

IEC 61496-3 Safety of machinery - Electro-sensitive prot ective

C Standards

DIN EN 775 Industrial robots - Safety

DIN EN 1525 Safety of industrial trucks - Driverless trucks and their

DIN EN 12895 Industrial trucks - El ectromagnetic compatibility

zones being reached by the upper limbs

systems; Part 1: General principl es for design

equipment in respect of approach speeds of parts of the human body

Part 1: General requirem ents

and requirements

equipment. General requirements and tests

equipment - Part 3: P articular requir ements for Active Opto-electronic Protective Devices responsive to Diffuse Reflection (AOP DD R)

systems

Guideline / Standard Designation

National Standards

DIN 15185-2 Warehousesyst ems with powered industrials trucks

Table 1.3-1: Guidelines and standards

This list does not claim to b e complete. In certain cases, the concrete requirements of the application will necessitate the application of additional guidelines and standards!

System Overvie

2.1 Brief description and functional principle of the SD3-A1

The SD3-A1 is an optical distance sensor th at takes two-dimensional m easurements. I 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 object, the reflected light is received and evaluated by the SD3-A1. The sc anner calculates the precise coordinates of the person or object bas ed on the t ravel time of the refl ected light and the c urrent an gl e of th e defl ecting unit. If the person or object 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 eith er automatically or manually.

Fig. 2.1-1: The 190° angle range of the SD3-A1 is divided into 0.36° angle

A laser diode coupled with transmitter optics produces focused li ght pulses. These pulses are projec t ed acr oss the m oni tored su rf ac e by a rot at in g m irror in suc h a way t hat a light pulse is triggered in each of the angle segments within 40ms (scanning rate: 25 scans/s).

segments.

Fig. 2.1-2: Functional principle of the SD3-

The SD3-A1 can detect peopl e up to a distanc e of 4.0m 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 × 150mm) are detect ed up to a di stance of 15m (c orresponds to the

warning zone) and signaled by way of a non-safety-related semiconductor output.

Eight programmable zone pairs (each of which consists of one detection zone and one warning zone) enable the scanner to be optim ally adapted to the needs of each particula application.

The SD3-A1 c an b e i mplem ented n ot onl y on m achin es and system s ( st ation ar y safeguarding of danger zones), but also on vehicles (mobile safeguard ing of transport vehicles).

Due to its wide rang e of measurem ent and its non-c ontact, electro-sensitive measurem en t p ri nciple, th e SD3-A1 can be effectively used as a protective device fo virtually any application.

2.2 Special features of the SD3-A1

x Eight freely programm able detecti on zones (up to a maximum of 4m)

x Eight freely programm able warning zones (up to a maximum of 15m)

x Expanded monitoring rang e of up to 190°

x ConfigPlug for easy device exchange without configuration expense

x Compact design (W × D × H: 140mm × 135mm × 155mm)

x Light weight (2kg)

x Low power consumption requirements (300mA, plus the load at the output s)

x Two types of int erfaces at one Sub-D jack (RS-232 and RS-422)

x User-friendly softw are

3 Safety Notes and Usage in Accordance with Intended Purpose

3.1

3.2

General safety notes

The protective functi on of the d evi c es c an be n egati vely affected, how ever, i f 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 / or limb for persons who are in the general area of the machines or systems.

Caution – laser radiation! The SD3-A1 is a laser device belonging to laser class 1. The valid legal and local regulations for operating laser syst ems must be compli ed with. Avoid p ositioning t he sc anner at ey e l evel.

Usage

The relevant regulations for machine safety apply for the use of the laser scanner SD3-A1. Responsible authoriti es (for example professional trade unions, OSHA) are also avai labl e for qu est ions rel at ed to safet y. In gen er al, the following u sage requirem ents must be observed:

x If the scanner is enclosed in a protective housing, additional window material, such

x Avoid touching the scanner optical window and the six diffusing light screens.

x The SD3-A1 is not suit abl e for use as a prot ec ti ve d evic e:

x The SD3-A1 corresponds to Type 3 in accordanc e with IEC 61496 -1 and 3.

x The elec tr ic al connection of the SD3-A1 to the control system must only b e made by

x The 24V DC (+2 0% / -30% ) power supply must be ensur ed by a safe network

equirements and usage in accordance with intended purpose

as plastic or gl ass must not be used as it may impair th e detection.

- if it is possible that dangerous fluids will be spewed out or objects will be ejected.

- for machines with long braking tim es (max. depth of the detection zone: 4m)

safety cat egory of 3 in accord anc e w it h EN 954-1 c an b e ac hi ev ed with the SD3-A1 if all other elements in th e safet y chain are set up to stop th e d angerou s m otion in accordance with that safety category.

an electrician.

disconnect in accordance with IEC 742. The sam e requirements apply to all connected input and output circuits.

x The 24V DC pow er m ust be supplied to th e scanner t hr ou gh a se pa rat e branc h w it h

a 1.25A delayed action fuse in the control cabinet.

x You must ensure that prot ec ti ve caps ar e scr ew ed ont o i nt er fac es X1 and X 2. This

will protect the interfaces against dust.

x The safety output has a double design. The two OSSDs must always be included in

the shut-off circ ui t of t he mac hi ne in such a mann er th at eit he r o f t he t w o is completely sufficient by itself t o turn OFF the m otion that presents a dang er.

x The alarm output 1 (Pin 5 on X1) must not be used to switch safety-related sign als.

x System tests (of the scanner, m achine, control c omponents and switch com ponents)

may only be performed when they do not result in potential hazards for people.

x Tampering with or making changes to the SD3-A1 can result in the loss of the safety

function.

x Only expert tr ained personnel is allowed to perform startup, maintenance, parameter

settings or detection zone configurations. Familiarity with the safety notes in this instruction manual (c onnecti on and operation) and in the instruction manual (so ftware operation) for th e “SD3SOFT” program constitutes part of this expert know l edge.

x The password required for configuring safety-relevant param eters must be kept in a

secure location by the safety official. Information about password levels can be found in the instruction manual (software operation) for the “SD3SOFT”.

x 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

x Glass, highly reflective materials such as mirrors (reflectance > 10.000%), or objects

that do not reflect any li ght back to the sensor can falsi fy the measurement result. More inform ation is available in Chapter 5.3.5.

x Do not expose the SD3-A1 to flying sparks (for example a welding flash). Doing so

may caus e damage t o t he optical wind ow.

x Vap or, sm ok e, dust and all parti cles visible i n t he air have a signi ficant neg ativ e

effect on measurement values and will result in the semiconductor outputs being turned OFF.

x Avoid ext rem e variat ions in tem p eratu re.

x Make sure that the following types of light sources are not present on the sc anning

plane:

 Laser light from o ne or m or e ot h er scanners or sens ors

 Infrared light

 Fluorescent light

 Stroboscopic light

Please consid er as well Chapter 5.2.

x It must not be used for vehicles with int ernal combustion engines.

x The SD3-A1 is conc eived for u se i nside enc losed spac es and w it h the op er ati ng

parameters listed in the technical specifications (temperature, humidity, shock, vibration, etc.). Please refer t o the list of parameters in Chapter 13.

x Avoid having reflective surfaces (such as glass, mirrors, retro-reflect ors, etc.) at fixed

contours in the scanning plane. If this is not possible, an additional detection zone must be provided.

3.4 Information

If alternating operation is included in the design, and thus detecti on zone changeover, the activation and effect of the detection zone in question must match the alternating operating mode.

x 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 ri sk analysi s.

x Braking paths, response and coast -down tim es must b e taken int o consideration

(for example overlapping detection zones).

x A “Start interlock” function is provided.

x If the machine has a restart key, it must not be possible to operate it from inside the

det ection z ones. Al l dang er areas m ust b e visible from the p osit ion of the but t on. Before releasing the start / restart interlock, all detection zones must be tested. No one is permitted inside the danger areas.

x There m ust b e no unmonitor ed zones in si de the dang er ar eas.

x There must be no possibility for direct access to the danger area that shortens the

necessary safety distance (use a protective grid, for example).

x The information on required detection zone additions in Chapter 5 m ust be

observed.

elated to detection zonechangeove

3.5 General information

x Shadow effects (e.g. surfaces or areas located behind stationary objects) must be

considered. As a rule, insufficient safeguarding must be adequately sup plemented by further safety measures such as protective grid, light curtains, and the like!

x Access to the detection zone in the dangerous area is not permitted.

x 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 c ontai n indivi dual speci ficati ons, for exam ple, on point s of access t o the danger zone and, if applicable, detection zone additi ons that must be given special considerati on. They al so pr ovide info rm ati on on how t o measur e safe ty dist anc es at machi nes.

x Det ecti on z on es w ith a r adi us sm aller than 20c m (at or c lose t o t he scann er) ar e not

admissible. 20cm is the preset minimum contour.

x When setting the dimensions of the detection zones, please comply with the

maxim um angle rang e st at ed in t he technic al sp ecificati ons (Chapt er 1 3.11).

x Needle-shaped detecti on zone contours are not p ermitted, since they do not ensure

any protective effect. For additional information, please refer to the SD3SOFT use software (Chapter entitled “Definition of detection zones”).

x Due to possible measurement errors, every detection zone has an additions area in

which detection is not guaranteed under all conditions. Please c onsider as well Chapter 5.3.5. Read Chapt er 5.4.6 and 5.7.7 for information on optimizing system availability.

x The required safety distances must be taken into account when m aking 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 combinati on with DIN EN 999 (see Section 2 and 5 of the standard). T olerance fields and / or additi ons (make sure to consid er Chapter 5.4 and 5.7).

x

fter the detection zones have been set, make a printout of the following

informati on:

 Detection zone contour with the X and Y coordinates

 Date

 Serial num b er of the sc ann er

 Name of the safety official

x When calcul ati ng the ad diti ons, be su re t o c onsider wh ether th e du st alg ori th m is

deactivated or activated (see Chapt er 5.3.5).

elated to determining detection zone contours

x When calculating the safety distanc es, be sure to consider all delay times, such as

the r es pons e tim e of th e sc anner, r esponse time of t he contr ol elem ents, and braking times and / or stopping times of the machine / system or AGV! Variations in delay time caused by fact ors such as reduced braking power must also be taken int considerati on.

x The effectiveness of the switch-off function must be tested along the defined contou

of the detecti on zone during th e initial startup and subsequent to any changes made to a machin e or syst em .

x 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 an changes made to an AGV.

x 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 safet measures (e.g. protective grids) must be installed.

x Following each definition of and change t o the detection zones, the configuration

must be checked to see whether the possibility of people standing in the dange 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

x If the danger zone can be accessed from the side, and if the detecti on zone cannot

be extended sufficiently in this direction, additional safety measures (e.g. protective grids) m ust be inst alled.

x We recommended marking th e contour of the detection zone on the floor by painting

a colored lin e or applying c olored adhesive tape.

x Check the mounting regul arly (in particular, the angle of inclination) in order t

guarantee the reliability of detection.

3.7 Additional safety notes for mobile use

x There are additional requirements for the use of scanners on automatic guided

vehicles (AGV) and transporter trolleys according to DIN EN 1525.

x If possible, expanded detection zones to each side should be provided in order to

safeguard access from the side and dir ectly in front of the vehicle.

x If is it not possible to completely safeguard the contour of th e vehicle including its

trailer and the dimensions of its load while making curves, additional protective devices such as switch strips must be att ached to the side of the vehicle.

x There m ust b e a m in imum safety dist anc e S

on both sides. A one-sided minimum safety distance is admissible in certain exception al cases. Th e specifications of DIN EN 1525 must be complied with.

x The basic value of the detecti on zone width for an AGV corresponds t o 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.

x If the SD3-A1 is mounted on vehicles, the mounting (especially the angle o

inclination), the vehicles' braking p ower, and if applicable, play in the vehicle guidance (the difference betw een the optimum and actual line of guidance) must be regularly checked in order to guarantee the reliability of detection.

. Furtherm ore, the greatest possible lateral shift of the

of 500mm to the side of the vehicle

4 Applications for the SD3-A1

Due to its continuous c overag e of the area, its wide r ange, and the ability to select among eight zone pairs, the SD3-A1 is able to handl e even complex applications.

4.1 Stationary safeguarding of the danger area

The SD3-A1 is used to safeguard dangerous working areas at machines and systems where bot h c on st ant an d v ariabl e dem ands are pl ac ed on t he geom etrical sh ap e 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 extr emities, at the same time without impeding th e production process. The SD3-A1 can b e m ounted di rectly at t he m achin e t abl e or on the sid e o r in fr ont of t he machine.

Fig. 4.1-1: Danger area guarding at st ationary machinery with two alternating work

Please comply with the safety notes in Chapt er 3 and Ch apter 5.4.7. For an example o how to calcul ate detection zone measures, pl ease refer t o Chapter 5.4.8.

areas

4.2 Access guarding by passage monitoring

Access guarding by passage monitoring (whole body trip control) is a suit able method when the access to a machine or to a hazardous zone can be precisely defined in structural terms, and there is no other unprotect ed access to the area. It is best to mount the l aser sc anner ab ov e the p as sag e i n questi on, in vertic al ali gnment. In order to sec ure the protecti ve equipm ent, laser scanner and fenc e against inadvertent misadjustm ent and manipulation, the detection zon es of the SD3-A1 must be defined on the basis of a reference boundary. In this operating mode, the scanner will use the polled environment as a r ef er ence and so ch ec k for c hang es in t he lay out of th e prot ec ti ve eq uipm ent, as w ell as checking every one of the individual measur ements it carries out with a view t detecting an intrusion. An exam ple of the configuration of the SD3-A1 to give access protection by passage monitoring will be found in Chapter 5.5.

Fig. 4.2-1:

Access guarding by whole body trip control with system check of a reference boundary

4.3 Safeguarding of danger points based on hand and arm protection

If the machine operator, in close proximity to the danger zone, needs to halt the hazardous m ovement of the machi ne or t o coordinate the handling of workpieces or thei rem ov al from t he machi ne, the m achine m ust b e provid ed wi th protect ion at the d an ger point. To safeguard danger points in this way a protective syst em needs to be installed. The SD3-A1 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 com bined wi th alt er nat i on of the d et ecti on z on es. In ord er to safeguar d t he prot ecti ve equipment, laser scanner and side-mounted panels (which serve as a reference and provide additional access protection) against inadvertent misadjustment or manipulati on, the detection zones of the SD3-A1 must be de fi ne d on th e basi s of a refer ence bound ar y. An exam pl e of th e c onfigur ation of th e SD3-A1 for the protecti on of danger p oints based on hand and arm protecti on may be found in Chapter 5.6.

Fig. 4.3-1: Safeguarding of danger p oints based on hand and arm protection with

alternation of detection zones

4.4 Mobile safeguarding of automatic guided vehicles

For this application, the SD3-A1 is installed on automatic guided vehicles in order to monitor the vehicle path. The aim is t o 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 t o be maintained. In contrast, using the SD3-A1 as a n on-c ont ac t “ advanc e bump er ” results in the cr eat ion of a substantially larger safety zone. The vehic l es c an m ove fast er, an d d own tim es are reduced to th e necessary minimum.

Fig. 4.4-1: Safeguarding an automatic guided vehicle

Please comply with th e safety n otes in Chapter 3. For an exampl e of how to calculate detection zone measures, please refer to Chapter 5.7.9.

4.5 Protecting transporter trolleys against collisions

Transport er trolleys are generally guided along a system of rails or grooves in the fl oor. Hence the vehicle paths are usually just slightly wider than the trolleys themselves. This represents an increased hazard for peopl e, since it is impossible to get out of the way o the t roll ey. For this re ason, tr anspo rt er t roll ey are u sed in encl osed areas equipped with suitable access safeguarding.

Fig. 4.5-1: Safeguarding a transport er trolley

Please comply with the safety notes in Chapter 3 and Chapt er 5.7.8. In these cases, the SD3-A1 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 geometric al shape of the detecti on zone are determ ined b the vehicl e width, speed, stopping distance and response time. Here as well, factors such as ad dition s in the di rect ion of travel for t ol erances in th e m easurement v alu e and reduced braki ng power du e 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 m onitored, so that a transport with overhanging load is not initiated.

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 configurati on on AGVs can be found in Chapter 5.7.9 and 5.7.10.

4.7 Other possible applications

x Object and contour measurement

x Logistics (counting, measuring, controlling)

x Projec tion control (e.g. in fully autom ati c parking ramps or l ots)

x Safeguarding or monitoring enclosed spaces

x and many more

5 Information for Planning and Mounting

It is essential that the following key points be complied with so that the SD3-A1 can provide optimum performance:

x The SD3-A1 must be placed so that areas of access to the danger zone being

monitored are completely covered by the detecti on zone.

x The mounting posi ti on of t he sc ann er sh oul d provid e prot ec ti on from hum idit y, dir

and extrem e temperatures below 0°C or over 50 °C.

x The mounting position must be selected in such a way as to minimize the possibilit

of mechanic al damage. Additional protective cover panels or safety bars m ust be install ed at exposed positions.

x Reinforcements, cover panels, m ounting niches, and other m achine elem ents ma

not in any way impair the fi el d of vi ew of t he sc anner.

x If there are areas of shadow caused by fixed obstacles that were defined as part o

the detection zone boundary, these should be safeguarded (e.g. by protective grids) in order to prevent people standing in them from being able to suddenl y enter the detection zone. This point must be taken into account in the hazard analysis of the machine or system.

x Be su re that ther e are n o retro-r eflec t ors or hig hl y refl ective sur fac es made o f m etal

or ceramic in the area of the detection zone and at the height of the scanning plan e. Suc h obj ect s c an cau se measur em ent er rors.

x In order to ensure a consist ent detection height at every point of the detection zone,

the scanner – and hence the scanning pl ane – must be placed parallel to reference section.

x If the “Rest art interl ock” function is included, the rest art butt on must be located

outside the detection zone in a place that is visible from the entire danger area.

x If the scanner is used without a start interlock or startup test with automatic start

restart, a st artup warning (visual or acoustic) must be provided.

x The scann er must not be u sed as an aid for clim bing. I f there is any risk , a suitabl e

diagonal protection (45°) should be set up.

Please comply with the safety notes in Chapter 3, Chapt er 5.4.7 and 5.7.8.

5.1 Attachment and dimensions

For attaching the SD3-A1, four drill holes are located at the back of the unit. Any laser scanner i nstall ation point is po ssi bl e w it h m ounting. Th e SD3-A1 can, for example, also be mounted on the head or inclined facing down. The mounting system MS-SD3-1 is available as an accessory offering following advantages:

x Speeds up the mounting process by providing screws that are accessible from the

front.

x

llows vertical inclinations of up to 9°, either up or down, infinitely adjustabl e within

this range.

x

llows lateral tilting of up to approx. 9° to either side from the midpoint setting,

infinitely adjustable within this range.

x Enables quick replacem ent of the scanner without requiring realignm ent.

For inform ation on which parts and dimensions are required for mounting, please refer to Chapter 13.13 and 13.14.

5.2

5.2.1 Constructive measures

Installing adjacent laser scanners

The SD3-A1 has been developed in a way that prevents several laser scanners from interfering with one other as much as possible.

n increase in the response time can, however, be caused by the installation of several adjacent laser scanners. If none of the constructive measures (secti on 5.2.1) described in the following sections or the specific adjustm ent (section 5.2.2) are impl emented, then

the SD3-A1 response time set and shown in the configuration and diagnos is software (SD3SOFT) is extended by 40ms. This ext ension in the response time must

be taken into account when calculating the safety distance!

The direct external light irradiation from laser scanners of the same kind (905nm laser light wavelength) in a line and at th e 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 parallel alignment and overl apping of the scan levels.

a = SD3-A1 b = Mac hi ne (view fr om above) c = Detecti on zones d = Shield plate, flush with the housing

Fig. 5.2-1: Shielding to prevent direct irradiation

5.2.2

Adjusting adjacent laser scann ers

In order to prevent faulty deactivation and scanners interfering with each other as much as possible, when using several laser scanners you must install these as shown in the following examples. Installation on the basis of the MS-SD3-1 m ounting system makes precise adjustm ent signific antly easier.

Installati on with height offset or a crossed alignment also prevents interferenc e from beam reflections onto surrounding objects. When safeguarding danger zones, please also ensure that it is not possible to crawl under the detection zone, so that gaps do not occur with access guarding.

Fig. 5.2-2: Installation with height offset (parallel alignment)

Fig. 5.2-3:

Installation without height offset (crossed alignment)

Fig. 5.2-4: Opposing installation without height offset (crossed alignment)

5.3 Information on setting the dimensions of detection zones

The hazards caused by machines and systems place a wide range of demands on safety distances and detection zones which must be appropriately defined.

5.3.1

5.3.2

Methods of configuring detection zones using the PC

With its SD3SOFT configuration and diagnostic software, the SD3-A1 offers various methods for setting the configurations of detection zones.

Numerical input

A separate dialog within the user program “SD3SOFT” allows the right, left and front edges of the detection zone to be set using numerical values in mm.

Graphic input

A separate dialog within the user program “SD3SOFT” allows th e basic contours of the detection zone to be entered. The contours can be adapt ed infinit ely to the desired size o the detecti on zone. The following shapes are available:

x circle

x rectangle

x polygon

In addition, the contours can be infinitely varied by:

x changing

x limiting and

x deleting

partial segm ents as desired

Range of the detection zone, resolution

The maximum range of the detection zone S with a diameter of 70mm and a reflectance factor of 1.8% (e.g. bl ack corduroy). The reference point of the measurement is the axis of the rotating mirror on the scanner 64mm behind the front edge of the scanner.

4m (including the additions) for an object

MAX

5.3.3

Range of the warning zone,

A maximum range of 10m is available for an object with a diameter of 100mm. The maximum available range for an object with a diameter of 150mm is 15m. Both of these figur es assum e a reflect anc e f act or of 20%.

Resolution in mm

a = Detection zone b = Warning zone c = Measurem ent field

Fig. 5.3-1: Detecting obj ects in the detection zone and in the warning zone. T he

referenc e p oint of t he distanc e meas ur em ent is th e axis of the r ot ati ng mirror.

esolution

5.3.4

Range of the measurement

ield

The maximum distanc e for contour measurement at a reflectance factor of 80% (white gypsum) is 50m.

Remissi on in %

a = Detection zone b

= Measurement field

Fig. 5.3-2: Detection of objects depending on the reflectanc e factor. The reference

point of the distance measurement is the axis of the rotating mirror.

5.3.5

Required detection zone additions Z

The SD3-A1 is equipped with a selectabl e dust algorithm to ensure optimum freedom from int erfer ence.

The following detection zone additions must be taken into account:

Addition Z suppression is deactivated

Addition Z suppression is activated

if dust

83mm

83mm (for a det ection zone size < 3.5m) 100mm (for a detection zone size  3.5m)

Activation and deactivation of the function is perform ed by SD3SOFT.

If r etro- refl ect or s or very shi ny surfaces, such as p oli sh ed or enam eled metal s or ceramics, may possibly be present in the scanning plane, the following table applies:

Addition Z reflectors or very shiny, surface-treated materials (e.g. metals and ceramics)

REFL

if retro-

0mm for reflectors more than 1.2m behind the detection zone line 110mm for reflectors up to 1.2m behind the

detection zone line are present in the scanning plane

+ Z

Z = Z

REFL

= Required detection zone addition, in mm

Z Z

= Measurem ent error of th e sc anner, in m m

= Addition for considering refl ectors, in mm

REFL

5.4 Safeguarding stationary danger zones

Please comply with the safety notes in Chapter 3.

5.4.1

5.4.2

The purpose of safeguarding

is for protection:

x to prot ec t p eople wh en enterin g a danger z on e

x to protect people from reaching a danger point with their extremities

x to protect objects from the danger of collision due to variable machine or part

movements.

Mounting position

The SD3-A1 can be m ounted ei th er in a stati on ar y posit i on ( e.g. on a w all or a m ac hine) or on moving parts (e.g. machine table).

The qu alified in st all er must en su re that t h e mounting positi on of the SD3-A1 allow s t he danger zone to be monitored completely.

If a restart button is being used, make cert ain that th e entire detection zone area can be viewed by the person pressing the button. It must not be possible to activate the button from t he d an ger area.

Refer to the safety notes in Chapter 3.6 with regard to lateral acc ess into the danger zone.

5.4.3

Mounting height

ccording to DIN EN 999, the lowest admissible height of the scanning plane for people,

as measured from the base level, is calculated according to the following formula:

= 15 × (d - 50mm)

MIN

= Lowest admissible scanni ng plane from the base level

MIN

d = Resolution of the scanner in mm (object size = 70mm throughout the detection

zone).

5.4.4

The adm issible h eight ran ge o f th e SD3-

A1 scanning plane lies between 0mm

(presettings leg detecti on) and 1,000m m above the base level. If the application requires a sc anning plane higher t han 300m m , or if c hi ldren have acce ss to the ar ea, th e anal ysis of the danger zone must consider the h azard caused by persons crawling below the scanning plane.

Recommendations for mounting to prevent unmonitored zones

Unmonitored zones can result if the scann er is mounted onto a protrudi ng attachment o if the c ontour of the m achine / syst em is v aried in depth.

5.4.4.1

Recessed installation (undercut) under the machine table

The undercut must be at least as deep as the zone not monitored by the detection zone lateral to and in front of the scanner. The minimum depth Z to recess the scanner, this is allowed up t o a maximum of 40mm ; the depth of the

is 135mm. If it is possible

UMIN

undercut is reduced by the depth value of the recess. If the mounting system is being used, the necessary dimensions of the undercut depth must be increased acc ordingly (see Chapter 13.13 and 13.14). The height of the undercut must be limited to prevent people from being able to step beneath it.

Fig. 5.4-1:

Recessed sc anner installation with undercut

The addition al safeguardi ng required for the particular application must be taken into account.

Pleas e n ote th at the un der cut m ust c ov er any unm onit ored z on es.

5.4.4.2

Recessed installation within the machine contour

Furth ermore, th e sc an ner c an b e r ec essed into the cont ours of a m ac hine. The r ec ess can have a depth of up to 40mm without the mounting system MS-S D3- 1, or up to 65mm with the mounting system MS-SD3-1. This is in reference to detection zones that cover an angle range of 180°. If it is not possibl e to comply with these values, or if unmonitored zon es r es ul t due t o the sha pe or m ov em ent of the machine, addition al safet y m easures must be taken.

The effectiveness of the detection zones can b e optimized by changing the depth at which the scanner is inst alled, or by adjusting the angle rang e (e.g. from 180° to 190°).

For inform ation on how to configure the sc anner in thi s way, please refer to the instruction manual (softw are operation) for the SD3SOFT.

Fig. 5.4-2: Recessed i nstall ation within t he machi ne cont ou r

If it is not possible to mount the SD3- posi tioned lat eral to or acr os s from the m achine.

A1 direct ly onto the m ac hi ne, it c an al so be

5.4.4.3

Extern al mounting lat eral to or a cross from the machine

Fig. 5.4-3: Lateral external scanner mounting without an undercut

If t he m achin e c ont ou r runs parallel t o th e 90° beam of t he l at erally plac ed SD3- distance between the detection zone boundary and the machine may not exceed 35mm.

Fig. 5.4-4: Mountin g the scanner across from the m achine with an undercut

A1, the

5.4.5

Additions

The axis of the rotating mirror (midpoint of the scanner) is of critical importance when configuring the detection zones. This axis is assigned a value of 64mm from the front edge of the sc anner when calculating detecti on zones.

Add 83mm or 100mm for the maxim um radial measurement error Z Chapter 5.3.5.

Add an addition Z area.

as described in Chapter 5.3.5 if reflectors c ould be present in the

REFL

as described in

Please note that safety additions must principally be added to the safety distance throughout the entire detection zone. In other words, additions may not be added to just one side or only to certain sections.

Please consult the operating instructions provided by the machine or system manufacturer.

5.4.6

System availability

There must be a buffer distance of 83mm between the surrounding contour and the detection zone contour (including the additions). This dist ance increases the up-time of the machine or system since it prevents the surrounding contour from being detected as relevant for generating a switch-off signal. If there is an undercut across from the scanner that is impossible for a person to step beneath (see Fig. 5.4-4), the depth of the und ercut can be calculated according to the following formula:

= Z +83mm - d

UMIN

= Depth of the und ercut, in mm

UMIN

Z = Required detection zone additions, in m m d = Resolution of the scanner (d = 70mm)

This is possible since it is absolutely certain that a person will be detected in front of the undercut.

Furth ermore, th e dust al gor it hm of th e SD3-

A1 can be implemented if floating particles may be present in the area. This algorithm , which can be activated in th e user program “SD3SOFT”, prevents the machine or system from b eing switched OFF unint entionally. Please note Chapter 5.3.5.

If the danger zon e analysis allows a multiple evaluation, detection errors caused by floating particles can be decreased. The number of evaluations that is decisive for the response tim e of the scanner (T be set in the user program “SD3SOFT”.

), and thus also requi res a larger detecti on zone, can

SCAN

In the event of an error event that lasts only briefly (for example the effect of extraneous light) the scann er perform s a one-time reboot. If autom atic startup / restart are activated, the scanner turns th e OSSDs back ON aft er this brief error event, and after the detection zone has been free for about 25s. This one-time reboot results in an additional increase in availability. This function does not have any effect if detection zone activation is faulty. If startup t est, startup interlock and / or manual restart are included, th ey will not be removed.

Safety notes: Automatic startup / restart must only be used in cases where there is absolutely no possibility that the effective detection zone could be entered or bypassed in some other way. D ependin g on th e hazard ass es sm ent, visual an d / or ac ou st ic start up warnings should be provided.

If parameters are set for the function “Manual restart”, the required enable from the startup / rest art button affects all detection zones and is ind ependent of any detection zone changeover. If the current detecti on zone is manually enabled, this enable also applies even if the system switches to another detection zone and this detection zone becomes free! If startup / restart interlock is in effect in the current detection zone, it is als o in ef fect for th e other d et ecti on zone t o which the system swi tc hes even if this detection zone is free.

5.4.7 Restart interlock

The SD3-A1 is equipped with a restart interlock function. You can select or deselect this function as needed to connected restarting of the machine to a manual ap proval. It affects all detection zones and does not depend on any detection zone changeovers. For information on how to configure the scanner appropri ately, please refer to SD3SOFT (Section: “Safety-relevant parameters” fold er).

The restart button must be mounted so that

x the entire danger zone (or detection zone area ) can be viewed from the operating

position.

x it is not possibl e to directly step or reach into the danger zone or danger point from

the operating position.

The button refer to the areas to be enabled in a easily understandable manner. Please comply with th e safety notes in Chapter 3 and 5.4.6.

5.4.8

–

Calculating the detection zone dimensions for safeguarding an area

According to IEC 61496-3 and DIN EN 999, the following formulas apply for calculating the safety distance and the m inimum depth of th e detection zone when th e direction o approach runs parallel to the detection zone:

S = (K × T) + C C = 1,200mm

Safety distance, minimum distance from the danger zone to the point o

0.4H

MIN

= 850mm = 15 (d –50mm)

MIN

= 1,000mm

MAX

detection, to the plane of detection, or to the detection zone, in mm

K =

Approach speed of a person or a person’s body parts (1,600m m/s), in mm/s

T = Lag time of the entire system (response time and braking time until standstill),

in s

C = Safety-related constant to consider entry into the danger zone before the

protective device is triggered, in mm

= Minimum value of the safety-related constant (850m m), in mm

MIN

= Height of the scanni ng plane from the reference point, in mm

= Minimum height of the scanning plane from the reference plane, in mm

MIN

= Maximum height of the scanning plane from the reference plane, in mm

MAX

= Resolution of the scanner (70mm throughout the detection zone), in mm

5.4.8.1

Additions and minimum depth of detection zone

The sum of the system-specific and application-specific detection zone additions (see Chapter 5.3.5) is calculated acc ording to the following formula:

= ZSM + Z

TOT

= Sum of the system-specific and applic ation-specific detection zone additions,

TOT

= Scann er m easurement error, i n mm

= Addition of the reflectors taken into account, in mm

REFL

= Addition for application-specific undercut, in mm

REFL

in mm

+ Z

The depth of the detection zone, with reference to the direct distance between the dange zone and the detection point or line, is calculated according to the following form ula:

= (K × (T

ST Depth of detection zone, distance from dang er area to detection point or line,

K Approach speed of a person or a person’s body parts (1,600m m/s), in mm/s

Response time of the scanner, in s

SCAN

Respons e tim e of th e machine or sy st em , in s

MACH

Lag time of the entire system, in s

LAG

Factor for increase in lag time

LAG

C Safety-related constant, in mm

5.4.8.2 Maximum

MAX

= G

BDIFF

Maximum range of the detection zone considering the diagonals, in mm

MAX

Depth of th e detection zone, in mm

Largest width of the detection zone between the axis of the rotating mirror

BDIFF

Largest width of the danger zone betw een the axis of the rotating mirror and

BDIFF

S Safety distanc e, minimum distance from the danger zone to the point of

Z Required detection zone additions, in mm

+ T

+ ( T

× L

SCAN

MACH

LAG

))) + C + Z

LAG

TOT

including system and application-specific additions, in mm

ange of detection zone

BDIFF

+ S + Z

and the outer edge of the detection zon e, in mm

the boundary of the danger zone, in mm

detection, to the plane of detection, or to the detection zone, in mm

Fig. 5.4-5: Considering the maximum measurement di stance when safeguarding an

area

5.4.8.3

Sample calculation of the depth of a detection zone

This example is based on the following application data (see 5.4-5):

Largest width between the axis of the rotating mirror and the

700mm

BDIFF

boundary of the danger zone

Access speed K 1,600mm/s (constant)

Response time of the SD3-A1 (adjustable)

Respo nse time of t he machi n e or system

Stopping time or lag time of the machine or system

0.08s

SCAN

0.1s

MACH

0.5s (time for braking the

LAG

dangerous movement until standstill)

Factor for increase in lag time L

Addition for system-specific measurem en t er ror

Addition caused by the mounting position that is selected

1.1 (fixed addition to account for

LAG

83mm (when dust algorithm is

125mm (distance betw een the

increased lag time)

switched OFF)

front edge of the undercut to the beam axis of th e sc anner)

Height of the sensor

H 300mm

scanning plane

Safety-rel ated const ant C 1,200mm – 0.4 × Height H

= 1,080mm

The formul a

S = ( K × ( T

SCAN

+ T

MACH

+ ( T

LAG

× L

LAG

))) + C

results in a safety distance of:

S = (1,600mm/s × (0.08s + 0.1s + (0.5s × 1.1))) + 1,080mm = 2,248mm

The formul a

= S + ZSM + Z

results in the detection zone depth:

= 2,248mm + 83mm + 125mm = 2,456mm

5.4.8.4

Sample calculation of a maximum

ange of a detection zone

The formul as:

MAX

BDIFF

= G

BDIFF

+ S + Z

yield, under consideration of the width of the danger zone results in the maximum distance to be monitored:

MAX

2,456mm2 + 3,031mm

= 700mm + 2,248mm + 83mm = 3,031mm

BDIFF

= 3,901mm

MAX

5.4.8.5

Sample calculation of an undercut

This example is based on the following applicati on data. If the scanner is mounted across from the machine (see Fig. 5.4-4), the undercut dimension c an be reduc ed by d = 70mm.

The formul a

= Z + 83 mm – d

UMIN

results in a minimum undercut:

= 83 mm + 83 mm – 70 mm = 96 mm

UMIN

It is not allowed for a person to be able to step beneath the undercut.

Fig. 5.4-6: The undercut

5.5 Access protection

Please have regard to the general safety notes in Chapter 3.

5.5.1

5.5.2

5.5.3

Object of protection

The object of protection is the safeguarding

x of individuals when they access a danger zone.

The SD3-A1 will detect the passage of individuals and the intrusion of an entire human body into the scanning fi eld of the laser scanner.

Installation position

Access protection is based on passage monitoring. This is a suitable system 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. In addition, the danger area must be open to inspection, and the button for manual triggering of the restart interlock must be situated outside the area. It is best if the laser scanner is firmly installed above the passage in question, in vertical alignment and in such a way that it cannot be manipulated.

Care must be taken to ensure that the positioning of the laser scanner SD3-A1 does not leave any areas through which a person might slip through without being detected. The distance of the scanning field limiting the passage and the boundaries of the detecti on zone must be defined in such a way that no gaps measuri ng more than 150mm can arise.

Safety-relevant settings, and calculation of the safety distance

To safeguard the protective equipment against inadvertent misadjustment o manipulation, the detection zon es of the SD3-A1 must be defined on the basis of a reference boundary. In addition, the response time must be defined as 80ms and the restart interlock must be set. To enable the system to recognize an entire human body, the laser scanner must have a resolution of 150mm. These safety-related settings will be automatically enabled in the SD3SOFT configuration and di agnosis software when the presetting ”Passage monitoring” has been selected.

For effective passage monitoring, a safety distance S must be observed between the detection zone of the laser scanner and the danger zone. The SD3-A1 can fulfill its protective function only if it has been installed and positioned in such a way as to allow for an adequate safety distance. The safety distanc e ensures that no body part whatever can reach the danger point until the hazardous movem ent of the machine has com e to a complete standstill.

The safet y distanc e f or a n ac c ess prot ecti on system may be c alculat ed, based on EN 999

by means of the following formula:

S = K × T + C

S = Safety distance, in mm

K = Approach velocity, in mm/s Here = 1,600mm /s

Overall time of delay, in s,

T =

a total consisting of:

Respo nse time of t he lase r sc an ner Here = 80m s

Overtravel time of the machine including the controls

C =

Added margin on account of the possibility of manual intrusion

Please also have regard, in this connection, to the diagrams gi ven in this chapter.

5.5.4 Definition of the

eference b oundary

Bas ed on measu r em ent of overtravel time

Here = 850mm

Fig. 5.5-1: Access protection by passage monitoring with system check of a

reference boundary

The reference boundary must cover at least two sides of the detection zone. The

detection zone itself must be defined in such a way that no gaps can arise through which a pers on could pass t hr ou gh th e passage w it hout b ei ng detect ed. The r ef er ence boundary is defined with reference to the non-moving parts of the passage. These will then be constantly monitored by the laser scanner, so that any indi viduals intruding or other manipulative intervention will be detected beyond the possibility of doubt. In defining the reference boundary, please also have regard to the indications given in the instruction manual (software operation) for the SD3SOFT configuration and diagnosis softw are.

5.6 Protecting danger points

Please have regard to the general safety notes in Chapter 3.

5.6.1

5.6.2

5.6.3

Object of protection

The object of protection is the safeguarding

x of indi viduals who work with a machine or spend time in th e danger zone

associated with it.

The SD3-A1 will detect the body parts of individuals and the intrusion of these body parts into the sc anning fi eld of the laser scanner. In this op erating m ode, hand and arm protec tion is effec ti vel y realised.

Installation position

Safeguarding of danger points on the basis of hand and arm protecti on is a suitable met hod if the m achine op era tor, in c l ose pr oxim it y t o th e danger zone, n eeds to h alt the hazardous m ovement of the machi ne or t o coordinate the handling of workpieces or thei rem ov al f rom t he m achi ne. It is best if the l as er scann er is firmly inst all ed ab ov e th e danger zone, in such a way that it cannot be manipulated. The health and safety office must ensu r e th at th e inst all ation p osi ti on of t he SD3-A1 does not leave any areas free through which manual intrusion could be effected. If appropriate, additional protective facilities should be installed to exclude any possibility of the operator’s reaching over or around or getting behind th e barrier. To prevent the latter, the dist ance from the scanning field to the machine table must not be more than 75mm. This can be guaranteed i suitable screen s are installed for the monitoring of the reference boundary (see the illustrations in this chapter).

Safety-related settings, and calculation of the safety distance

In order to safegu ard the protective equipment against inadvertent misadjustment and manipulation, the detection zon es of the SD3-A1 must be defined on the basis of a reference boundary. To make it possible to recogni se the hand or arm of a person, the laser scanner must have a resolution of 30 or 40mm. These safety-related values will be automatically set in the SD3SOFT configuration and di agnosis software when the presetting “Hand protecti on” or “Arm protection” has been selected. At the same time the detection zone limits will be limited to 1.60m or 2.20m, and cannot be extended beyond this.

To safeguard the danger point, a safety distance S must be observed between the

detection zone of the laser scanner and the danger zone. The SD3-A1 can fulfill its protec tive fu nc ti on onl y if it has been inst all ed an d p osi tion ed in such a w ay as to all ow for an adequate safety distance. The safety distanc e ensures that no body part whatever can reach the danger point until the hazardous movem ent of the machine has come to a complete standstill.

The safety distance S when safeguarding a danger point may be calculated, based on EN 999, by means of the followi ng formula:

S = K × T + C

S = Safety distance in mm

K = Approach velocity in mm/s

At a close distance of 500mm, a velocity of 2,000mm/s should be assum ed. If the calcul ation involves a distanc e in excess of 500mm, K may be taken to be 1,600m m/s. But in this case the safety distanc e is subject t o a minimum value of 500mm.

Overall time of delay in seconds,

T =

a total consisting of:

Response tim e of the laser scanner Adjustable, max. 200ms

Overtravel time of the machine including the controls

C = 8 × (d - 14 ) in mm

dded margin dep endent on the depth of penetration of the detection zone, based on the resolution of the laser scanner: C (30mm) = 128mm, (40mm) = 208mm

The resol ut ion t o whic h t he l as er sc anner

d =

has been set

In this connection please also have regard to the illustrations given in this chapter.

Bas ed on measu r em ent of overtravel time

Here = 30mm or 40mm

5.6.4

Defining the

eference boundary

Fig. 5.6-1:

The reference boundary m ust cover at least two sides of the detection zone. The detection zone itself must be defined in such a way that no gaps can arise through which or over which a person could reach without being detected. The detection zone must also provide safeguards against a person getting b ehind the barrier. This can be very effectively managed by screening th e sides of the danger zone. The reference boundary should be defined with reference to the non-moving parts of the screen arrangement. The detecti on zone must be defined as large enough to ensure an overlapping greater than the tolerance zone of the reference bound ary. The detection zone will then be constantly monitored so that any body parts intruding or other manipulative intervention will be detected beyond the possibility of doubt. In defining the reference boundary, please also have regard t o the indic ations given in the instruction manual (softw are operation) for the SD3SOFT configuration and diagnosis software.

Safeguarding of danger point based on hand and arm protection with monitoring of a reference boundary

5.7 Safeguarding mobile machines

Please comply with the safety notes in Chapter 3.

5.7.1

5.7.2

5.7.3

5.7.4

The purpose of safeguarding

is for protection:

x to protect people when entering vari able danger zones

x t o prot ec t obj ect s l oc at ed in the vehic le p at h

x t o prot ec t t he aut om atic guide d vehi cl e and its load

Installing adjacent laser scanners

The SD3-A1 has been developed in a way that prevents several laser scanners from interfering with one other as much as possible.

An increase in the response time can, however, be caused by the installation of several adjacent laser scanners. If none of the constructive measures (section 5.2.1) described in the following sections or the specific adjustment (section 5.2.2) are implemented, then

the SD3-A1 response time set and shown in the configuration and diagnos is software (SD3SOFT) is extended by 40ms. This ext ension in the response time must

be taken into account when calculating the safety distance!

Mounting position

For the purpose of safeguarding the path of a vehicle, the SD3-A1 is mounted on the front of a vehicle (in each dir ection of travel), preferably in the center.

The scanner, and henc e the beam axis, m ust be aligned horizontally in order to achieve a consistent scanning height.

Please comply with the safety notes in Chapter 3.7.

Mounting height

s a rule, the sc anner should be mount ed as low as possible in order to prevent people from c rawling b en eat h th e detection zon e. This spec i fic at i on is limited du e t o suc h f acto rs as uneven floors or the deflection of the springs in the AGV.

The maximum mounting height must be select ed so that an object (cylinder with a diameter of 200mm in the prone position) i s reliably detect ed (see DIN EN 1525). The detection must be tested at the position of maximum depth within the detection zone. For

GV applications, sufficient resolution of detecti on is achieved when a n object (upright cylinder) with a diameter of 70mm can be detected throughout the detection zone.

Fig. 5.7-1:

Depending on the application, further additi ons may be necessary. Additi onal inform ation is available in Chapter 5.7.6.

Mounting height on an AGV

5.7.5

Recommendations for mounting to prevent unmonitored zones

The creation of unmonit ored zones is dependent upon the following fact ors:

x the vehicle width

x the design of the vehicle (e.g. attachments, shape)

x the position of the scanner

x the installati on depth

x the selected angle range.

If the detection zone of a SD3-A1 mounted on an AGV does not cover the entire front o the vehicle, you can prevent the creation of unm onitored zones by changing the installati on depth of th e scanner or by adjusting the angl e range (from 180° to 190 °).

If this is not possible due to constructional limitations, additional safety measures such as mechanical cover pan els, switch strips or bum pers must be implemented. Please comply with the safety notes in Chapter 3.7.

Fig. 5.7-2: Three possibilities for mounting the SD3-A1 onto an AGV

5.7.6

Additions

Add 83mm or 100mm for the maximum radial measurement error Z Chapter 5.3.5.

Add an addition Z area.

as described in Chapter 5.3.5 if reflectors could be present in the

REFL

as describ ed in

Without information from the AGV manufacturer, take int o account the wear and tear on the brakes by adding an addition L this is not already included in the braking distance S

of at least 10% of the braking distance, as long as

STOP

If there is a very sm all distance between the bottom of the AGV and the floor, the detection differenc e between the leg and the toes must be considered in the calculation. For AGVs with a floor clearanc e of less than 120mm, an addition Z This refers only to the travel of direction.

must be added.

AFLR

Fig. 5.7-3:

Diagram for calculating the addition to compensate for inadequate AGV floor clearance

5.7.7

System availability

There must be a buffer distance of 83mm between the surrounding contour and the detection zone contour (including the additions). This dist ance increases the up-time o the AGV, since it prevents the surrounding contour from being detected as relevant for generating a switch-off signal due to a measurement error.

Furth ermore, th e dust al gor it hm of th e SD3-A1 can be implem ented if floati ng particles may be present in the area. Thi s algorithm can be activated in the user program “SD3SOFT” and prevents the AGV from being switched OFF unintentionally. Please note Chapter 5.3.5.

), and thus also requi res a larger detecti on zone, can

SCAN

5.7.8 Restart

t least 2s m ust el apse following th e release of a vi olated d et ect i on z on e befor e the A GV is allowed to startup again (in accordanc e with DIN EN 1525). The rest art can be initiated either manually or automatically. In case of automatic restart, the delay time of up to 10s can be set in advanc e using the program “SD3SOFT”. If a restart butt on is provided, i must be mounted outsid e the danger zone at a position from which the entire dange zone can be viewed. The areas that will be released must also be referred to in an easily understandable manner. The st artup / restart interlock affects all detection zones and does not depend on any detection zone changeovers. Please comply with the safety notes in Chapter 3 and Chapt er 5.7.7.

5.7.9

Calculating the dimensions of the detection zone of an AGV application

Following are the specificati ons and calculation examples for the mobile safeguarding o automatic guided vehicles..

According to IEC 61496-3, the following form ulas apply for calculating the safety dist ance:

5.7.9.1

5.7.9.2

S = (V

MAXAGV

T S

STOP

× T) + S

MAXAG

STOP

Maximum speed of the AGV, in mm/s = Respo nse time of t he sc anner an d t he AGV , in s

Braking distance of the AGV until standstill, in mm

Direction-related minimum depth of the detection zone and additions

The depth of the detection zone in the direction of travel, with respect to the distance between the edge of the roadway and the boundary of the detecti on zone, is calculated acc ording t o the following formula:

= V

MAXAGV

SCAN

AGV

STOP

TOT

×( T

MAXAG

Depth of the detection zone in the direction of travel, in mm

SCAN

+ T

) + ( S

STOP×LSTOP

) +

TOT

Maximum speed of the AGV, in mm/s =

Response time of the scanner, in s

Response time of the AGV, in s

Fact or for wear and tear on th e brakes

Total of the system- and application-specific additions in the direction of

travel in mm

= ZSM + Z

REFL

AFL

ZSM = Scann er m easurement error, i n mm

= Addition of the reflectors taken into account, in mm

REFL

AFLR

Maximum

MAX

Addition for inadequate floor clearance by the AGV, in mm

= Application-specific addition, in m m

ange of detection zone

BDIFF

= G

BDIFF

= Maximum range of the detection zone, in mm

MAX

= Depth of the detecti on zone in the directi on of travel, in mm

BDIFF

= Sum of the system- and applic ation-specific additi ons to the side, in mm

= ZSM + Z

REFL

= Application-specific addition, in m m

+ Z

BDIFF

Largest width of the detection zone, in mm

Largest width of the danger zone, in mm

+ Z

REFL

= Scan ner m easurem ent err or, in mm Z = Addition of the reflectors taken into account, in mm

(see Chapter 5.3.5)

Fig. 5.7-4:

In accordanc e with DIN EN 1525, a minimum safety distance of 0.5m width b etween the vehicle and its environment must be maintained.

Considering the maximum measurement dist ance for safeguarding AGVs

5.7.9.3 Sample calculation of the depth of a detection zone

Thi s exam pl e is based on th e foll owing typic al applic ation dat a (with out ac cess against the directi on of travel and without retro-refl ectors):

Largest width of the danger zone from the axis of the rotating mirror

Maximum speed

Response time SD3-A1 (sel ectabl e)

Response time of AGV control

Braking distance

Factor for wear and tear on the brakes 1.1 (fixed addition to acc ount for

Measurem en t er ror

Distance between AGV and floor = Z

= G

BDIFF

= V

MAXAGV

= T

SCAN

= T

AGV 0.1s

= S

STOP

= L

STOP

= Z

SM 83m m

90mm (results in an additi on of

AFLR

1,400mm

1,800mm/s

0.08s

1,900mm

wear and tear on the brakes)

50mm accordi ng to Fig. 5.7-3 for calculating the addition for inadequate floor clearance)

5.7.9.4

The formul a

S = V

MAXAG

SCAN

) + (S

STOP

× L

STOP

)

× (T

+ T

results in a safety distance of:

S 1,800mm/s × (0.08s + 0.1s) + (1,900mm × 1.1)

= = 2,414mm

The formul a

= S + ZSM + Z

REFL

+ Z

AFLR

+ Z

results in the following required depth of the detection zone in the direction of travel:

= 2,414mm + 83mm + 0mm + 50mm + 0mm = 2,547mm

Sample calculation of a maximum range of a detection zone

The formul a

MAX

BDIFF

= G

BDIFF

+ Z

+ S

yields, under consideration of the width of the danger zone results in the maximum distance to be monitored:

MAX

BDIF

MAX

2,547mm

= 1,400mm + 83mm = 1,483mm

2,947mm

+ 1,483mm

5.7.10

Side guarding configuration on AGVs

All previous considerations and the Chapt er 5.7.9 (Calculating the dim ensions of the detection zone of an AGV applicati on) also apply for sid e guarding on AGVs. With AGVs that drive along conveyor segments it should always be ensured that big enough undercut is provided (see also, details in Chapter 5.4.4). If the structure of the conveyo segment does not allow an undercut, then it must be assumed that a person is in the space between the vehicle and the conveyor. This is especially the case with spaces o mor e than 100m m . This pers on i n t he sp ac e b etw e en v ehic le and c onveyor shoul d be detected simultaneou sly with a person in the driveway, which must be taken int consideration with the dimensioning of the detection and w arning zones. The same safety distance calculations therefore apply.

A laser scanner resolution of 150m m is required to detect an entire person. This safetyrelevant setting is automatically set in the SD3SOFT configuration and diagnostics software with selection of the "person detection" presetting. The definition of a referenc e contour as with acc ess guarding i s not necessary, as the approach of th e person to be protected is made in the direction of the detection zone! If the conveyor segment height is over 500mm and the dist ance between vehicl e and conveyor is mor e than 100m m, then the detecti on zone between vehicl e and conveyor can be aligned. With conveyor segment heights below 500mm there is the increased danger of the conveyor segm ent being crossed over. In this case the alignment of the detection zone with the conveyor edge guarantees detection of a person at this point. If a laser scanner resolution finer than 150mm is additionally required for the safe position detection of the load, then this can also be selected in this application. The person in the in between space continues to be safely detected.

6 Details on Switching Over Detection and Warning Zones

During the course of an optimum machine utilization an alternate infeed or machining cycle often occurs, which brings the most diverse danger areas with it. vehicle system applications by their very nature include various danger areas, depending on the o per ating st at us. I f the appr oac h or pr es ence of p eop le is now to be expect ed i n these areas, the need exists of a precisely adjusting safety system. With its eight switchabl e and freely configurabl e detection and warning zones (zone pairs), the SD3-A1 satisfies m ultifaceted requirements with regard to guarding the most diverse applications.

The definition of the necessary zone pair cont ours is possible with the convenient and easy to use configuration and diagnostics softw are, "SD3SOFT".

The zone p air s are act iv at ed via the con nect ion of 24V DC to t he corre spondin g c ont rol inputs, FP 1 to FP 4, which are provided on the X1 plug of the scanner. Please find detailed information on the scann er connection in Chapter 7.2 and Chapter 9.

If the SD3-A1 is to be restarted or switching is to be made between different zone pairs, the following points must be observed:

x The zone pair planned for the start must be defined with speci al consideration of the

danger areas valid for this moment.

x The sequence of the monitoring zones to be activated must ensure that the lower

threshold of the application-related detecti on zone minimum values is never crossed.

x W ith selecti on of zone pair 8 the monit oring function of the scanner is deactivated,

i.e. no detection zones are monit ored and the safety outputs (OSSDs) remain constantly active! With zone pair 8 the laser scanner may not be started. Zone pair 8 is planned for application-related situations in which it has been absolutely ensured that there is no danger for any people present. These are, for exampl e, vehicl es with crawler mode or in completely partitioned OFF and secured areas, vehicles in approach mode in the area of loading or p arking positions, as well as machines in the " s etu p" op er ati ng mode.

utom ated gui ded

Please observe the connection and interface assignment in Chapter 9.5 and the safet notes in Chapter 3.

6.1 Sequence of zone pair switchovers

The SD3-A1 safety laser scanner has eight detection / warning zones. Switchover between these zone pairs is possible at all times, provided the operating situation allows this. During the switchover process the SD3-A1 monitors the zone pair activated before the switchover until a new one has been clearly activated. Th e rules for the switchover depend on th e amount of the select ed zone pairs and their num bers. The procedures described in the followin g tables apply.

Table 6.1-1 applies with activation (start or switchover) of zone pairs 1 to 8.

Zone pai

1 1 - 0 - 0 - 0 Zone pair 1 is active

2 0 - 1 - 0 - 0 Zone pair 2 is active

3 0 - 0 - 1 - 0 Zone pair 3 is active

4 0 - 0 - 0 - 1 Zone pair 4 is active

5 1 - 1 - 1 - 0 Zone pair 5 is active

6 1 - 1 - 0 - 1 Zone pair 6 is active

7 1 - 0 - 1 - 1 Zone pair 7 is active

8 0 - 1 - 1 - 1 Zone pair 8 is active

Table 6.1-1: Connection of control inputs FP 1 to FP 4 with activation of zone pairs

The foll owi ng poi nt s als o appl y f or th e switch over:

x T he swi tc hover m ust be m ad e w it hin 40ms, i.e. aft er 40ms one of the inp ut

x The switchover process executed by the control unit must concur with the laser

If these points are not observed the laser scanner will fail within 40ms and will show this with the additi onal 2Hz flashing of the green LED 1.

Control input

FP 1 – FP 2 – FP 3 – FP 4

1 to 8

connections shown in Table 6.1-1 must be valid and provided stable. During the switchover time the old zone pair is monitored; the new one after max. 80ms.

scanner’s configuration, which was set beforehand with SD3SOFT.

6.2 Practical AGV application (example)

The foll owi ng exampl e sh ows the sequenc e of zone pai r c hang eo vers for an ef fic i ently implemented AGV under consideration of the ambi ent conditions. Please observe the particular danger zone analysis for each detection zone in combination with the correspondi ng route segm ents. Also note the safe sequences of changeovers and starts. For information on programming the startup detection zones (detection zones enabled for starting up the scanner) and on determ ining the sequence in which the detection zon es are to be activated, please see the instruction manual (software operation) for the SD3SOFT.

Activating an ZP

ZP 1 Straight secti on High speed

ZP 2 2m before the curve ZP 1 Low speed

ZP 3 Beginning of the curve ZP 2 Steering l ock - curve

ZP 1 Straight secti on ZP 3 Steering lock - straight

FP = 1 × detection zone + 1 × warning zone

Table 6.2-1:

If the AGV is controlled by a PLC, for instance, which corresponds t o Category 3 or higher acc ording to DIN EN 954-1, the previous zon e pair (ZP) can be deactivated immediately after the next zone pair has been activated, with no time delay. This results in a faster switching sequence.

The applic able safety guidelines and standards as well as the operating instructions fo the syst ems m ust be strictly complied with.

AGV position Deactivating

an ZP

Practical AGV application

AGV control of position

High speed

Fig. 6.2-1: E xam pl e of a zon e pair changeov er for an AGV on a cur ve d ro ut e

Fig. 6.2-2: Example of zone pair changeover with combined with reducing speed of

the AGV

7 Functions of the SD3-A1

The SD3-A1 is equipped with the X1 and X2 interfaces. The following functions are available through them:

7.1 Restart

Depending on the operating state, the restart inp ut X1-2 has several functions:

x E nables t he restart interl ock foll owi ng th e int err upti on of a d et ecti on zone

x E nables t he start in terl ock foll owi ng a s yst em st art

x Restarts after a devic e error has been eliminated

x Recognizes a defined enable signal

 after a devi ce error

 after a detection zone interruption for enabling the restart interlock

To activate the functions, apply 24V to input X1-2. In the meantim e, the safety outputs OSSD 1 and OSSD 2 are switched OFF; the indicator at the scanner (LE D 3) is lit up red. The duration of the signal must be between 0.12s and 5s.

The restart input X1-2 must be connected to an external, perm anently installed button. X1-2 must not be connected with the remaining c ontrols in order to prevent an unintended release with a restart pulse under some circum stances.

Force-guided, norm ally closed contacts c an be monitored in the rest art circuit (relay monitoring).

Please note the Chapter 5 (Inform ation for Planning and Mounting) and 9.1 (Electrical power supply).

7.2 Channels for zone pair changeovers, FP 1 to FP 4

To activate the zone pairs, apply 24V (see Chapt er 9.1) to the following inputs:

x X1-4 (FP 1)

x X1-6 (FP 2)

x X1-7 (FP 3)

x X1-8 (FP 4)

The following points also apply for the switchover:

x T he swi tc hover m ust be m ad e w it hin 40ms, i.e. aft er 40ms one of the inp ut

connections shown in Table 6.1-1 must be valid and provided stable. During the switchover time the old zone pair is monitored; the new one after max. 80ms.

x The switchover process executed by the control unit must concur with the laser

scanner’s configuration, which was set beforehand with SD3SOFT.

If these points are not observed the laser scanner will fail within 40ms and will show this with the additi onal 2Hz flashing of the green LED 1.

7.3 Alarm 1 (X1-5)

As long as the output X1-5 is switched ON, the syst em signals trouble-free operation. If it i s sw it ched OFF, the f ollow ing states are r ep orted :

x Interrupti on of the warning zone is shown by the continuously lit LE D 2 in the

indicator field of the scanner.

x W arning state:

For instance, the system m ay detect a slight dirt buildup on the optical window. To signal this state, LE D 5 on the scanner flashes (2Hz). The user should clean the optical window before it gets dirti er; waiting too long will cause a device error to be reported and the outputs OSS D 1 and OSSD 2 to be switched OFF.

x Device error:

Such as an erroneous reference measurem ent or extreme dirt buildup on the optic al window. This state is signaled by LED 5 flashing quickly (4Hz).

Both the reporting of a warning zone int errupti on and the si gnaling of the warning and err or state can be sel ected eith er s eparately or i n combin ation. Thi s proc edure is described in the instruction manual (softw are operati on) for the program “ SD3SOFT”.

Output X1-5 is equipped with an internal electronic current limit to protect it against damage from overload.

7.4 Alarm 2 (X1-15)

As long as the output X1-15 is switch ed ON, the syst em signals trouble-free operation. If it i s sw it ched OFF, the f ollow ing states are r ep orted :

x W arning state:

x Device error:

Suc h as an err oneou s r ef er enc e m easurem ent or ext rem e dirt buildup on the opt ic al window. This state is signaled by LED 5 flashing quickly (4Hz).

Out put X1-15 i s equipp ed wi th an intern al elec tronic curr ent lim it to pr otect it again st damage from overload.

7.5 OSSD 1 (X1-12) and OSSD 2 (X1-11)

When the det ection zone is int errupted, the two semiconduct or outputs switch OFF and, by way of elements such as positively guided relays, cause the monitored machine(s) to shut down. It is not admissible to control different safety circuits with a single OSSD. Connected loads must exhibit a low-pass behavior in accordance with the plausibility control conducted by the scanner (f anint er nal el ec tr onic current li mit t o pr ot ect them against dam age from ov erload.

For some sample connections, see Chapter 8.

 1kHz, CL 100nF). The OSSDs are equipped with

7.6

Data

ommunication

The int er face X2 all ow s t he SD3-A1 to support two types of connections to the PC.

Com m unicati on via t he X2 c onn ector in RS -232 mod e does not require any furth er bridging. T o enable data transfer in RS-422 mod e, connect pi n 5 with pin 6. The scanner automatic ally adjusts itself to the appropriate transfer type and baud rate.

The int er face (X2) i s used for

x configuring and setting parameters for the SD3-A1

x transferring measurement data while the scanner is in op eration

x evaluating the coordinates during p arameter setting (e.g. for AGV applications)

x advanced status and control diagnostics.

Guard operation is only permitted with the PC cable (X2) or dumm y connected screwed ON. This also applies for transport and storage.

Please note the pin assignments specified in Chapter 9.5. For additional information on using th e X2 interf ac e, r ef er to th e inst ru ct ion m anual (s oftw are op er atio n) for th e program “SD3SOFT”.

8 Integrating the SD3-A1 into Machine Controls

The following examples illustrate possibilities for integrating the SD3-A1 into machine controls.

Once the operating voltage pin X1-3 (+U detection zone has been activated (X1-4, X1-6, X1-7 or X1-8), the unit is ready fo operation.

Please see the point “Define Detection / Warning Zones” in the instruction manual (so ftware operati on) fo r the p rogr am “SD3SOFT”.

) has been connected to pin X1-1 (GND) and a

8.1

Integrating the SD3-A1 with external wiring with relays and

eightfold zone pair changeover

In this connection example, the restart interlock function is provided by the connected command unit “st art interlock”, which applies the voltage of 24V to the input RESTART X1-2. The SD3-A1 itself must be configured using the “SD3SOFT” user software so that the op er ati ng mode “with rest art int erl ock” i s ac tive.

Fig. 8.1-1: W iring the SD3-

and restart interlock (example)

Relays K1 and K2 must have forced contacts. They are operated directly at the two failsafe semiconductor outputs OSSD 1 (X1-12) and OSSD 2 (X1-11). Relay K3 has a deenergizing delay. A suitable mechanism must be provided for extinguishing sparks. Please note that doing this will cause the switching time to be extended.

Channels “x” and “y” must be integrated for Category 3 in accordanc e with DIN EN 954-1. Integrating one channel based on “z” is only permitted with a one-channel control system and taking int o consideration the results of a risk analysis.

Serial machine controls are admissible only insofar the valid regulations allow.

A1 with evaluation of the OSSDs, zone pair chang eover

Fig. 8.1-2: W iring the SD3-A1 with evaluati on of the OSSDs, zone pair changeover,

restart interlock and static relay monitoring

Relays K1 and K2 must have forced contacts. They are operated directly at the two failsafe semiconductor outputs OSSD 1 (X1-12) and OSSD 2 (X1-11). A suitable mechanism m ust be provided for extinguishing sparks. Please note that doing this will cause the switching time to be extended.

Serial machine controls are admissible only insofar the valid regulations allow.

8.2

Connecting the SD3-A1 to a safety sequence circuit with

manual restart interlock, relay monitoring, without zone pai changeover

Fig. 8.2-1: W iring the SD3-A1 with manual restart int erlock and relay monitoring,

In this exampl e, the relay monitoring i s perform ed by an external safety module (e.g. SRB 324ST). Relays K4 and K5 must be equipped with positively gui ded cont acts. A suitable mechanism must be provided for extinguishing sparks. Please note that doing this will cause the switching time to be extended.

Please refer to the operating instructions for the components.

Serial machine controls are admissible only insofar the valid regulations allow.

and without zone pair changeover

8.3

Connecting the SD3-A1 to a PLC with corresponding safety

level (Category 3 or higher, EN 954) and zone pair changeover

Fig. 8.3-1: Connecting the SD3-A1 to a failsafe PLC with a safety level (at least

Category 3, EN 954) and zone pair ch angeover (example)

All switching functions in this sample connection are controlled directly by the PLC.

The changeover of 4 zone pairs is achieved by way of the inputs X1-4 (FP 1), X1-6 (FP 2) X1-7 (FP 3) and X1-8 (FP 4).

For applic ations in which the scanner must be separately enabl ed for its detection zone, the signal can be given either by the machine controls or by connecting a command unit for rest art inte rl ock. T h e SD3-A1 itself must be configured using the “SD3SOFT” user progr am so t hat the operat in g m od e “with rest art int erloc k” is active.

9 Electrical Connection

9.1 Electrical power suppl

The SD3-A1 re qui r es a direc t v oltag e of 24V and 8W of pow e r pl us the load at the outputs (max. 25W ).

The pow er m ust be suppli ed b y w ay of an ext er nal 1. 25A, semi ti me-l ag fus e (e.g. i n an electronics cabinet). In addition, a permanent current of 2.5A must be ensured before safeguarding begins in order to guarantee that the fuse will be triggered in case of a fault.

In keeping with electrical safety requirements, the power to the SD3-A1 all connected input and output circuits must be provided by a power supply unit with protective isolation from a safety transformer according t o IEC 742 or c omparabl e (this also applies for the use of battery chargers for AGV applications).

9.2 Connecting the PC and control cables to the scanne

Two connector adapt ers with cable screw c oupling are supplied with the SD3-A1. Two o these are needed to acc ommodate the 9-pin Sub-D connector and the 15-pin Sub-D jack (PC cable and c ontrol cable). A housing i s used as protection of the X2 interface when data communication with the PC is not desired.

The cable screw couplings can accommodate cable diameters from 6.5mm to 10.5mm.

Fig. 9.2-1: Preparing the connectors

The con nect or ada pt er of c ontrol c abl e X1 must be conn ected w it h interf ac e X1 and

screwed tightly to the SD3-A1. The c onn ector adapter of cable X2, or else the X 2 dum m cap (without a cable), must also be screwed tightly to the SD3-A1. Screw thread bolts are located on the top of the scanner housing for this purpose. If one of the two connection housings is missing, the SD3-A1 no longer meets the requirements of protection type 65. For inform ation on th e assignment of the connector, pl ease refer t o Chapter 2.2 and 9.5.

9.3 Connector assembl

Every connector adapt er consists of the following individual parts:

x Housing with sealing ring and fastening nuts

x Cable screw c oupling (M16) with dummy plugs

x Sub-D9 connector and / or Sub-D15 jack, each with a solder connection

9.4

Points to consider

x The cross-section of cable X1 must be at l east 0.5mm

x The outer diameter of the cable must be between 6.5mm and 10mm.

x The maximum cable length for X1 is 50m .

x The maximum cable length for X2 is 10m (for RS-232).

x The maximum cable length for X2 is 50m (for RS-4 22, twisted pair).

x Use shielded cables.

x Connect the cable shielding with PE to the electronics cabinet only.

x The cables must not be laid loose.

Scanner control cables may not be laid in a st and parall el to power supply cabl es for machines. This minim izes the effects of inductive interferenc e factors from m otors carrying high current. In addition, the cables should be laid so that they cannot be damaged (e.g. by being cru shed or pinched).

Cabling prepared for c onnection to the scann er is available as an optional accessory in various lengths and for b oth int erfaces. F or further information, see Chapter 13.

hen preparing and laying the cables

9.5 Interface pin assignments

Pin assignments for connector X1

PIN Signal Description

1 GND Power supply ground

2 Restart Input, scanner reset, and connecting of the restart button

3 UB 24V DC power supply; protected by a 1.25A delayed-action

4 FP 1 Zone pair control input

5 Alarm 1 Semiconductor output that switches OFF when the warning

6 FP 2 Zone pair control input

7 FP 3 Zone pair control input

8 FP 4 Zone pair control input

9 Reserved Internally connected

10 Reserved Internally connected

11 OSSD 1 Semiconductor output, switches OFF when the detection zone

12 OSSD 2 Semiconductor output, switches OFF when the detection zone

13 Reserved Internally connected

14 Reserved Internally connected

15 Alarm 2 Semiconductor output with shut-off wh en warning and

Table 9.5-1: Pin assignm ents for connector X1

fuse

zone is violated as well as for warning m essages such as “optical window slightl y dirty”, error messages such as “optical window very dirty”, and for internal errors (the functions can also be selected in combination).

is violated, Channel 1

is violated, Channel 2

malfunction message

Pin assignme nts for connector X2 used as an RS-232 port

PIN Signal Description

1 Reserved Internally connected

2 TxD Data communication, transmit

3 RxD Data comm unication, receive

4 Reserved Internally connected

5 GND / shield Ground / shield

6 RS-232 Internally connected

7 N.C. Do not assi gn

8 N.C. Do not assi gn

9 Reserved Reserved for t esting purposes

Table 9.5-2:

Pin assignme nts for c onnector X2 used as an RS-422 port

PIN Signal Description

1 Tx + Data communication, receive

2 Tx - Data communication, receive

3 Rx - D ata comm unication, transmit

4 Rx + Data communication, transmit

5 GND / shield Ground / shield

6 RS-422 Select RS-422 interface by connecting a bridge to pin 5

7 NC Do not assign

8 NC Do not assign

9 Reserved Reserved for t esting purposes

Table 9.5-3:

For the pin arrangement, please refer to Chapt er 2.2 and 9.5 in the instruction m anual (connection and operation) of the SD3-A1.

Pin assignm ents for connector X2 used as an RS-232 port

Pin assignm ents for connector X2 used as an RS-422 port

10 Commissioning

Communication with the PC needs to be established so that the SD3-A1 can be configured and the detecti on zones and warning zones can be programm ed. This is also necessary for displaying the measurement contours and for the system check.

The program “SD3SOFT”, which is included with delivery, makes this easy and convenient to do. Refer to the instruction manual (software operation) to find additional important inform ation and helpful explanations.

10.1 Hardware and software requirements

The following components are required for the initial startup:

x SD3-A1

x RS-232 interf ace cabl e (1:1, w it hout cr oss-c onnec ti on )

x Shielded control cable for the power supply and for activating a zone pair

x Power supply that meets the requirements specified in Chapter 9.1

x PC, color monitor

x “SD3SOFT” program

The PC should fulfill the following requirements:

x Intel

x At least 64MB RAM

x CD d rive

x Hard drive with at least 50MB of free m emory (m ore if detection zone data and / or

x Mouse

x Interface RS-232 (serial)

x Microsoft

processor, Pentium® class or higher (or compatible models such as AMD®or

Cyrix

)

configurati on data are going to be st ored)

Windows 95 / 98 / NT® / 2000 / XP

10.2 Installing “SD3SOFT” and starting up the SD3-A1

x First, run the installation program “start.exe” in order to install the program on the

PC.

x Start the software by calling up the program.

x C onnec t the c ontrol cabl e and the P C c able.

x T hen appl y t he sup pl y v oltage t o the SD3-A1. The scanner will now attempt to

communicate with the PC; this process is displayed on the screen.

x W hen the connection between the SD3-A1 and the PC was successful, you can

enter the appropriate passw ord and then change the parameters and zone pairs o the SD3-A1 to meet t he needs of th e part ic ul ar applicati on.

The standard password to be entered in the access level “Authorized User” o the SD3-A1 is: “SD3SUNX”. Please n ote that the passw ord must be changed

following the initial configurati on of the scann er, and that the data carrier must be kept locked up in a secure location.

x The SD3-A1 is ready for operation once the scanner settings and detection zone

configurati ons have been transferred.

Every SD3-A1 is factory-equipped with the maximum safety parameters. For this reason, first the device settings and then the detection zones m ust be adapted to the req uirem ents of th e applic ation b efore the sc ann er i s put int o operation. the scanner, remove the PC interface cable from position X2, put on the dummy cap provided with delivery, and screw it tight.

For a list of parameters, please see the instruction manual (software operation) for the SD3SOFT. Please observe Chapter 11, Maintenance and Testing.

fter configuring

10.3 SD3-A1 status indicato

There are five LEDs l ocated on the front of the scanner behind the cover with the matte finish. These LE Ds i nd ic at e th e status of th e SD3-A1.

Fig. 10.3-1: The SD3-

A1 status indicator

Meaning of the individual LEDs

LED Colo

1 Green • Sensor functi on is active, active

2 Yellow

3 Red OSSD outputs are switched OFF

4 Green OSSD outp ut s ar e sw it ch ed ON

5 Yellow

Function / Meaning Pictograph

detection zone is free

• Fault input zone pairs, Light flashing at 2Hz

• Configuration conflict, Light flashing at 4Hz

• Warning zone is assigned

• Constantly lit: Start interlock Restart int erloc k

• Flashing slowl y (1): W arning message (approx. 2Hz)

Optical window dirt y

• Flashing quickly (((1))): device message (approx. 4Hz)

ok.

STOP

ok.

Table 10.3-1: Meaning of the SD3-

A1 LED displays

10.4 Status information of the SD3-

Scanner display LED numbers

1 2 3 4 5

– – 1 0 – LED 3 The OSSD outputs ar e switched OFF

1 0 0 1 0 LED 1

1 1 0 1 0 LED 1

0 1 1 0 – LED 2

1 0 0 1 (1) LED 1

0 0 1 0 (((1))) LED 3

1 0 1 0 1 LED 1

0 1 1 0 1 LED 3

Indica to

LED 4

LED 2 LED 4

LED 3

LED 4 LED 5

LED 5

LED 3 LED 5

LED 5

Status

(e.g. during booting).

The sens or func tion is active (me asurem ent operation without an int errupti on of the activated zone pair). The OSSDs are switched “active high”.

The sens or func tion is active (me asurem ent operati on w it hout a vi ol ation of th e ac ti vat ed detection zone). Violation of th e activated war ning zon e. T h e OS SD s are switch ed “active high”.

Violation of the warning zone. Violation of the detection zone. The OSSDs are switched OFF.

The sens or func tion is active (me asurem ent operati on w it hout a vi ol ation of th e ac ti vat ed det ection z on e). The OSS Ds are sw it ched “active high”. Warning message signaled by slow flashing at approx. 2Hz (e.g. with optical window dirty)

The OSSDs are switched OFF. Fault message indicated by fast flashing at about 4Hz (e.g. with defect or safety-related fault)

The sens or func tion is active (me asurem ent operation without an int errupti on of the activated zone pair). The OSSDs are switched OFF. Restart interlock is active.

Interruption of the zone pair. The OSSDs are switched OFF. Restart int erloc k is activ e.

1 = LED is lit up 0 = LED is dark – = Undefined

Table 10.4-1: St atus i nf ormat ion of t he SD3-A1

Upon delivery, the SD3- with activated startup interlock and manual rest art. For this reason, LED 5 is constantly li up when the sc anner is switched ON. W hen starting up your SD3-A1, please modify the par am et ers to meet t he sp ecific n eeds of you r ap pl ic at ion.

A1 is programmed with the largest possible detection zone and

10.5 Restart and device swap-out

The SD3-A1 can be connected via the X1 standard plug or the ConfigPlug with integrated configuration mem ory. With a restart the laser sc anner st arts in every case with the configurati on that was set when it went out of operation. Thereafter a technic al expert does n ot h av e t o look at it, bu t the t est in acc ordanc e with the sp ecifi cati on s for d ail y testing must be perform ed.

With a device exchange, however, the procedure is different!

When the X1 standard plug is used th e configuration must be transferred with the PC to the replacem ent devic e. All procedures and specifications of the first start up apply here. A technical expert should look at the device!

If the ConfigPlug is used with integrated configuration memory, the SD3- saved configuration automatically from the ConfigPlug when it is switched ON. The ConfigPlug must be clearly identified with a nameplate and the switch in the plug must be at the "1" (left) default position. During the startup with the automatic configuration read-back, the laser scanner signals the successful transfer with a brief flashing of the two yellow LEDs 2 and 5. In this case it does not have to be looked at by a technical expert, but the test in accord ance with the specifications for daily testi ng must also be performed.

Fig. 10.5-1: SD3-

A1 ConfigPlug with switch setting "1"

1 reads the

11 Maintenance and Testing

When placing the system in service for the first time, when it has been out of service for some time, aft er conversions and repair work, make certain the scanner and any other safety parts are checked specifically for the application and operation by the responsible trained specialist. This must be done taking into consideration applicable local requirem ents, esp ecially for guidelines on m achines and using work material and w ork safety guidelines. If the correct functi onality is not clearly confirmed or if safety-relat ed parameters have been changed, turn OFF the machine or vehicle immediately. Provisional measures are not permitted. Please comply with the safety notes in Chapter 3!

11.1

Test before first startup by person qualified and authorized to perform the task

x Check in accordance with the guidelines cited above, using the checklists provided

following if necessary to verify that the protective equipm ent has been properly attached is c onnected to the control system electrically and that its effect works in all operating m odes of the machine or vehicle.

x The result of the test must be documented, along with the scanner setting, in an

understandable form. Printouts of scanner parameters and all define d detection zone contours must be included with the materials. Keep these where they are inacc es sible for unauthoriz ed per sonn el.

x Duri ng initi al startup, you should anticipate unexpected behavior in the m achine or

vehicle. Because of this, people must be kept out of the danger area.

x Operating personnel must be instructed by trained specialists before st arting w ork.

Instruction is part of the area of responsibility of the machine operator.

x Ensure that a daily test is performed. Please take note in this regard of the “Daily

test with the test piece performed by responsible operating personnel”.

11.2 Extended shutdown of the SD3-A1

If a s yst em is tak en out of op erati on and th e SD3-A1 is pl ac ed in st or age for l at er u se with other m achines / vehicles, the factory settings should be rest ored. Please see the chapter entitled “Set default configuration values” in the instruction manual (software operation) for the SD3SOFT.

11.3

11.4

Regular tests by a person qualified and authorized to perform the task

Regular tests must be perform ed taking into consideration applicable local requirements, especially for guidelines on machines and using w ork material and w ork safety guidelines. The purpose of these tests is to discover changes (for example lag tim es) or manipulations on a machine, vehicle or piece of safety equipm ent. To do this, see the checklists under Chapter 11.5 or 11.6

x Have the effectiveness of the safety equipment checked within the required periods,

but at least once a year by a trained and knowledgeabl e person.

x The checklists mentioned above are ideal for regular tests, especially checks fo

safety-related chang es to the machine, the vehicle or the piece of safety equipment.

est by with test piece performed by responsible operating

Daily personnel

The SD3-A1 is a safety-oriented laser scanner of Category 3. It is extremely important, however, t o check the effectiveness of the detection zone with the test piece daily or aft er a sh ift change. T hi s ensur es th at i f t he paramete rs or operati ng mode is ch anged, th e protective function is ensured at every point in the detection zone.

11.4.1

Checklist for daily test of stationary applications by personnel

esponsible operating

1) Are t here any problems in th e extern al st at e of th e prot ec ti ve equipment, the cable, cable connections and any command devices?

re the fastening screws in the mounting system firm l

2) tightened?

3) Are the fastening screws in the SD3-A1 firmly tightened? Yes No

4) Are both protecti ve caps (X1 and X2) screwed on and are the firmly in place?

5) Do the safety equipment and c ommand devices show any safety-relevant changes or gaps in safety (e.g. changes in access possibilities or changes in the surrounding area)?

6) If the protective function of the SD3-A1 is present for all required m onitoring cases (e.g. testing the switch-off function with a test piece al ong the detection zone contour), the LED 3 for SD3-A1 must light up with each attempt and the movem ent that poses a danger must be stopped immediately. Possibility o danger to the person running the test must be excluded?

7) Is the startup test / restart interlock (if there is one) working? Yes No

8) Does the base marking match the detection zone contour? Yes No

9) Do the necessary detection zones match the configuration protoc ol?

10) If correct functionality is not c ertain or id the SD3-A1 LED 5 is flashing, tak e the m ac hi ne out of op er ation im m edi at ely. Are any doubts resolved?

Yes No

If the answer to any of the questions above is No, the machin e should be checked by a trained specialist.

11.4.2

Checklist for daily test of mobile applications by

esponsible operating personnel

1) Are t here any problems in th e extern al st at e of th e prot ec ti ve equipment, the cable, cable connections and any command devices?

re the fastening screws in the mounting system firm l

tightened?

3) Are the fastening screws in the SD3-A1 firmly tightened? Yes No

4) Are both protective caps (X1 and X2) screwed on and are the firmly in place?

5) Do the safety equipm ent and command devices show any safety-relevant changes or gaps in safety (e.g. by widening the vehicle)?

6) If the protective function of the SD3-A1 is present for all required m onitoring cases (e.g. testing the switch-off function with a test piece along the detecti on zone contour, th e LED 3 for SD3-A1 must light up with each attempt and the movement that poses a danger must be stopped immediately. Possibility o danger to the person running the test must be excluded)?

7) Does the v ehicle act uall y st op within t he limi ts defin ed b y t he responsible specialist (test of switch-off function using a test piece. Is the possibility of danger to the person running the test excluded)?

8) Is the startup test / restart interlock (if there is one) working? Yes No

9) Do the necessary detection zones match the configuration protoc ol?

10) If correct functionality is not certain or id the SD3- flashing, take the vehicle out of operation immediately. Are any doubts resolved?

A1 LED 5 is

Yes No

If t he answer to any of the que stion s above is No, the v ehi cl e s hould be c heck ed by a trained specialist.

11.5 Checklist for testing stationary applications

The following checklist represents an aid. It helps in, but does not replace the test before the i niti al st art up as wel l as the reg ul ar t ests perf orm ed by a trained spec iali st .

1) Is the mounting position and adjustment of the SD3-A1 correct and is the possibility of misusing the SD3-A1 (for exampl e to climb on excluded)?

2) Is the external condition of the additional safety equipment and control devices free of problems?

re all connection pieces and conn ection cables in flawless

3) condition?

re the two safety outputs (OSSDs) connected to the following mac hine c ontr ol system in ac c ordance with the corresp on ding safety category?

re the fol lowing switch elements that are c ontr oll ed by th e SD3-A1, for example contactors with forced contacts or safety valves monitored by th e feedback loop (EDM)?

6) Does the actual connection of the SD3-A1 to the machine control syst em match the circuit di agrams?

7) W as the safet y distanc e c alc ul at ed according t o the appli c abl e formulas for safeguarding danger areas and is this minimum distance observed between the detecti on zone contour and the danger areas?

8) Is the effect of any potentially refl ective surfaces taken into considerati on with an addition in the calculation of th e safetyrel at ed distanc e? As an alt ernat e solution, hav e th e su rf ac es been changed (e.g. matted)?

9) Does the risk assessment take into account the fact that detection zone heights above 300mm are considered high enough to crawl under in the Standard (EN 999)?

Yes No

10) Is access to the danger area only possible through the activated detection zone of the SD3-A1 in qu esti on, or are ot her entranc e or access possibilities safeguarded with suitable safety parts, for exam ple g u ard fenc es?

11) Is the possibility of being between the activated detection zone and the danger area reliably ruled out?

12) Is an installed protection to prevent walking behind (e.g. undercut) in effect?

13) Is the SD3-A1 able to cover the entire danger area? Are dead zones excluded?

Yes No

14) Has the effectiveness of the activated detection zone been

tested with th e blac k t est pi ec e (70m m diamete r)?

Yes No

15) Does the base mark match the correctly identified detection zone?

16) Is the start / restart button for resetting the SD3-A1 positioned according to requirem ents and does it work properly?

17) Does the SD3- during the entire motion of the machine that is causi ng a hazard?

18) Is the motion causing the hazard stopped when electrical power to the SD3-A1 is disc onnected and is a confirmati on of the start / restart button necessary to reset the machine after the power is restored?

re all test and parameter inaccessible to unauthorized

19) personnel?

the SD3-A1 where it is clearly visible for operating personnel?

A1 work in all necessary oper ating modes and

Yes No

Yes No20) Is an identi fying sign placed on th e machin e for the d ail y t est o

11.6 Checklist for testing mobile applications

The following checklist represents an aid. It helps in, but does not replace the test before the i niti al st art up as wel l as the reg ul ar t ests perf orm ed by a trained spec iali st .

1) Is the mounting position and adjustment of the SD3-A1 correct and is the possibility of misusing the SD3-A1 (for exampl e to climb on excluded)?

2) Is the external condition of the additional safety equipment and control devic es free of problems?

re all connection pieces and conn ection cables in flawless

3) condition?

re the two safety outputs (OSSDs) connected to the following vehi cle c ontr ol system i n ac c ord anc e w ith t he corresp on ding safety category?

re the fol lowing switch elements that are c ontr oll ed by th e SD3-A1, for example contactors with forced contacts or safety valves monitored by th e feedback loop (EDM)?

6) Does the act ual conn ecti on of the SD3- system m atch the circuit diagrams?

7) Has the safety distance for safeguarding automatic guided vehicles (AGV) been calculated and observed acc ording to applicable formulas?

9) Does the risk assessment take int o consideration th e fact that the height of the detection zone must be as low as possible (DIN EN 1525)?

10) Is an installed protection to prevent walking behind (recessing the SD3-A1) in effect?

A1 to the vehicle control

Yes No

11) Has the effectiveness of the activated detection zone been tested with the bl ack test pieces (70m m diameter st andin g and 200mm diameter on their sides)?

12) Is the start / restart button for resetting the SD3- according to requirem ents and does it work properly?

13) Does the SD3-A1 work in all necessary operating modes and during the entire m oti on of t he vehic le th at is c au sing a hazard?

A1 positioned

Yes No

14) Is the motion causing the hazard stopped when electrical power

to the SD3-A1 is disc onnected and is a confirmati on of the start / restart button necessary t o reset the vehicle after the power is restored?

15)

re all test and parameter inaccessible to unauthorized

personnel?

Yes No

16) Is an identi fying sign placed on th e machin e for the d ail y t est o the SD3-A1 where it is clearly visible for operating personnel?

Yes No

11.7 Replacing the optical

11.7.1 General information:

x Only professionall y t rai ned p er sonn el are perm it ted to replace opt ical wind ows.

x Be careful everything stays clean during all jobs (I f possible, w ork in a dust-free

environment. An adverse environment is not good for working on the device).

1) Loosening the housing part s

2) Dism ounting the optical window

indo

Loosen the four Allen screws on the rear housing wall. Tak e th e two h ou sing p arts carefully apart from each other and place them on a level sur fac e.

Loosen th e scr ews on the fast eni ng straps. Remove the fastening straps

Press the ol d optical wi nd ow ou t throug h the rear (through the housing)

3) Checking the condition of the scanner

4) Inserting the new optical window

Please do not fail to observe:

Check the mirror, optics and housing parts to make certain they are free of dust. Dry if necessary with a dry, oil-free, light jet of compressed air with appropriate components.

Do not touch any parts in the device. Avoid leaving fingerpri nts (grease from finger s may cause the devic e to function improperly).

Hold the n ew optical window b y t he sides and carefully insert it in the correct position, pressing the optical window together slightly as you do so. Make cert ai n the rubber seal i s n ot d am ag ed. Make certain it is in the groove in the housing designed for that purpose.

Check to m ake sure t he optic al w indow is seat ed corr ectly. T here sh oul d b e no gap between the optical window and th e housing that l ets light through.

Then f asten the n ew optical window in place again wi th th e fast ening straps. A s you screw in the screws, you can apply a little pressure on the outermost edge of the optical window with your thumbs. The new fastening st rap (which h as been avai labl e since 2002) is th e on e t o us e.

5) Assembling the housing

When assembling the housing, note that the two retaining bolts slide into the rubber sleeves provid ed for them. To do this, carefully join the two housing parts on a level surface.

fter that, carefully screw in the screws on the rear wall of the housing, working back and forth around the circle from screw to screw.

Remove any fing er prints on th e optical window

11.7.2

Initial measurement of the new optical wind ow

fter the optical window has been properly mounted, it is essential to perform a calibration of the optic al window. Correct functionality of the scann er cannot be guaranteed without calibrating the optical window!

Please note: The calibration should be performed with an ambient temperature of +20°C to +25°C!

Safety Notes: The optical window (dark red) must be clean and in new condition. Dirty and scratched panes must not be calibrated and used. They w ould represent a

safety risk since the laser light would be weakened under some circum stances.

11.7.3

Procedure when using th e SD3SOFT user software version 1.00 or late

1) Starting the PCs

2) Connection of X1 (electrical power supply with zone pair activated) and X2 (RS-232

cable 1:1)

3) Start SD3SOFT user software

4) Select the “Auth orized user” access level

5) Confirm the ech o data shown by the scanner

6) Click on the “Calibrate optical window monit oring” ic on under “System data”

7) Start the optical window calibration with “Calibration” (lasts a few seconds, typic ally

with values between 100 and 700).

8) Click on the “Close” button

11.8 Cleaning

11.8.1

Cleaning the optical window when dirty

Different methods will work better under different conditions depending on load and medium. What is the best approach?

Note: SD3-A1 cl ean sets are available for cleaning the optical

window. They contain a special cleaning agent and suitable cleaning cl oths. Tw o sizes are available. For more information, see the chapter entitled “Accessories and spare parts”.

Please note:

Generally it is sufficient to rem ove particles relatively quickly moving the cleaning cl oth horizontally. I cleaning takes longer (for example because o fingerprints), the scanner will report the fault in optical window monitoring (after cleaning, press “Restart”).

Description Solution

Particles, loose, abrasive • Remove with no contact using suction or blow off

with oil-free air