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ROTOSCAN RS4-4 / RS4-4E

1. d db ga Lie a 0 fe a 0 i le a AGV at high speed b AGV at low speed c AGV curving to the left at low speed d AGV at high speed Fig 6 2 1 Example of a zone pair changeover for an AGV on a curved route RS4 Leuze SF2 b N O 0 ser a i a a AGV driving fast b AGV driving slowly c AGV maneuvering oO d Loading ramp Fig 6 2 2 Example of zone pair changeover with combined with reducing speed of the AGV Leuze RS4 57 7 1 7 2 58 Functions of the ROTOSCAN RS4 4 RS4 4E The ROTOSCAN RS4 4 RS4 4E is equipped with the X1 and X2 interfaces The following functions are available through them Restart Depending on the operating state the restart input X1 2 has several functions e Enables the restart interlock following the interruption of a detection zone e Enables the start interlock following a system start e Restarts after a device error has been eliminated e Recognizes a defined enable signal after a device error after a detection zone interruption for enabling the restart interlock To activate the functions apply 24 V to input X1 2 In the meantime the safety outputs OSSD 1 and OSSD 2 are switched off the indicator at the scanner LED9 is lit up red The duration of the signal mu
2. 2002 Processing of parameter commands The verification of displayed data remained unacknowledged for too long 2007 Verification of parameter data received The date of the detection zone currently being transferred is older than the date of the detection zone in the scanner 2201 Area monitoring Number of measurements in the scan too small due to motor speed error or switch off of the watchdog Internal fuse faulty 2302 Control of software sequence Error occurred while starting the scanner Sequential error 2401 Reference measurement on the dark reference element No distance value can be calculated for reference measurement Glare from another source of light 905 nm or deviation in motor rotation speed 100 RS4 Leuze Leuze Loca Description No Description tion 2401 Reference measurement on 13 No removal value can be calculated the dark reference element for reference measurement Dust in device because connector housing or dummy connector not screwed on 2402 Reference measurement on _ 10 No distance value can be calculated the light reference element for reference measurement Glare from another source of light 905 nm or deviation in motor rotation speed 2701 Processing of messages for 1 Invalid diagnostic command system diagnostics received Software and firmware incompa
3. Yes Yes Yes Yes Yes Yes Yes No No No No No No No 79 11 6 Checklist for Testing Mobile Applications The following checklist represents an aid It helps in but does not replace the test before the initial startup as well as the regular tests performed by a trained specialist 1 Isthe mounting position and adjustment of the RS4 4 correct and Yes No is the possibility of misusing the RS4 for example to climb on excluded 2 Is the external condition of the additional safety equipment and Yes No control devices free of problems 3 Are all connection pieces and connection cables in flawless Yes No condition 4 Are the two safety outputs OSSDs connected to the following Yes No vehicle control system in accordance with the corresponding safety category 5 Are the following switch elements that are controlled by the RS4 Yes No for example contactors with forced contacts or safety valves monitored by the feedback loop EDM 6 Does the actual connection of the RS4 to the vehicle control Yes No system match the circuit diagrams 7 Has the safety distance for safeguarding automatic guided Yes No vehicles AGV been calculated and observed according to applicable formulas 8 Is the effect of any potentially reflective surfaces taken into Yes No consideration with an addition in the calculation of the safety related distance As an alternate solution have the surfaces been changed e g
4. Approx 2 kg Dynamic stress across 3 axles In accordance with IEC 60068 Part 2 6 10 150 Hz max 5 G Continuous shock across 3 axes In accordance with IEC 60068 Part 2 29 10 G 16 ms Interference immunity In accordance with DIN EN 61496 1 corresponds to requirements for type 4 additionally in accordance with DIN 40839 1 3 test pulses 1 2 3a 3b and 5 not used for vehicles with internal combustion engines Rotating mirror drive Brushless direct current motor Rotating mirror bearing Maintenance free ball bearing Table 14 12 1 Technical Data on the Environment and Material RS4 Leuze 14 13 Dimensional drawings of the ROTOSCAN RS4 Leuze Front ca 195 R Smallest bending radius 50 mm lumiflex accessory Axis of the rotating mirror Scanning plane d b All dimensions given in mm RS4 Side view View above from 97 14 14 Dimensional drawings of the mounting system Side view Scanner mounting G surface Overview of parts 98 RS4 Leuze 15 Leuze Diagnostic Codes and Causes Loca Description No Description tion 102 Processing of commands 2 Data transmission error on the X2 processing of messages interface 103 Control of command 2 Data tr
5. Leuze lumiflex ROTOSCAN RS4 4 RS4 4E Laser Scanner for Personal Protection and Measurement Tasks Connecting and Operating Instructions 4 Leze umit ipi 20 600702 03 05 A001 Subject to change without prior notice About these connecting and operating instructions of the RS4 and the RS4soft operator s manual These connecting and operating instructions for the ROTOSCAN RS4 contain important information on proper usage of laser scanners and usage in accordance with intended purpose For additional information on the configuration of the RS4 please refer to the operator s manual for the RS4soft configuration and diagnostics software It is essential to observe all information in the connecting and operating instructions and in the operator s manual especially the safety notes The connecting and operating instructions and the operator s manual must be kept in a safe place They must be available during the entire period when the ROTOSCAN RS4 is in use Documents are also automatically installed on the PC when RS4soft is installed and can be viewed at any time with the Help menu AN Safety and warning notices are identified by the symbol ZA References to important information are identified by the symbol References to the safety of laser devices are identified with the symbol A Leuze lumiflex GmbH Co KG is not liable for damage caused by improper usage The user must also be familiar with all th
6. the initial startup as well as the regular tests performed by a trained specialist 1 Is the mounting position and adjustment of the RS4 correct and is the possibility of misusing the RS4 for example to climb on excluded Is the external condition of the additional safety equipment and control devices free of problems Are all connection pieces and connection cables in flawless condition Are the two safety outputs OSSDs connected to the following machine control system in accordance with the corresponding safety category Are the following switch elements that are controlled by the RS4 for example contactors with forced contacts or safety valves monitored by the feedback loop EDM Does the actual connection of the RS4 to the machine control system match the circuit diagrams Was the safety distance calculated according to the applicable formulas for safeguarding danger areas and is this minimum distance observed between the detection zone contour and the danger areas Is the effect of any potentially reflective surfaces taken into consideration with an addition in the calculation of the safety related distance As an alternate solution have the surfaces been changed e g matted Does the risk assessment take into account the fact that detection zone heights above 300 mm are considered high enough to crawl under in the Standard EN 999 10 Is access to the danger area only possible through the activated dete
7. 5 3 5 Required Detection Zone Additions Z The ROTOSCAN RS4 is equipped with a selectable dust algorithm to ensure optimum freedom from interference The following detection zone additions must be taken into account Addition Zgyy if dust suppression is deactivated 83 mm Addition Zgyy if dust suppression is activated 83 mm for a detection zone size lt 3 5 m 100 mm for a detection zone size gt 3 5 m Activation and deactivation of the function is performed by RS4soft 28 RS4 Leuze 5 4 5 4 1 5 4 2 Leuze If retro reflectors or very shiny surfaces such as polished or enameled metals or ceramics may possibly be present in the scanning plane the following table applies Addition Zper_ if retro 0 mm reflectors or very shiny for reflectors more than 1 2 m behind the detection surface treated materials zone line e g metals and ceramics are present in the scanning 110 mm plane for reflectors up to 1 2 m behind the detection zone line Z Zsm ZREFL Z Required detection zone addition in mm Zsm Measurement error of the scanner in mm ZrerL Addition for considering reflectors in mm Safeguarding Stationary Danger Zones Please comply with the safety notes in Chapter 3 The Purpose of Safeguarding is for protection e to protect people when entering a danger zone e to protect people from reaching a danger point with their extremities e to protect objects
8. K1 K2 K3 ROTOSCAN RS4 4 j f i f K3 J z a Fuse 1 25 A semi time lag d DZ2 WF2 b Restart button e DZ3 WF3 c DZ1 WF 1 f DZ4 WF4 Fig 8 1 1 Wiring the ROTOSCAN RS4 with evaluation of the OSSDs zone pair changeover 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 accordance with DIN EN 954 1 Integrating one channel based on z is only permitted with a one channel control system and taking into consideration the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow RS4 61 62 24V at if e GND PE a 2s y Ki K2 im i b C dje f Kil Q x y K2 N A HHHH T ae a S89 10 a Ea ee Ta E dr len L i i J xt j k K2 K1 K2 l ROTOSCAN RS4 4 f J zZ a Fuse 1 25 A semi time lag d DZ2 WF2 b Restart button e DZ3 WF3 c DZ1 WF 1 f DZ4 WF4 Fig 8 1 2 Wiring the ROTOSCAN RS4 with evaluation of the OSSDs zone pair changeover restart interlock and static relay monitoring Rel
9. Leuze 1 2 wo Sh Oo eS N Starting the PCs Connection of X1 electrical power supply with zone pair activated and X2 RS232 cable 1 1 Start RS4soft user software Select the Authorized Customer authorization level Confirm the echo data shown by the scanner Click on the Calibrate optical window monitoring icon under System data Start the optical window calibration with Calibration lasts a few seconds typically with values between 100 700 Click on the Close button RS4 85 11 8 11 8 1 86 Cleaning 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 RS4 clean sets are available for cleaning the optical window They contain a special cleaning agent and suitable cleaning cloths Two sizes are available For more information see the chapter entitled Accessories and Spare Parts Please note Generally it is sufficient to remove particles relatively quickly moving the cleaning cloth horizontally If cleaning takes longer for example because of fingerprints the scanner will report the fault in optical window monitoring after cleaning press Restart A Description Solution with oil free air direction only Particles loose abrasive e Remove with no contact using suction or blow off e Wipe clean with a cleaning cloth wip
10. Loosening the housing parts Loosen the four Allen screws on the rear housing wall Take the two housing parts carefully apart from each other and place them on a level surface Loosen the screws on the fastening straps Remove the fastening straps Press the old optical window out through the rear through the housing 82 RS4 Leuze 3 Checking the condition of the scanner 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 fingerprints grease from fingers may cause the device to function improperly 4 Hold the new optical window by the sides and carefully insert it in the correct position pressing the optical window together slightly as you do so Make certain the rubber seal is not damaged Make certain it is in the groove in the housing designed for that purpose Check to make sure the optical window is seated correctly There should be no gap between the optical window and the housing that lets light through Find the correct position to avoid a light gap Then fasten the new optical window in place again with the fastening straps As f you screw in the screws you can apply a z little pressure on the outermost edge of the optical window with your thumbs The new fastening strap whi
11. e Use shielded cables e Connect the cable shielding with PE to the electronics cabinet only e The cables must not be laid loose Scanner control cables may not be laid in a stand parallel to power supply cables for machines This minimizes the effects of inductive interference factors from motors carrying high current In addition the cables should be laid so that they cannot be damaged e g by being crushed or pinched Cabling prepared for connection to the scanner is available as an optional accessory in various lengths and for both interfaces For further information see Chapter 13 RS4 Leuze 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 the restart button of the restart button 3 UB 24 V DC power supply protected by a 1 25 A delayed action fuse 4 FP 1 Changeover to zone pair 1 5 Alarm 1 Semiconductor output that switches off when the warning zone is violated as well as for warning messages such as optical window slightly dirty error messages such as optical window very dirty and for internal errors the functions can also be selected in combination 6 FP 2 Changeover to zone pair 2 7 FP 3 Changeover to zone pair 3 8 FP 4 Changeover to zone pair 4 9 NC Do not assign 10 NC Do not assign 11 OSSD 1 Semiconductor output switches
12. Distance max 35 mm a d Detection zone Fig 5 4 3 Lateral external scanner mounting without an undercut If the machine contour runs parallel to the 90 beam of the laterally placed RS4 the distance between the detection zone boundary and the machine may not exceed 35 mm 5 Zumin el ja E l a ROTOSCAN RS4 7 SE 2 b Machine a c Minimum distance from the environment i d Detection zone Z Required detection zone additions AA AN ZuMIN Minimum depth of the undercut Zo m Fig 5 4 4 Mounting the scanner across from the machine with an undercut Leuze RS4 33 5 4 5 5 4 6 34 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 64 mm from the front edge of the scanner when calculating detection zones Add 83 mm or 100 mm for the maximum radial measurement error Zgjy as described in Chapter 5 3 5 Add an addition Zper _ as described in Chapter 5 3 5 if reflectors could be present in the area 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 System Availability There must be a b
13. RS4 4 RS4 4E status indicator 0 0 00000000 71 10 4 Status information of the ROTOSCAN RS4_ 0 0 02 73 RS4 Leuze 11 12 13 14 15 16 Leuze Maintenance and Testing 0 ccc c eee eee 74 11 1 Test before First Startup by Person Qualified and Authorized to Perform the Task 74 11 2 Extended Shutdown of the RS4 2 eee 74 11 3 Regular Tests by a Person Qualified and Authorized to Perform the Task 75 11 4 Daily Test by with Test Piece Performed by Responsible Operating Personnel 75 11 4 1 Checklist for Daily Test of Stationary Applications by Responsible Operating Personnel 76 11 4 2 Checklist for Daily Test of Mobile Applications by Responsible Operating Personnel 77 11 5 Checklist for Testing Stationary Applications 00 00 0000 eee eee 78 11 6 Checklist for Testing Mobile Applications 00 00 0022 80 11 7 Replacing the Optical WINdOW 2 c cwncwnseccanaee ss caaneea das ani wee a vias 82 11 7 1 General informatl n 2 2c eek cde eea ene eee Aare RE EEO EEE Ee REM RE 82 11 7 2 Initial Measurement of the New Optical Window 0 0000020008 84 11 7 3 Procedure when Using the RS4soft User Software Version TOGO later sie wes boo marinn eee Ree RAS eee KORE eae E Ko 85 WAG AClOAMING irename mais hee e eRe eee eed ke oeee deka ae E 86 11 8 1 Cleaning the Optical Window when Dirty 0 000022 eee eee eee 86 11 8 2 Clean
14. Sy 2414 mm 83 mm 0 mm 50 mm 0 mm 2547 mm Sample calculation of a maximum range of a detection zone The formula 2 2 Suave Sr Sener SspirF GgpiFF Zs yields under consideration of the width of the danger zone results in the maximum distance to be monitored Smax J2547mm 1483mm 2 Sppirr 1400 mm 83 mm 1483 mm Smax 2947 mm RS4 53 6 1 54 Information on Detection Zone and Warning Zone Changeovers In the course of using machines to their optimum capacity alternating cycles of material insertion and processing often necessitate the creation of variable danger zones Due to their very nature AGV applications also necessarily comprise various danger zones If it is possible for a person to gain access to these danger areas it is necessary to implement a safeguarding system that adapts to the changing conditions For this purpose the ROTOSCAN RS4 provides four zone pairs each consisting of one detection zone and one warning zone which the user can select among and freely configure A convenient user program called RS4soft is available to determined the required zone pair contours To activate the zone pairs apply 24 V to the corresponding inputs provided at connector X1 on the scanner Please refer to Chapter 7 2 and Chapter 9 for more detailed information on wiring the scanner Note the following points if the ROTOSCAN RS4 is going to be started up again or if you are going to swit
15. This state is signaled by LED 5 flashing quickly 4 Hz Output X1 15 is equipped with an internal electronic current limit to protect it against damage from overload RS4 59 7 5 7 6 60 OSSD 1 X1 12 and OSSD 2 X1 11 When the detection zone is interrupted the two semiconductor 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 fg lt 1 kHz C lt 100 nF The OSSDs are equipped with an internal electronic current limit to protect them against damage from overload For some sample connections see Chapter 8 Data Communication The interface X2 allows the ROTOSCAN RS4 to support two types of connections to the PC or laptop Communication via the X2 connector in RS232 mode does not require any further bridging To enable data transfer in RS 422 mode connect pin 5 with pin 6 The scanner automatically adjusts itself to the appropriate transfer type and baud rate The interface X2 is used for e configuring and setting parameters for the ROTOSCAN RS4 e transferring measurement data while the scanner is in operation e evaluating the coordinates during parameter setting e g for AGV applications e advanced status and control diagnostics Guard operatio
16. a Assignment of interface X1 PPa Alarm 2 FP3 7 Do not assign FP2 6 Alarm 5 Do not assign FP 14 OSSD2 OSSD1 UB 3 F Do not assign Restar Do not assign GND 1 9 Assignment of interface X2 as RS232 port Reserved ae o 6 RS232 detection TxD 2 o e o 7 Do not assign RxD 3 o i o 8 Do not assign Reserved 4 o a s GND shield s o eserve Assignment of interface X2 as RS432 port Tx Tx RS432 detection Rx Do not assign Rx Do not assign GND shield Reseved Connection Pin 5 to Pin 6 Leuze Safety notes and usage in accordance with intended purpose 3 1 General safety notes Leuze lumiflex products are developed and manufactured with careful application of standard rules of the industry The protective function of the devices can be negatively affected however if they are used improperly or not in accordance with their intended purposes If this occurs it may not be possibly to safeguard danger areas completely or at all which may result in danger to life and limb for persons who are in the general area of the machines or systems Caution laser radiation The ROTOSCAN RS4 is a laser device belonging to laser class 1 The valid legal and A local regulations for operating laser systems must be complied with Avoid positioning the scanner at eye level 3 2 Usage requirements and usage in accordance with intended purpose The relevant regulations for machine safety apply for the
17. for an efficiently implemented AGV under consideration of the ambient conditions Please observe the particular danger zone analysis for each detection zone in combination with the corresponding route segments 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 determining the sequence in which the detection zones are to be activated please see the RS4soft user s manual Activating AGV position Deactivating AGV control of an FP an FP position FP1 Straight section High speed FP2 2 m before the curve FP1 Low speed FP3 Beginning of the curve FP2 Steering lock curve FP1 Straight section FP3 Steering lock straight High speed FP 1 x detection zone 1 x warning zone Table 6 2 1 Practical AGV Application If the AGV is controlled by a PLC for instance which corresponds to Cat 3 or higher according to DIN EN 954 1 the previous zone pair FP can be deactivated immediately after the next zone pair has been activated with no time delay This results in a faster switching sequence The applicable safety guidelines and standards as well as the operating instructions for the systems must be strictly complied with RS4 55
18. from the danger of collision due to variable machine or part movements Mounting Position The ROTOSCAN RS4 can be mounted either in a stationary position e g on a wall or a machine or on moving parts e g machine table The qualified installer must ensure that the mounting position of the ROTOSCAN RS4 allows the danger zone to be monitored completely If a restart button is being used make certain that the entire detection zone area can be viewed by the person pressing the button It must not be possible to activate the button from the danger area Refer to the safety notes in Chapter 3 6 with regard to lateral access into the danger zone RS4 29 5 4 3 5 4 4 30 Mounting Height According 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 Hin 15 d 50 mm Hmn Lowest admissible scanning plane from the base level Resolution of the scanner in mm object size 70 mm throughout the detection zone The admissible height range of the RS4 scanning plane lies between 0 mm Presettings leg detection and 1000 mm above the base level If the application requires a scanning plane higher than 300 mm or if children have access to the area the analysis of the danger zone must consider the hazard caused by persons crawling below the scanning plane Recommendations for Mounting to Prevent Unmonitored Zones Unmoni
19. in the dangerous area is not permitted When setting the dimensions of the detection zone you must comply with the formulas cited in Chapters 5 4 8 and 5 7 8 Be sure to comply with higher level machine standards e g DIN EN 1525 if applicable These contain individual specifications for example on points of access to the danger zone and if applicable detection zone additions that must be given special consideration They also provide information on how to measure safety distances at machines Detection zones with a radius smaller than 20 cm at or close to the scanner are not admissible 20 cm is the preset minimum contour When setting the dimensions of the detection zones please comply with the maximum angle error stated in the technical specifications Chapter 14 11 Needle shaped detection zone contours are not permitted since they do not ensure any protective effect For additional information please refer to the RS4soft user software Chapter entitled Definition of Detection Zones Due to possible measurement errors every detection zone has an additions area in which detection is not guaranteed under all conditions Please consider as well Chapter 5 3 5 Read Chapter 5 4 6 and 5 7 6 for information on optimizing system availability The required safety distances must be taken into account when making detection zone configurations Safety distances are calculated according to formulas found in either the machine s
20. 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 distance ensures that no body part whatever can reach the danger point until the hazardous movement 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 following formula S KxT C S Safety distance in mm K Approach velocity in mm s At a close distance of 500 mm a velocity of 2000 mm s should be assumed If the calculation involves a distance in excess of 500 mm K may be taken to be 1600 mm s But in this case the safety distance is subject to a minimum value of 500 mm T Overall time of delay in seconds a total consisting of Response time of the laser scanner Adjustable max 200 ms Overtravel time of the machine including Based on measurement of the controls overtravel time C 8x d 14 inmm Added margin dependent on the depth of penetration of the detection zone based on the resolution of the laser scanner C 30mm 128 mm C 40mm 208 mm d The resolution to which the laser scanner Here 30 mm or 40 mm has been set In this connection please also have regard to the illustrations given in this chapter 44 RS4 Leuze 5 6 4 Leuze Defining the reference boundary a ROTOSCAN RS4 4E SF1 Detection zone 1 enabled b Reference bounda
21. of 15 m corresponds to the warning zone and signaled by way of a non safety related semiconductor output RS4 Leuze 2 2 Leuze Four programmable zone pairs each of which consists of one detection zone and one warning zone enable the scanner to be optimally adapted to the needs of each particular application The ROTOSCAN RS4 can be implemented not only on machines and systems stationary safeguarding of danger zones but also on vehicles mobile safeguarding of transport vehicles Due to its wide range of measurement and its non contact electro sensitive measurement principle the ROTOSCAN RS4 can be effectively used as a protective device for virtually any application Special Features of the ROTOSCAN RS4 4 RS4 4E e Four freely programmable detection zones up to a maximum of 4 m e Four freely programmable warning zones up to a maximum of 15 m e Expanded monitoring range of up to 190 e Compact design W x D x H 140 mm x 135 mm x 155 mm e Low weight 2 kg e Low power requirements 300 mA plus the load at the outputs e Two types of interfaces at one Sub D jack RS232 and RS422 e User friendly software RS4 11 Status displays on the RS4 12 Protective caps Sensor function Warning zone is assigned OSSDs are turned off OSSDs are turned on Restart interlock locked Continuous light Optical window is dirty Light flashing at 0 25 Hz Fault light flashing at 16 Hz RS4
22. off when the detection zone is violated Channel 1 12 OSSD 2 Semiconductor output switches off when the detection zone is violated Channel 2 13 NC Do not assign 14 NC Do not assign 15 Alarm 2 Semiconductor output with shut off when warning and malfunction message Table 9 5 1 Pin Assignments for Connector X1 Leuze RS4 67 Pin Assignments for Connector X2 used as an RS 232 Port PIN Signal Description 1 Reserved 2 TxD Data communication transmit 3 RxD Data communication receive 4 Reserved 5 GND shield Ground shield 6 RS 232 Reserved 7 NC Do not assign 8 NC Do not assign 9 Reserved Reserved for testing purposes Table 9 5 2 Pin Assignments for Connector X2 used as an RS 232 Port Pin Assignments for Connector X2 used as an RS 422 Port PIN Signal Description 1 TX Data communication receive 2 Tx Data communication receive 3 Rx Data communication transmit 4 Rx Data communication transmit 5 GND shield Ground shield 6 RS 422 Select RS422 interface by connecting a bridge to pin 5 7 NC Do not assign 8 NC Do not assign 9 Reserved Reserved for testing purposes Table 9 5 3 Pin Assignments for Connector X2 used as an RS 422 Port For the pin arrangement please refer to Chapter 2 2 and 9 5 the connection and operating instructions of the RS4 68 RS4 Leuze 10 10 1 10 2 Leuze Comm
23. s Liag Factor for increase in lag time C Safety related constant in mm Maximum range of detection zone 2 2 Smax St Sevier Spoirr GgpiFF S Z Smax Maximum range of the detection zone considering the diagonals in mm St Depth of the detection zone in mm SppIFF Largest width of the detection zone between the axis of the rotating mirror and the outer edge of the detection zone in mm GBDIFF Largest width of the danger zone between the axis of the rotating mirror and the boundary of the danger zone in mm S Safety distance minimum distance from the danger zone to the point of detection to the plane of detection or to the detection zone in mm Z Required detection zone additions in mm Leuze RS4 37 Ggpire SspiFF a ROTOSCAN RS4 4 b Dangerous machine danger zone c Safety fence to prevent stepping behind d Axis of the rotating mirror e Detection zone Ggp FF Largest width of the hazardous zone S Safety distance Sg Entire width of the detection zone Sgp FF Largest width of the detection zone Smax Maximum geometrical distance ST Depth of the detection zone Zau Detection zone addition application specific Z Detection zone additions ZUMIN Undercut Fig 5 4 5 Considering the maximum measurement distance when safeguarding an area 38 RS4 Leuze 5 4 8 3 Sample calculation of the depth of a detection zone This example is ba
24. startup and restart are activated the scanner turns the OSSDs back on after this brief error event and after the detection zone has been free for about 25 seconds 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 test startup interlock and or manual restart are included they will not be removed RS4 Leuze nN gt A L 5 4 7 Leuze 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 Depending on the hazard assessment visual and or acoustic startup warnings should be provided If parameters are set for the function Manual restart the required enable from the startup restart button affects all detection zones and is independent of any detection zone changeover If the current detection 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 also in effect for the other detection zone to which the system switches even if this detection zone is free Restart Interlock The ROTOSCAN RS4 is equipped with a restart interlock function You can select or deselect this function as needed to connected restart
25. undercut must cover any unmonitored zones RS4 31 5 4 4 2 Recessed installation within the machine contour Furthermore the scanner can be recessed into the contours of a machine The recess can have a depth of up to 40 mm without the mounting system RS4 MS or up to 65 mm with the mounting system RS4 MS This is in reference to detection zones that cover an angle range of 180 If it is not possible to comply with these values or if unmonitored zones result due to the shape or movement of the machine additional safety measures must be taken The effectiveness of the detection zones can be optimized by changing the depth at which the scanner is installed or by adjusting the angle range e g from 180 to 190 For information on how to configure the scanner in this way please refer to the RS4soft user s manual included with delivery Lateral access safe ROTOSCAN RS4 f Machine guarding if needed detection zone Front machine edge Detection zone addition Lateral Access protection Maximum recessing 40 mm h Installation niche Z Oaad0m nou wea Fig 5 4 2 Recessed installation within the machine contour If it is not possible to mount the ROTOSCAN RS4 directly onto the machine it can also be positioned lateral to or across from the machine 32 RS4 Leuze 5 4 4 3 External mounting lateral to or across from the machine d b a ROTOSCAN RS4 b Machine ve c
26. use of the laser scanner ROTOSCAN RS4 4 RS4 4E Responsible authorities for example professional trade unions OSHA are also available for questions related to safety In general the following usage requirements must be observed e Ifthe scanner is enclosed in a protective housing additional window material such as plastic or glass must not be used as it may impair the detection e Avoid touching the scanner optical window and the six diffusing light screens e The ROTOSCAN RS4 is not suitable for use as a protective device if itis possible that dangerous fluids will be spewed out or objects will be ejected for machines with long braking times max depth of the detection zone 4 m For these cases Leuze lumiflex offers suitable safety interlocking devices safety switches with and without guard locking e The ROTOSCAN RS4 corresponds to Type 3 in accordance with IEC 61496 1 and 3A safety category of 3 in accordance with EN 954 can be achieved with the ROTOSCAN RS4 if all other elements in the safety chain are set up to stop the dangerous motion in accordance with that safety category e The electrical connection of the RS4 to the control system must only be made by an electrician e The 24 V DC power supply 20 30 must be ensured by a safe network disconnect in accordance with IEC 742 The same requirements apply to all connected input and output circuits Leuze RS4 13 The 24 V DC power supply must b
27. 2 Cleaning fluid for synthetic materials 1000 ml 112310 RS4 cleantex2 100 cleaning cloths soft and lint free 112320 Leuze RS4 89 Brief description Description Order No RS4 MGS X1 Set RS4 connector cpl 15 p for X1 interface 426266 side cable guiding RS4 MGS X2 Set RS4 connector cpl 9 p for X2 interface 426265 side cable guiding RS4 MG X1 Set RS4 connector cpl 15 p for X1 interface 50035735 RS4 MG X2 Set RS4 connector cpl 9 p for X2 interface 50035768 RS4 Win RS4 scanner optical window with seal 50035816 RS4 Foil PIC RS4 Picto foil for scanner LEDs 50035855 RS4soft configuration and diagnostic software on RS4 SW CD CD ROM 50035734 Table 13 1 1 Accessories and spare parts for the RS4 4 The connecting and operating instructions for the RS4 and the operator s manual for RS4soft are available in German English French and Italian RS4 Leuze 13 2 Leuze Coding of the Control Cable X1 The following table defines the pin assignments for the 12 pin connector cable Pin No Color code Meaning 1 bk GND 2 bl Restart 3 rd Up 4 or FP 1 5 ge Alarm 1 6 gn FP 2 T vio FP 3 8 gray FP 4 9 n c 10 n c 11 wh OSSD 1 12 wh bk OSSD 2 13 n c 14 wh br 15 br Alarm 2 Table 13 2 1 Coding of the Control Cable X1 RS4 91 14 14 1 14 2 92 Technical data Test Pieces The follow
28. 4 Adap P RS4 scanner adapter with already 50035814 existing mounting system RS4 COB 230 RS4 configuration and test equipment 230 V 97005001 RS4 AB RS4 Analysis box for neutral signal detection 520090 RS4 TB 70 500 RS4 test piece cylinder 500 mm in length 50036433 70 mm in diameter reflectance factor approx 1 8 RS4 TB 200 1000 RS4 test piece cylinder 1 000 mm in length 50036434 200 mm in diameter reflectance factor approx 1 8 RS4 CB X1 5 RS4 control cable prepared on scanner side 50035736 for connection to the scanner 5 m RS4 CB X1 10 RS4 control cable prepared on scanner side 50035737 for connection to the scanner 10 m RS4 CB X1 20 RS4 control cable prepared on scanner side 50035849 for connection to the scanner 20 m RS4 CB X1 35 RS4 control cable prepared on scanner side 50035850 for connection to the scanner 35 m RS4 CB X1 50 RS4 control cable prepared on scanner side 50035851 for connection to the scanner 50 m RS4 CB X2 3 RS4 PC cable prepared on both sides for 50035863 connection to scanner 3 m RS4 CB X2 5 RS4 PC cable prepared on both sides for 50035865 connection to scanner 5 m RS4 CB X2 10 RS4 PC cable prepared on both sides for 50035867 connection to scanner 10 m RS4 clean Set1 Cleaning fluid for synthetic materials 150 ml 430400 25 cleaning cloths soft and lint free RS4 clean Set2 Cleaning fluid for synthetic materials 1000 ml 430410 100 cleaning cloths soft and lint free RS4 cleanfluid
29. 7 5 3 4 Range of the measurement field 0 ccc eee eee 28 5 3 5 Required Detection Zone Additions Z 0 02 eee 28 5 4 Safeguarding Stationary Danger Zones 0 0 cee eee 29 5 4 1 The Purpose of Safeguarding 02 cece ce eee 29 5 42 Mounting POSION ss lt cusicee sdacdsuwn ess sktw nde oe de ddan be aS KRR eee aS 29 SAG M uUmng Height ccesacacsceeerg 13 Souk ee 2 Soo uae Cues Se Ken eke ee eke 30 5 4 4 Recommendations for Mounting to Prevent Unmonitored Zones 30 SAS Additions socorro taani Ade SRET LOOK mde aT OKEK REET SORE URED RAD 34 S46 Syst m Availability vii rsss cenami renees Pee eee eee eks 145 1001 eee eee EESE 34 SAT Restart IMeHlOCk 2 4 cck kh cada tnmi es Poe Aaa ee KE ESOS eda mE EE RES oH 35 5 4 8 Calculating the Detection Zone Dimensions for Safeguarding an Area 36 5 5 ACCOSS protection ia ccccisceahedsntaa da ae adil Geese e henner aoiae eames 41 5 5 1 Ojat Of protectiON ssori reciia raea a A EE AEE Ea RN Kaeo 41 55 2 Installation POSION csc acetitaeesscteavad det eeant E EA dee een E danas 41 5 5 3 Safety relevant settings and calculation of the safety distance 41 5 5 4 Definition of the reference boundary 0 0 0 cece eee 42 RS4 3 10 5 6 Prolecting Ganger POIs oii ie cnd ian sutinsi pn ee dake Beaded aes Dawe 43 5 6 1 Obj ct Of PIOIECHON soacri ceases eee Ky GERERE E E aa EEA by EEEN EESE 43 562 Installation DO
30. SWON ccc track cee E E eeeen wees ee RddG eres eas EEE 43 5 6 3 Safety related settings and calculation of the safety distance 43 5 6 4 Defining the reference boundary 0 0 0 eee teens 45 5 7 Safeguarding Mobile Machines 0 0 00 ccc cece eee eee 46 5 7 1 The Purpose of Safeguarding 0 0 50 c cece eee 46 5 7 2 Mounting Position c xcnkieeess dancers sa ccanen eee deeded ae dae ORw baw eas 46 5 1 9 Mounting Height iccccceedccacnene ne sO bd ames iis PSSA ESS CARRY RR 46 5 7 4 Recommendations for Mounting to Prevent Unmonitored Zones 47 DS Additions gueiae nenne Seek nanan gated eats E aod di tian mney EE EAE 49 5 7 6 System Availability cccn cn v0 SaGed eee Pekka REESE GORD R REA e RRR EER 50 577 ROSA Gi ais Romar mina he Re ee eh PRES cere Hee Re weer wade R RE 50 5 7 8 Calculating the Dimensions of the Detection Zone of an AGV Application 51 Information on Detection Zone and Warning Zone Changeovers 000005 54 6 1 Sequence of a Zone Pair Changeover from FP 2 to FP 4 Example 54 6 2 Practical AGV Application Example 0 0 00 eee eee 55 Functions of the ROTOSCAN RS4 4 RS4 4E ow ee 58 7 1 Restart caticee Dei tatin Penake E E Rae Ae A EEA ee 58 7 2 Channels for Zone Pair Changeovers FP 1toFP 4 0 eee cece eee ee 58 7 3 AA TERS cc wre eees atacadaas pIE E Pies GoM ey inh cece e ren SERES 59 VA PIU QTI ebeo iii
31. able to suddenly enter the detection zone This point must be taken into account in the hazard analysis of the machine or system Be sure that there are no retro reflectors or highly reflective surfaces made of metal or ceramic in the area of the detection zone and at the height of the scanning plane Such objects can cause measurement errors In order to ensure a consistent detection height at every point of the detection zone the scanner and hence the scanning plane must be placed parallel to reference section If the Restart interlock function is included the restart button must ne located outsidethe detection zone in a place that is visible from the entire danger area If the scanner is used without a start interlock or startup test with automatic start restart a startup warning visual or acoustic must be provided The scanner must not be used as an aid for climbing If there is is any risk a suitable diagonal protection 45 should be set up Please comply with the safety notes in Chapter 3 Chapter 5 4 7 and 5 7 7 RS4 Leuze 5 1 5 2 5 2 1 Leuze Attachment and Dimensions For attaching the ROTOSCAN RS4 four drill holes are located at the back of the unit The mounting set RS4 MS is available as an accessory e Speeds up the mounting process by providing screws that are accessible from the front e Allows vertical inclinations of up to 9 either up or down infinitely adjustable within this r
32. ange e Allows lateral tilting of up to approx 9 to either side from the midpoint setting infinitely adjustable within this range e Enables quick replacement of the scanner without requiring realignment For information on which parts and dimensions are required for mounting please refer to Chapter 14 13 and 14 14 Mounting Adjacent Sensors In order to prevent erroneous switch offs caused by mutual influence between adjacent sensors the following points must be taken into consideration Direct irradiation To prevent the direct irradiation of outside light by a second sensor of the same type laser light wavelength 905 nm a shield plate must be installed in the scanning plane It is sufficient to place this shield at the height of the scanner s optical window and flush with the front edge of the housing b em a d ROTOSCAN RS4 Machine view from above Detection zones Shield plate flush with the housing Qaq00m Fig 5 2 1 Shielding to prevent direct irradiation RS4 25 5 2 2 5 3 5 3 1 26 Indirect Irradiation If multiple laser supported systems are in use the mutual influence of beams reflected by objects in the area cannot be completely excluded This effect can easily be prevented by staggering the levels at which the laser devices are mounted A height offset of 100 mm in reference to a distance of 4 m between objects is sufficient Another way to implement the heigh
33. ansmission error on the X2 processing interface 104 Processing of commands 2 Data transmission error on the X2 Processing of configuration interface 105 Processing of commands 6 Function access command not generation of output permitted with currently selected messages authorization level 201 Processing of the receive 4 Too much data sent over the X2 protocol interface Message will be overwritten by new message 302 Processing of the transmit 2 The verification of displayed data protocol remained unacknowledged for too long 306 Output of measurement 5 Previous message not yet values completely output 801 Event processing 2 Event memory cannot be read internal fault 805 Processing of the commands 6 Event memory cannot be to the event memory transferred Data transmission error on interface X2 1002 Motor control during 1 Motor does not reach rated speed initialization after start Internal fault 1002 Motor control during 2 Motor speed not constant after start initialization Internal fault 1110 Test of the switch outputs 4 Switch outputs OSSD have a state other than the one the scanner expected Possible wiring or control error 1110 Test of the switch outputs 5 Switch output OSSD cannot be switched off 1110 Test of the switch outputs 6 Switch output OSSD cannot be switched on 1111 Short circuit test of switch 7 Short circuit of a switch output outputs OSSD with ground 1111 Short circuit test of switch 8 Short circuit of a s
34. ated on the front of the scanner behind the cover with the matte finish These LEDs indicate the status of the ROTOSCAN RS4 ay 7X J Association to function Easy to interpret pictographs on ROTOSCAN RS4 provide information on the meaning of the LEDs Green Yellow Red Green Yellow akrwon ll Fig 10 3 1 The ROTOSCAN RS4 status indicator Leuze RS4 71 Meaning of the individual LEDs LED Color Function Meaning Pictograph 1 Green Sensor function is active ok active detection zone is free s 2 Yellow Warning zone is assigned 3 Red OSSD outputs are switched off 4 Green OSSD outputs are switched on 5 Yellow e Constantly lit Start interlock Restart interlock e Flashing slowly 1 Warning message approx 0 25 Hz Optical window dirty e flashing quickly 1 device message approx 4 Hz Table 10 3 1 Meaning of the RS4 LED displays RS4 Leuze 10 4 Leuze Status information of the ROTOSCAN RS4 Scanner display Indicator Status LED numbers 123 4 5 10 LED 3 The OSSD outputs are switched off e g during booting 100 1 0 LED 1 The sensor function is active measurement LED 4 operation without an interruption of the activated zone pair The OSSDs are switched active high 11010 LED 1 The sensor function is active measurement LED 2 operation without a violation of
35. ation is included in the design and thus detection zone changeover the activation and effect of the detection zone in question must match the alternating operating mode Leuze The new detection zone must be activated before turning off the previous detection zone The time at which the changeover is made must be based on a risk analysis Braking paths response and coast down times must be taken into consideration for example overlapping detection zones A Start interlock function is provided If the machine has a restart key it must not be possible to operate it from inside the detection zones All danger areas must be visible from the position of the button Before releasing the start restart interlock all detection zones must be tested No one is permitted inside the danger areas There must be no unmonitored zones inside the danger areas There must be no possibility for direct access to the danger area that shortens the necessary safety distance use a protective grid for example The information on required detection zone additions in Chapter 5 must be observed RS4 15 3 5 General information related to determining detection zone contours 16 Shadow effects e g surfaces or areas located behind stationary objects must be considered As a rule insufficient safeguarding must be adequately supplemented by further safety measures such as guard fences light curtains and the like Access to the detection zone
36. ays 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 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 accordance with DIN EN 954 1 Integrating one channel based on z is only permitted with a one channel control system and taking into consideration the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow RS4 Leuze 8 2 Connecting the ROTOSCAN RS4 to a Safety Sequence Circuit with Manual Restart Relay Monitoring without Zone Pair Changeover ep 424 V i f T tT GND 3 PE a cic d 4 4 b LE e K5 K4 K5 K4 q gt S 12345 67 8 9 1011 12131415 S535 83483181214 24 S 21S22 1323 A2 Ai ROTOSCAN RS4 4 MSI SR2 F j x y Zz Fuse 1 25 A semi time lag i lt lt Restart button x y K5 Fuse 4 A delay action Fuse 1 A delay action ao oo ll N Fig 8 2 1 Wiring the ROTOSCAN RS4 with external restart interlock and relay monitoring and without zone pair changeover In this example the relay monitoring is performed by an external safety module e g MSI SR2 F Relays K4 and K5 must be equipped with po
37. be manipulated The health and safety officer must ensure that the installation position of the ROTOSCAN RS4 4E 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 the barrier To prevent the latter the distance from the scanning field to the machine table must not be more than 75 mm This can be guaranteed if suitable screens 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 safeguard the protective equipment against inadvertent misadjustment and manipulation the detection zones of the ROTOSCAN RS4 4E must be defined on the basis of a reference boundary To make it possible to recognise the hand or arm of a person the laser scanner must have a resolution of 30 or 40 mm These safety related values will be automatically set in the RS4soft configuration and diagnosis software when the presetting Hand protection or Arm protection has been selected At the same time the detection zone limits will be limited to 1 60 m or 2 20 m and cannot be extended beyond this RS4 43 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 ROTOSCAN RS4 4E can fulfil
38. ccess 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 ROTOSCAN RS4 4E 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 detection zone must be defined in such a way that no gaps measuring more than 150 mm can arise Safety relevant settings and calculation of the safety distance To safeguard the protective equipment against inadvertent misadjustment or manipulation the detection zones of the ROTOSCAN RS4 4E must be defined on the basis of a reference boundary In addition the response time must be defined as 80 ms and the restart interlock must be set To enable the system to recognise an entire human body the laser scanner must have a resolution of 150 mm These safety related settings will be automatically enabled in the RS4soft configuration and diagnosis 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 ROTOSCAN RS4 4E can f
39. ce from the back wall of the scanner to the axis of the rotating mirror is 68 mm d The 190 detection zone enables an expanded monitored range e The detection zone is limited by the scanner recess at the front of the vehicle 180 f The protruding attachment results in the creation of unmonitored zones Sag Lateral safety distance between the edge of the roadway and the boundary of the detection zone ZtToT Sum ofthe system and application specific additions in the direction of travel Zs Sum ofthe system and application specific additions to the side Fig 5 7 2 Three possibilities for mounting the ROTOSCAN RS4 4 onto an AGV RS4 Leuze 5 7 5 Leuze 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 64 mm from the front edge of the scanner when calculating detection zones Add 83 mm or 100 mm for the maximum radial measurement error Zsyp as described in Chapter 5 3 5 Add an addition Zper as described in Chapter 5 3 5 if reflectors could be present in the area Without information from the AGV manufacturer take into account the wear and tear on the brakes by adding an addition Lgtop of at least 10 of the braking distance as long as this is not already included in the braking distance Sgtop If there is a very small distance between the bottom of the AGV and the floor the detection difference be
40. ch among different zone pairs e When selecting the zone pair for the startup pay careful attention to the danger zones that are valid at the moment of startup e Always switch on the second zone pair before switching off the first zone pair e The changeover must take place within 1 s e At no time during the switching process may all of the zone pairs be deactivated simultaneously e Only one zone pair may be active at any one time except during the changeover process e The sequence of the activated monitoring fields must ensure that the application specific minimum detection zone size is met at all times e It must be impossible for changeover signals to change simultaneously as the result of a systematic error This is achieved by using independent circuits e g separately actuated binary switches under consideration of the switching behavior described in this chapter Please see the assignments of connections and or interfaces in Chapter 9 5 and in the safety notes in Chapter 3 Sequence of a Zone Pair Changeover from FP 2 to FP 4 Example e Zone pair 2 X1 6 is the active zone pair e Zone pair 4 X1 8 is then activated in addition e In this state both zone pair monitors are switched on e Zone pair 2 X1 6 must be switched off within one second e Zone pair 4 X1 8 is now active RS4 Leuze 6 2 Leuze Practical AGV Application Example The following example shows the sequence of zone pair changeovers
41. ch has been k available since 2002 is the one to use If f an old fastening strap is still installed please ask for a replacement at no cost with Order No 50040217 from your Leuze lumiflex Service Support Center Old fastening strap New fastening strap Leuze lumiflex RS4 83 11 7 2 84 5 Assembling the housing When assembling the housing note that the two retaining bolts slide into the rubber sleeves provided for them To do this carefully join the two housing parts on a level surface Retaining bolts Rubber sleeves After 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 finger prints on the optical window Initial Measurement of the New Optical Window After the optical window has been properly mounted it is essential to perform a calibration of the optical window Correct functionality of the scanner cannot be guaranteed without calibrating the optical window Please note The calibration should be performed with an ambient temperature of 20 C 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 would represent a safety risk since the laser light since the laser light would be weakened under some circumstances RS4 Leuze 11 7 3 Procedure when Using the RS4soft User Software Version 1 09 or later
42. cted 3 Are the fastening screws in the RS4 firmly connected Yes No 4 Are both protective caps X1 and X2 screwed on and are the Yes No firmly in place 5 Do the safety equipment and command devices show any safety Yes No relevant changes or gaps in safety e g by widening the vehicle 6 If the protective function of the RS4 is present for all required Yes No monitoring cases e g testing the switch off function with a test piece along the detection zone contour the LED3 for RS4 must light up with each attempt and the movement that poses a danger must be stopped immediately Possibility of danger to the person running the test must be excluded 7 Does the vehicle actually stop within the limits defined by the Yes No responsible specialist test of switch 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 Yes No protocol 10 If correct functionality is not certain or id the RS4 LED 5 is flashing Yes No take the vehicle out of operation immediately Are any doubts resolved If the answer to any of the questions above is No have the vehicle checked by a trained specialist Leuze RS4 77 11 5 78 Checklist for Testing Stationary Applications The following checklist represents an aid It helps in but does not replace the test before
43. ction zone of the RS4 in question or are other entrance or access possibilities safeguarded with suitable safety parts for example guard fences 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 RS4 able to cover the entire danger area Are dead zones excluded RS4 Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Leuze No No No No No No No No No No No No No Leuze 14 Has the effectiveness of the activated detection zone been tested with the black test piece 70 mm diameter 15 Does the base mark match the correctly identified detection zone 16 Is the start restart button for resetting the RS4 positioned according to requirements and does it work properly 17 Does the RS4 work in all necessary operating modes and during the entire motion of the machine that is causing a hazard 18 Is the motion causing the hazard stopped when electrical power to the RS4 is disconnected and is a confirmation of the Start restart key necessary to reset the machine after the power is restored 19 Are all test and parameter inaccessible to unauthorized personnel 20 Is an identifying sign placed on the machine for the daily test of the RS4 where it is clearly visible for operating personnel RS4
44. data exchange Table 14 10 1 Technical data interfaces Optics Angle range max 190 Angle resolution 0 36 Lateral tolerance without mounting system with mounting system 0 18 with respect to the back wall of the housing 0 22 with respect to the mounting surface Scanning rate 25 scans s or 40 ms scan Laser protection class Class 1 as per EN 60825 1 1994 A1 2002 A2 2001 Wavelength 905 nm Repeat frequency 25 kHz Table 14 11 1 Technical data optics RS4 95 14 12 Environment and Material Protection type IP 65 in accordance with IEC 60529 Operating temperature 0 50 C Storage temperature 20 C 60 C housing to the axis of the rotating mirror Humidity DIN 40040 Table 10 Identifying letter E moderately dry Dimensions 140 x 155 x 135 W x H x D in mm Distance from the middle of the 48 75 mm scanning plane to the bottom edge of the housing Distance from back edge of the 68 mm Connection 2 connectors plugged in from above Control cable length X1 Max 50 m at a cable cross section of 0 5 mm2 shielded Connect shield with PE to the electronics cabinet only Data cable length X2 RS 232 Max 10 m Data cable length X2 RS 422 Max 50 m twisted pair Transmitter Infrared laser diode 905 nm Housing Die cast aluminum plastic Weight
45. e RS4 manuals to be able to use the system properly Version V5 1 Reprinting and duplication is prohibited in whole or in part without prior approval of Leuze lumiflex GmbH Co KG Liebigstrasse 4 D 82256 Furstenfeldbruck Germany Tel 49 81 41 53 50 0 Fax 49 81 41 53 50 190 E mail lumiflex leuze de http www leuze de 2 RS4 Leuze CONTENTS 1 Leuze Approvals and Certificates 0 ccc eee eee eee 6 1 1 Manulacturer Certification 2 oisaccadawns saceun wee aa dma en a NRRL Dw 6 1 2 Approval and Declaration of EC Conformity 0 0 00 2 e eee eee eee 6 1 3 Specialized Technical Terms and Abbreviations 2 0 000 0000000 T 1 4 Guidelines and Standards 2 css rrrisicsri ssia aue oa damon S ae a am aw 8 SYSTEM OVENWIOW nics ccc cimenec ccc ne eee irri ni Cee ae ee aR Re a 9 2 1 Brief Description and Functional Principle of the ROTOSCAN RS4 9 2 2 Special Features of the ROTOSCAN RS4 4 RS4 4E eee 11 Safety notes and usage in accordance with intended purpose 0 00008 13 3 1 General safety NOS 2 ices ecdeandan teres Shenk ii oumadh ee hese eae Oe Ree 13 3 2 Usage requirements and usage in accordance with intended purpose 13 3 3 Restrictions TON USS oorsese eens aaa PELE e See EGS 15986 RPE Ree 14 3 4 Information Related to Detection Zone Changeover 0 0 00 0002 15 3 5 General information related to determining detection zone con
46. e curving to the rig Traveling straight ahead a 4 5 22 Fig 4 4 1 Safeguarding an automatic guided vehicle example Please comply with the safety notes in Chapter 3 For an example of how to calculate detection zone measures please refer to Chapter 5 7 8 Protecting Transporter Trolleys against Collisions Transporter trolleys are generally guided along a system of rails or grooves in the floor Hence the vehicle paths are usually just slightly wider than the trolleys themselves This represents an increased hazard for people since it is impossible to get out of the way of the trolley For this reason transporter trolley are used in enclosed areas equipped with suitable access safeguarding RS4 Leuze umiflex DZ1 Detection zone 1 for slow speed DZ2 Detection zone 2 for high speed a Emergency stop and triggering manual restart interlock b Direction of travel c Undercut g2 ENN SS S KSW x lt r S ZINA ANNS AN RES Nt FIMSSOSSony S ZA N BAS uN N N RS Fig 4 5 1 Safeguarding a transporter trolley example Please comply with the safety notes in Chapter 3 and Chapter 5 7 7 In these cases the ROTOSCAN RS4 4 is used to detect people or objects in the vehicle path and then automatically bring the vehicle to a halt Select Manual restart mode The demands placed on the geometrical shape of the detection zone are determined by the vehicle width speed stopping distance and respon
47. e fed to the scanner through a separate branch with a 1 25 Amp delayed action fuse in the control cabinet Guard operation is only permitted with the control cable X1 of the dummy connector This also applies for transport and storage The safety output has a double design The two OSSDs must always be included in the shut off circuit of the machine in such a manner that either of the two is completely sufficient by itself to turn off the motion that presents a danger The alarm output 1 Pin 5 on X1 must not be used to switch safety related signals System tests of the scanner machine control components and switch components may only be performed when they do not result in potential hazards for people Tampering with or making changes to the ROTOSCAN RS4 can result in the loss of the safety function Only expert trained personnel is allowed to perform startup maintenance parameter settings or detection zone configurations Familiarity with the safety notes in this Connecting and Operating Instruction and in the operating instructions for the RS4soft program constitutes part of this expert knowledge The password required for configuring safety relevant parameters must be kept in a secure location by the safety official Information about password levels can be found in the RS4soft user s manual If the machine is designed for start interlock manual restart all detection zones must be checked before enable no one
48. e pean ee a kane epee kind sae cde N 59 78 OSSD 1 X1 12 and OSSD 2 X1 11 dvscssee nisi cciaes eum ee des ewadnan nares 60 7 6 Data Communication 2 2ccce testeris retensie nnr i AE weed be eede eee Le 60 Integrating the ROTOSCAN RS4 4 into Machine Controls 00 0c eee eens 60 8 1 Integrating the ROTOSCAN RS4 with External Wiring with Relays and Quadruple Zone Pair Changeover 0 0 0 0 0 cece eee eee 61 8 2 Connecting the ROTOSCAN RS4 to a Safety Sequence Circuit with Manual Restart Relay Monitoring without Zone Pair Changeover 0 0 00 0e eee 63 8 3 Connecting the ROTOSCAN RS4 to a PLC with Corresponding Safety Level Cat 3 or higher EN 954 and Zone Pair Changeover 0 0 0000 64 Electrical connection 200i cc cncecccn ane ed ae ened eee ee ane ee eee 65 9 1 Electhical POWO SUPP cue eceurds can ded dots cage eed EE Is DEEE E E E sees 65 9 2 Connecting the PC and Control Cables to the Scanner 00 0000 65 9 3 CGONNSCIOFASSOMDY sci aen a dacnciwn ns sa cknne aeii nines aw ew a 66 9 4 Points to Consider When Preparing and Laying the Cables 66 9 5 Interface Pin Assignments 2 0 6 2 2 ce ee ee ee ee ea ce ee ees 67 COMMISSIONING esci beck keene eee eee Rad ee REE ede eee ee 69 10 1 Hardware and Software Requirements 00 00 00 c cee eee 69 10 2 Installing RS4soft and Starting Up the ROTOSCAN RS4 2 00 69 10 3 ROTOSCAN
49. eding the production process The ROTOSCAN RS4 4 can be mounted directly at the machine table or on the side or in front of the machine DZ1 Detection zone 1 activated DZ2 Detection zone 2 deactivated WF1 Warning zone 1 activated WF2 Warning zone 2 deactivated a Emergency stop and manual restart interlock b ROTOSCAN RS4 4 Leuze Fig 4 1 1 Stationary danger zone monitoring of a robot with two alternating work areas example Please comply with the safety notes in Chapter 3 and Chapter 5 4 7 For an example of how to calculate detection zone measures please refer to Chapter 5 4 8 p RS4 19 4 2 20 Access guarding by passage monitoring Access guarding by passage monitoring whole body trip control is a suitable method when the access to a machine or to a hazardous zone can be precisely defined in structural terms and there is no other unprotected access to the area It is best to mount the laser scanner above the passage in question in vertical alignment In order to secure the protective equipment laser scanner and fence against inadvertent misadjustment and manipulation the detection zones of the ROTOSCAN RS4 4E must be defined on the basis of a reference boundary In this operating mode the scanner will use the polled environment as a reference and so check for changes in the layout of the protective equipment as well as checking every one of the individual measurements it carries out with a view to de
50. ent FTS Automatic Guided Vehicle see AGV N O Normal open contact OSSD Output Signal Switching Device Safety relevant switch output PC Personal Computer DZ Detection Zone German SF Reset Defined Reset or ROTOSCAN RS4 4 RS4 4E RS 232 RS 232 interface RS 422 RS 422 interface ZP Zone pair contains 1 x detection zone and 1 x warning zone German FP WZ Warning Zone German WF Table 1 3 1 Specialized Technical Terms and Abbreviations RS4 1 4 Guidelines and Standards The following guidelines and standards are of critical importance for the implementation of laser scanners Guidelines providing particularly relevant information for users of such systems are marked with an asterisk Guideline Standard Designation European Guidelines 98 37 EG Machine guideline 73 23 EWG Low voltage guideline 89 336 EWG EMC guideline A Standards DIN EN 292 1 and 2 Safety of machinery basic concepts DIN EN 1050 Principles of risk assessment B1 Standards DIN EN 294 Safety distances DIN EN 954 1 Safety related parts of controls DIN EN 999 Approach speeds of body parts B2 Standards DIN EN 60204 1 Electrical equipment of machines DIN EN 60825 1 Safety of machines with laser components DIN EN 61496 1 Electro sensitive protecting equipment IEC 61496 3 AOPDs responsive to diffuse reflection x AOPDDR C Standards DIN EN 775 Industrial robots safety DIN EN 1525 Automatic
51. evice is triggered in mm Minimum value of the safety related constant 850 mm in mm Height of the scanning plane from the reference point in mm Minimum height of the scanning plane from the reference plane in mm Minimum height of the scanning plane from the reference plane in mm Resolution of the scanner 70 mm throughout the detection zone in mm RS4 Leuze 5 4 8 1 5 4 8 2 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 according to the following formula Zrot Zsm Zreri Zau Ztot Sum ofthe system specific and application specific detection zone additions in mm Zsm Scanner measurement error in mm ZrerL Addition of the reflectors taken into account in mm Zau Addition for application specific undercut in mm The depth of the detection zone with reference to the direct distance between the danger zone and the detection point or line is calculated according to the following formula Sty K x Tscan Tac Tag X Lag ZtoT Sy Depth of detection zone distance from danger area to detection point or line including system and application specific additions in mm K Approach speed of a person or a person s body parts 1600 mm s in mm s Tscan Response time of the scanner in s TMacH Response time of the machine or system in s TLac Lag time of the entire system in
52. f the scanner e Warning state For instance the system may detect a slight dirt buildup on the optical window To signal this state LED 5 on the scanner flashes 0 25 Hz The user should clean the optical window before it gets dirtier waiting too long will cause a device error to be reported and the outputs OSSD 1 and OSSD 2 to be switched off e Device error Such as an erroneous reference measurement or extreme dirt buildup on the optical window This state is signaled by LED 5 flashing quickly 4 Hz Both the reporting of a warning zone interruption and the signaling of the warning and error state can be selected either separately or in combination This procedure is described in the user s manual for the program RS4soft Output X1 5 is equipped with an internal electronic current limit to protect it against damage from overload Alarm 2 X1 15 As long as the output X1 15 is switched on the system signals trouble free operation If it is switched off the following states are reported e Warning state For instance the system may detect a slight dirt buildup on the optical window To signal this state LED 5 on the scanner flashes 0 25 Hz The user should clean the optical window before it gets dirtier waiting too long will cause a device error to be reported and the outputs OSSD 1 and OSSD 2 to be switched off e Device error Such as an erroneous reference measurement or extreme dirt buildup on the optical window
53. for its detection zone the signal can be given either by the machine controls or by connecting a command unit for restart interlock The ROTOSCAN RS4 itself must be configured using the RS4soft user program so that the operating mode with restart interlock is active RS4 Leuze 9 1 9 2 Leuze Electrical connection Electrical Power Supply The ROTOSCAN RS4 requires a direct voltage of 24 V and 8 W of power plus the load at the outputs max 25 W The power must be supplied by way of an external 1 25 A semi time lag fuse e g in an electronics cabinet In addition a permanent current of 2 5 A 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 ROTOSCAN RS4 all connected input and output circuits must be provided by a power supply unit with protective isolation from a safety transformer according to IEC 742 or comparable this also applies for the use of battery chargers for AGV applications Connecting the PC and Control Cables to the Scanner Three connector adapters with cable screw coupling are supplied with the ROTOSCAN RS4 4 Two of these are needed to accommodate the 9 pin Sub D connector and the 15 pin Sub D jack PC cable and control cable Two of these are needed to accommodate the 9 pin Sub D connector and the 15 pin Sub D jack PC cable and control cable A housing is used as
54. g black corduroy The reference point of the measurement is the axis of the rotating mirror on the scanner 64 mm behind the front edge of the scanner 5 3 3 Range of the Warning Zone Resolution A maximum range of 10 meters is available for an object with a diameter of 100 mm The maximum available range for an object with a diameter of 150 mm is 15 m Both of these figures assume a reflectance factor of 20 Resolution in mm 1000 500 200 150 100 80 60 40 20 0 0 2 0 5 1 2 4 6 10 20 50 100 Distance in m a Detection zone b Warning zone c Measurement field Fig 5 3 1 Detecting objects in the detection zone and in the warning zone The reference point of the distance measurement is the axis of the rotating mirror Leuze RS4 27 5 3 4 Range of the measurement field The maximum distance for contour measurement at a reflectance factor of 80 white gipsum is 50 m Remission in 10000 Reflectors 1000 White gypsum 100 Writing paper Gray carton 10 Black corduroy 1 8 1a 1 0 a Detection zone b Measurement field 1 4 10 15 100 Distance in m Fig 5 3 2 Detection of objects depending on the reflectance factor The reference point of the distance measurement is the axis of the rotating mirror
55. gs of the ROTOSCAN RS4 0 0 0 0 eee eee 97 14 14 Dimensional drawings of the mounting system 0 0000002 e eee eee 98 Diagnostic Codes and Causes 00 cece cee eee 99 Declaration of conformity 0 cece 102 RS4 5 1 1 1 2 Approvals and Certificates Manufacturer Certification VEZIE 9 ee Le S DIN EN ISO 9001 5 oy S Q S QS S Qi The manufacturer of the ROTOSCAN RS4 distance sensor Leuze lumiflex GmbH Co KG based in 82256 F rstenfeldbruck Germany has a quality assurance system that is certified in keeping with ISO 9001 In the development and manufacture of the ROTOSCAN RS4 distance sensor all the European guidelines and standards that apply were taken into account Approval and Declaration of EC Conformity EC prototype testing in accordance with DIN EN 61496 1 and IEC 61496 3 TUV PRODUCT SERVICE GMBH IQSE Ridlerstr 65 80339 Munich NO 2D F r Functional Gf Safety g RS4 Leuze 1 3 Leuze 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 Reflection BWS See ESPE EDM External Device Monitoring Monitoring of external control parts relay monitoring ESPE Electro Sensitive Protecting Equipm
56. guided vehicles AGV and their systems DIN EN 12895 Floor conveyor vehicles electromagnetic compatibility RS4 Leuze 2 1 Leuze Guideline Standard Designation National Standards DIN 15185 2 Warehousing systems using rail guided aisle conveyance vehicles Table 1 4 1 Guidelines and Standards This list does not claim to be complete In certain cases the concrete requirements of the application will necessitate the application of additional guidelines and standards Copies of safety standards can be purchased from the Beuth Publishing Company in Berlin Germany System Overview Brief Description and Functional Principle of the ROTOSCAN RS4 The ROTOSCAN RS4 4 RS4 4E is an optical distance sensor that takes two dimensional measurements It could also be referred to as an optical area radar device The sensor uses a rotating deflecting unit to periodically emit light pulses within a working range of 190 If these pulses strike a person or an obstacle the reflected light is received and evaluated by the ROTOSCAN RS4 4 RS4 4E The scanner calculates the precise coordinates of the person or object based on the travel time of the reflected light and the current angle of the deflecting unit If the person or obstacle is within the bounds of a previously defined area called a detection zone a safety oriented switching function is performed This switching function causes the semiconductor outputs to be switched
57. ime entered incorrectly password Table 15 0 1 Diagnostic Codes and Causes RS4 101 16 Declaration of conformity a Leuze lumiflex EC Deciaration of Conformity according to Machinery Directive 98 37 EC Annex II C Hereby we Leuze lumiflex GmbH Co KG Liebigstrasse 4 D 82256 F rstenfeldbruck declare that the following described safety device in our delivered version complies with the appropriate basic safety and health requirements of the Machinery Directive 98 37 EC based on its design and type as brought into circulation by us In case of alteration of the satety device not agreed upon by us this declaration will lose its validity Description of the safety device Laser scanner for personal protection and measurement tasks Safety device type ROTOSCAN RS4 4 Safety classification AOPDDR type 3 Safety function Electro sensitive protective device Applied EC Directives and Standards Machinery Directive 98 37 EC EMC Directive 89 336 ECC DIN EN 60204 1 06 93 DIN EN 61496 1 06 98 IEC 61496 3 02 01 DIN EN 954 1 03 97 DIN V VDE 0801 01 90 and modification A1 10 94 EN 50082 2 02 96 EN 50081 2 03 94 Notified body according to 7 Machinery Directive Annex VII TUV PRODUCT SERVICE GmbH Zertifizierstelle Ridlerstrasse 65 D 80339 Munchen Charged to do EC type examination Examination certificate no Z10 04 05 22795 044 CE marking The compliance with the directive 89 336 ECC is certified by the CE mark on
58. ing in one air or direction only Particles loose not abrasive Suction off with no contact or blow off with oil free e Wipe clean with a cleaning cloth wiping in one direction only Particles adhering e Wet or moisten the cloth with cleaning agent e Wipe clean with a cleaning cloth wiping in one Particles statically charged Suction off with no contact e Wipe clean with cloth moistened in cleaning agent direction only Particles drops greasy e Wet or moisten the cloth with cleaning agent e Wipe clean with a cleaning cloth wiping in one direction only Drops of water e Wipe clean with a cleaning cloth wiping in one direction only Drops of oil e Wet or moisten the cloth with cleaning agent e Wipe clean with a cleaning cloth wiping in one direction only Fingerprints e Wet or moisten the cloth with cleaning agent e Wipe clean with a cleaning cloth wiping in one Scratches e Replace optical window RS4 Leuze 11 8 2 Cleaning the Optical Window Cleaning Diffusing Light Panes The front and light panes and diffusion screens must be washed depending on the load on the application in question Generally this is a quick process Fig 11 8 1 Cleaning the Optical Window Sharp cleaning materials and cloths that scratch must never be used Fig 11 8 2 Cleaning Diffusing Light Panes Note Dirt can often be eliminated in a work step If the optical window i
59. ing of the machine to a manual approval It affects all detection zones and does not depend on any detection zone changeovers For information on how to configure the scanner appropriately please refer to RS4soft Section Safety relevant parameters folder The restart button must be mounted so that e the entire danger zone or detection zone area can be viewed from the operating position e itis not possible 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 the safety notes in Chapter 3 and 5 4 6 RS4 35 5 4 8 36 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 minimum depth of the detection zone when the direction of approach runs parallel to the detection zone S c S Cmn Hin Hmax KxT C Cun 850mm 1200 mm 0 4 H Hin 15 d 50 mm HMax 1000 mm Safety distance minimum distance from the danger zone to the point of detection to the plane of detection or to the detection zone in mm Approach speed of a person or a person s body parts 1600 mm s in mm s Lag time of the entire system response time and braking time until standstill in s Safety related constant to consider entry into the danger zone before the protective d
60. ing test pieces are defined for the purpose of controlling the effectiveness of the monitoring function by the detection zones e Cylinder 500 mm in length reflectance factor 1 8 0 2 for stationary applications diameter 30 40 50 70 150 mm e Cylinder 1000 mm in length 200 mm in diameter reflectance factor 1 8 0 2 for mobile systems e g AGV Detection zone Detection range from housing at a resolution of 30mm 1 60 m ata resolution of 40mm _ 2 20m ata resolution of 50mm 2 80m at a resolution of 70mm 4 00m at a resolution of 150mm 4 00 m Reflectance factor min 1 8 Min adjustable range 200 mm Detection range oftestpiece min 0 mm Response time min 80 ms 2 scans adjust up to 640 ms 16 scans Number of detection zones 4 changeover via switch inputs Output 2 failsafe PNP transistor outputs 24 V 250 mA Safety category Requirement class 4 as per DIN V 19250 fail safe category 3 as per EN 954 1 Type 3 as per DIN EN 61496 1 IEC 61496 3 Startup The startup test and start interlock can be adjusted separately Restart Automatic or manual adjustable from 160 ms to 10 s Table 14 2 1 Technical Data Detection Zone RS4 Leuze Detection Zone Additions Addition with deactivated dust suppression 83 mm Addition for activated dust suppression 83 mm for a detection zone size lt 3 5 m 100 mm for a detection zo
61. ing the Optical Window Cleaning Diffusing Light Panes 87 SONICO a ee eee eee ee ee ee ee eee er eee ee ee 88 12 1 Disposal cceckcdcaeseke ie ke AEROSe PEAS Ree a EHS SEGARA EERE S See 88 DGNVery PaCkaGe sc caccc in iiccawer need REAR RR RRR RR RGR a tka 88 13 1 Accessories and spare parts 4scncksiacenene edb ae eee we he N eee EK Ya 89 13 2 Coding of the Control Cable X1 csc cccccnss ceca a eee eg iawn ne ew Kee 91 Technical data ssa nc 105608 ewe chee ee een sD AIRE EERE Sede FoR we ee 92 TAA T S PIECOS Lc sexicuseehads caben rans cin meee edd Aden aa esa OOK aww Dea 92 THE Detection Zono seese ii cenc tninn a E E Re eke EAE ERER aa eee 92 14 3 Detection Zone Additions 000 eee 93 144 Warning ZONe ooeec irienn ia seeee Sp eadeee een lei Same a DEDREDORE ERE Ww Aa DS 93 14 5 Contour Measurement 2 66 nee eee eee eee eee eea bese eee eee anew anes 93 14 6 Electrical Power Supply 2 ccc cc ewec chee cee dese ae hee eee Pesala Roe 94 TAr WADUTS oe 6155582 pele hea er Gk rE R Ne Tee ORNs a E E OEE 94 148 OQUPUIS aciri cc edi enw h eee dod see EASE MERE EE EE EEdES EEE OEE AR ORE REO 94 149 SoftWare cuss csccnsde ee deh awO ROSETTA ROO e ee DAO AOTR SETZER e e OEE 95 AO WACHACES 4 333040 E ne E E AE ew ela ease eres 5904 kee Lea eee ee 95 TAA ODUCS cotta Anew ee he e E E ead see et es a taba si tes 95 14 12 Environment and Matetial osc cccccscasscttaneee cee saaeeen ds FOES EE ET iiaa 96 14 13 Dimensional drawin
62. is permitted in the danger area 3 3 Restrictions for Use 14 Glass highly reflective materials such as mirrors reflectance gt 10 000 or objects that do not reflect any light back to the sensor can falsify the measurement result More information is available in Chapter 5 3 5 Do not expose the ROTOSCAN RS4 to flying sparks for example a welding flash Doing so may cause damage to the optical window Vapor smoke dust and all particles visible in the air have a significant negative effect on measurement values and will result in the semiconductor outputs being turned off Avoid extreme variations in temperature RS4 Leuze Make sure that the following types of light sources are not present on the scanning plane Laser light from one or more other scanners or sensors Infrared light Fluorescent light Stroboscopic light Please consider as well Chapter 5 2 It must not be used with internal combustion engines The ROTOSCAN RS4 is conceived for use inside enclosed spaces and with the operating parameters listed in the technical specifications temperature humidity shock vibration etc Please refer to the list of parameters in Chapter 14 Avoid having reflective surfaces such as glass mirrors retro reflectors etc at fixed contours in the scanning plane If this is not possible an additional detection zone must be provided 3 4 Information Related to Detection Zone Changeover If alternating oper
63. issioning Communication with the PC or laptop needs to be established so that the ROTOSCAN RS4 can be configured and the detection zones and warning zones can be programmed This is also necessary for displaying the measurement contours and for the system check The program RS4soft which is included with delivery makes this easy and convenient to do Refer to the operating instructions to find additional important information and helpful explanations Hardware and Software Requirements The following components are required for the initial startup e ROTOSCAN RS4 e RS amp 232 interface cable 1 1 without cross connection e Shielded control cable for the power supply and for activating a zone pair e Power supply that meets the requirements specified in Chapter 9 1 e PC or laptop color monitor e RS4soft program The PC should fulfill the following requirements e Intel processor Pentium class or higher or compatible models such as AMD or Cyrix e Atleast 64 MB RAM e CD drive e Hard drive with at least 50 MB of free memory more if detection zone data and or configuration data are going to be stored e Mouse e Interface RS 232 serial e Microsoft Windows 95 98 NT 2000 XP Installing RS4soft and Starting Up the ROTOSCAN RS4 e First run the installation program Setup exe in order to install the program on the PC e Start the software by calling up the program e Connect the contr
64. itional safety measures e g safety grids must be installed Following each definition of and change to the detection zones the configuration must be checked to see whether the possibility of people standing in the danger zone as well as any barriers provided have been considered by an appropriate layout of the detection zone s Additional Safety Notes for Stationary Use If the danger zone can be accessed from the side and if the detection zone cannot be extended sufficiently in this direction additional safety measures e g safety fences must be installed We recommended marking the contour of the detection zone on the floor by painting a colored line or applying colored adhesive tape Check the mounting regularly in particular the angle of inclination in order to guarantee the reliability of detection RS4 17 3 7 18 Additional Safety Notes for Mobile Use There are additional requirements for the use of scanners on automatic guided vehicles AGV and transporter trolleys according to DIN EN 1525 If possible expanded detection zones to each side should be provided in order to safeguard access from the side and directly in front of the vehicle If is it not possible to completely safeguard the contour of the vehicle including its trailer and the dimensions of its load while making curves additional protective devices such as switch strips must be attached to the side of the vehicle There must be a minimum safety di
65. ltage drops In accordance with DIN EN 61496 1 Non fused ground conductor Connection not allowed Table 14 6 1 Technical data electrical power 14 7 Inputs Restart Reset For connecting a command device for operating mode with restart interlock and or device reset dynamically monitored 24 VDC optically isolated Zone pair changeover For selecting among 4 zone pairs via 4 control cables with internal monitoring zone pair 1 detection zone and 1 warning zone 24 VDC optically isolated Signal definition High logical 1 16 30 V Low logical 0 lt 3V Table 14 7 1 Technical data inputs 14 8 Outputs Detection zone 2x failsafe semiconductor output PNP max 250 mA short circuit monitored overload protected Warning zone dirt 2x PNP transistor output max 100 mA Fault Load characteristics maximum Low pass behavior limit frequency fy lt 1 kHz Cload lt 100 nF Level high OSSD active Ug 3 2 V Level low OSSD inactive lt 2 0 V Level high alarm active Ug 4V Level low alarm inactive lt 2 0 V Table 14 8 1 Technical data outputs 94 RS4 Leuze 14 9 14 10 14 11 Leuze Software User software Configuration and Diagnostics Software under Windows 95 98 2000 NT XP with safe protocol for programming Table 14 9 1 Interfaces Technical data software RS 232 RS 422 For device configuration and
66. matted 9 Does the risk assessment take into consideration the fact that Yes No 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 Yes No the RS4 in effect 11 Has the effectiveness of the activated detection zone been Yes No tested with the black test pieces 70 mm diameter standing and 200 mm diameter on their sides 12 Is the start restart button for resetting the RS4 positioned Yes No according to requirements and does it work properly 13 Does the RS4 work in all necessary operating modes and during Yes No the entire motion of the vehicle that is causing a hazard 80 RS4 Leuze Leuze 14 Is the motion causing the hazard stopped when electrical power Yes No to the RS4 is disconnected and is a confirmation of the Start restart key necessary to reset the vehicle after the power is restored 15 Are all test and parameter inaccessible to unauthorized Yes No personnel 16 Is an identifying sign placed on the machine for the daily test of Yes No the RS4 where it is clearly visible for operating personnel RS4 81 11 7 Replacing the Optical Window 11 7 1 General information e Only professionally trained personnel are permitted to replace optical windows e Be careful everything stays clean during all jobs If possible work in a dust free environment A production hall is not a good place for working on the device 1
67. n is only permitted with the PC cable X2 or dummy 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 the X2 interface refer to the user s manual for the program RS4soft Integrating the ROTOSCAN RS4 4 into Machine Controls The following examples illustrate possibilities for integrating the ROTOSCAN RS4 into machine controls Once the operating voltage pin X1 3 UB has been connected to pin X1 1 GND and a detection zone has been activated X1 4 X1 6 X1 7 or X1 8 the unit is ready for operation Please see the point Start detection zone in the user s manual for the program RS4soft RS4 Leuze 8 1 Leuze Integrating the ROTOSCAN RS4 with External Wiring with Relays and Quadruple Zone Pair Changeover In this connection example the restart interlock function is provided by the connected command unit WA which applies the voltage of 24 V to the input RESTART X1 2 The ROTOSCAN RS4 itself must be configured using the RS4soft user software so that the operating mode with restart interlock is active 24 V n GND t PE a x y K1 K2 Moi a 3 c dje f K3 K3 amp Ki K3 K2 K3 x y X Zz lt r 1234567 8 9 1011 1213 1415 Jl D K1 TE O ER x1 a AIA K2
68. ne size gt 3 5 m Addition if retro reflectors or very shiny surfaces such as certain metals or ceramics are present in the scanning plane 0 mm more than 1 2 m behind the detection zone line 110 mm in the detection zone or up to 1 2 m behind detection zone line Table 14 3 1 Detection Zone Additions 14 4 Warning zone Detection range 0 15m Reflectance factor min 20 Object size 150 x 150 mm Response time Double evaluation 80 ms corresponds to 2 scans up to 16 scans can be selected 640 ms Number of warning zones 4 selectable via switch inputs Output PNP transistor output max 100 mA Table 14 4 1 Technical data warning zone 14 5 Contour Measurement Measurement range 0 50m Reflectance factor min 20 Output Serial interface RS 232 10 m RS 422 50 m Radial resolution 5mm Lateral resolution 0 36 Table 14 5 1 Technical data contour measurement Leuze RS4 93 14 6 Electrical Power Supply Power supply 24 VDC 20 30 supply according to IEC 742 with safety transformer or comparable for DC DC converters Overload protection Provide by 1 25 A semi delay fuse in the electronics cabinet Current consumption approx 300 mA use a power supply with 2 5 A Power consumption 8 W at 24 V plus the output load Excess voltage protection Over voltage protection with safe end cut off Vo
69. ng When placing the system in service for the first time when it has been out of service for some time after 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 requirements especially for guidelines on machines and using work material and work safety guidelines If the correct functionality is not clearly confirmed or if safety related parameters have been changed turn the machine or vehicle off immediately Stopgap measures are not permitted Please comply with the safety notes in Chapter 3 Test before First Startup by Person Qualified and Authorized to Perform the Task e Check in accordance with the guidelines cited above using the checklists provided below if necessary to verify that the protective equipment has been properly attached is connected to the control system electrically and that its effect works in all operating modes of the machine or vehicle e The result of the test must be documented along with the scanner setting in an understandable form Printouts of scanner parameters and all defined detection zone contours must be included with the materials Keep these where they are inaccessible for unauthorized personnel e During initial startup you should anticipate unexpected behavior in the machine or vehicle Because of this people mu
70. nning plane 150 mm Axis of the rotating mirror Safety distance Depth of the detection zone Detection zone additions in the direction of travel NvA200m ST ZTOT Fig 5 7 1 Mounting height on an AGV Depending on the application further additions may be necessary Additional information is available in Chapter 5 7 5 Recommendations for Mounting to Prevent Unmonitored Zones The creation of unmonitored zones is dependent upon the following factors e the vehicle width e the design of the vehicle e g attachments shape e the position of the scanner e the installation depth e the selected angle range If the detection zone of a ROTOSCAN RS4 4 mounted on an AGV does not cover the entire front of the vehicle you can prevent the creation of unmonitored zones by changing the installation depth of the scanner or by adjusting the angle range from 180 to 190 RS4 47 48 If this is not possible due to constructional limitations additional safety measures such as mechanical cover panels switch strips or bumpers must be implemented Please comply with the safety notes in Chapter 3 7 Saa gt H fs E ROTOSCAN RS4 4 b l Ei mounted on the front of a vehicle MA i E HO D lo 5 ROTOSCAN RS4 4 recessed into the front of a vehicle ROTOSCAN RS4 4 b mounted on a protruding vehicle a ROTOSCAN RS4 4 b Automatic guided vehicle c The distan
71. o start up again in accordance with DIN EN 1525 The restart can be initiated either manually or automatically In case of automatic restart the delay time of up to 10 s can be set in advance using the program RS4soft If a restart button is provided it must be mounted outside the danger zone at a position from which the entire danger zone can be viewed The areas that will be released must also be referred to in an easily understandable manner The startup 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 Chapter 5 7 6 RS4 Leuze 5 7 8 5 7 8 1 5 7 8 2 Leuze Calculating the Dimensions of the Detection Zone of an AGV Application Following are the specifications and calculation examples for the mobile safeguarding of automatic guided vehicles According to IEC 61496 3 the following formulas apply for calculating the safety distance S Vmax X T Sstop Vmaxacv Maximum speed of the AGV in mm s Response time of the scanner and the AGV in s Sstop 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 detection zone is calculated according to the following formula St Viaxaav X Tscan Tets S
72. off The safety oriented switching function cannot be reset until the detection zone is clear Depending on the operating mode the reset can be initiated either automatically or manually RS4 9 DZ WF 10 Detection zone max 4m Warning zone max 15 m Maximum registration of measurement value max 50 m Detection zone programmed in the ROTOSCAN RS4 example Warning zone programmed in the ROTOSCAN RS4 example Configurable detection V ZB zone and warning zone AZ expansion 5 ee Configurable detection j zone and warning zone S b SF gt l expansion 5 WF gt Object in the detection zone a gt Fig 2 1 1 The 190 angle range of the ROTOSCAN RS4 is divided into 0 36 angle segments A laser diode coupled with transmitter optics produces focused light pulses These pulses are projected across the monitored surface by a rotating mirror in such a way that a light pulse is triggered in each of the angle segments within 40 ms scanning rate 25 scans s 4 k ttt t Att Fig 2 1 2 Functional principle of the ROTOSCAN RS4 The ROTOSCAN RS4 can detect people up to a distance of 4 0 m corresponds to the detection zone even if they are wearing very dark clothing or exhibit a low degree of reflectance Dangerous movements are brought to a standstill by two failsafe semiconductor outputs Objects min 150 x 150 mm are detected up to a distance
73. ol cable and the PC cable e Then apply the supply voltage to the ROTOSCAN RS4 The scanner will now attempt to communicate with the PC this process is displayed on the screen RS4 69 70 e Ifthe connection between the ROTOSCAN RS4 and the PC was successful you can enter the appropriate password and then change the parameters and zone pairs of the ROTOSCAN RS4 to meet the needs of the particular application The standard password to be entered in the authorized level Authorized Customer of the ROTOSCAN RS4 is RS4LEUZE Please note that the password must be changed following the initial configuration of the scanner and that the data carrier must be kept locked up in a secure location e The ROTOSCAN RS4 is ready for operation once the scanner settings and detection zone configurations have been transferred Every ROTOSCAN RS4 is factory equipped with the maximum safety parameters For this reason first the device settings and then the detection zones must be adapted to the requirements of the application before the scanner is put into operation After configuring the scanner remove the PC interface cable from position X2 slip on the dummy cap provided with delivery and screw it tight For a list of parameters please see the in the Configuration and Diagnostics Software RS4soft Please observe Chapter 11 Testing and Maintenance RS4 Leuze 10 3 ROTOSCAN RS4 4 RS4 4E status indicator There are five LEDs loc
74. one itself must be defined in such a way that no gaps can arise through which a person could pass through the passage without being detected The reference 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 individuals 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 Operating Instructions for the RS4soft configuration and diagnosis software Protecting danger points Please have regard to the General Notes on Safety in Chapter 3 Object of protection The object of protection is the safeguarding e of individuals who work with a machine or spend time in the danger zone associated with it The ROTOSCAN RS4 4E will detect the body parts of individuals and the intrusion of these body parts into the scanning field of the laser scanner In this operating mode hand and arm protection is effectively realised Installation position Safeguarding of danger points on the basis of hand and arm protection is a suitable method if the machine operator in close proximity to the danger zone needs to halt the hazardous movement of the machine or to coordinate the handling of workpieces or their removal from the machine It is best if the laser scanner is firmly installed above the danger zone in such a way that it cannot
75. or example the effect of extraneous light the scanner performs a one time reboot If automatic startup and restart are activated the scanner turns the OSSDs back on after this brief error event and after the detection zone has been free for about 25 seconds 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 test startup interlock and or manual restart are included they 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 Depending on the hazard assessment visual and or acoustic startup warnings should be provided If parameters are set for the function Manual restart the required enable from the startup restart button affects all detection zones and is independent of any detection zone changeover If the current detection 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 also in effect for the other detection zone to which the system switches even if this detection zone is free Restart At least 2 seconds must elapse following the release of a violated detection zone before the AGV is allowed t
76. pecific C standards or the general B standards IEC 61496 3 in combination with DIN EN 999 see Section 2 and 5 of the standard Tolerance fields and or additions make sure to consider Chapter 5 4 and 5 7 After the detection zones have been set make a printout of the following information Detection zone contour with the X and Y coordinates Date Serial number of the scanner Name of the safety official When calculating the additions be sure to consider whether the dust algorithm is deactivated or activated see Chapter 5 3 5 RS4 Leuze 3 6 Leuze When calculating the safety distances be sure to consider all delay times such as the response time of the scanner response time of the control elements and braking times and or stopping times of the machine system or AGV Variations in delay time caused by factors such as reduced braking power must also be taken into consideration The effectiveness of the switch off function must be tested along the defined contour of the detection zone during the initial startup and subsequent to any changes made to a machine or system The effectiveness of the switch off function must be tested for the detection zone contours along the entire driving route during the initial startup and following any changes made to an AGV In the event that there is insufficient room available to allow the full dimensions of a detection zone for example because of the position of the scanner add
77. protection of the X2 interface if data communication with the PC is desired The cable screw couplings can accommodate cable diameters from 6 5 mm to 10 5 mm Jack X1 Connector X2 Fig 9 2 1 Preparing the connectors RS4 65 9 3 9 4 66 The connector adapter of control cable X1 must be connected with interface X1 and screwed tightly to the ROTOSCAN RS4 The connector adapter of cable X2 or else the X2 dummy cap without a cable must also be screwed tightly to the ROTOSCAN RS4 4 Threaded drill holes are located on the top of the scanner housing for this purpose If one of the two connection housings is missing the ROTOSCAN RS4 no longer meets the requirements of protection type 65 For information on the assignment of the connector please refer to Chapter 2 2 and 9 5 the connection and operating instructions of the RS4 Connector Assembly Every connector adapter consists of the following individual parts e Housing with sealing ring and fastening bolts e Cable screw coupling M16 with dummy plugs e Sub D9 connector and or Sub D15 connector each with a solder connection Points to Consider When Preparing and Laying the Cables e The cross section of cable X1 must be at least 0 5 mm e The outer diameter of the cable must be between 6 5 mm and 10 mm e The maximum cable length for X1 is 50 m e The maximum cable length for X2 is 10 m for RS232 e The maximum cable length for X2 is 50 m for RS422 twisted pair
78. re the firmly in place Do the safety equipment and command devices show any safety relevant changes or gaps in safety e g changes in access possibilities or changes in the surrounding area If the protective function of the RS4 is present for all required monitoring cases e g testing the switch off function with a test piece along the detection zone contour the LED3 for RS4 must light up with each attempt and the movement that poses a danger must be stopped immediately Possibility of danger to the person running the test must be excluded Is the startup test restart interlock if there is one working Does the base marking match the detection zone contour Do the necessary detection zones match the configuration protocol 10 If correct functionality is not certain or id the RS4 LED 5 is flashing If the answer to any of the questions above is No have the machine checked by a take the machine out of operation immediately Are any doubts resolved trained specialist Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes RS4 Leuze No No No No No No No No No No 11 4 2 Checklist for Daily Test of Mobile Applications by Responsible Operating Personnel 1 Are there any problems in the external state of the protective Yes No equipment the cable cable connections and any command devices or any command devices 2 Are the fastening screws in the mounting system firmly Yes No conne
79. ry of the detection zone SF2 Detection zone 2 disabled S Safety distance G Danger point m Screen e Distance from the screen to the intrusion zone of the danger point e gt 150 mm tolerance zone the reference boundary must be defined with reference to the screen Fig 5 6 1 Safeguarding of danger point based on hand and arm protection with monitoring 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 or over which a person could reach without being detected The detection zone must also provide safeguards against a person getting behind the barrier This can be very effectively managed by screening the sides of the danger zone The reference boundary should be defined with reference to the non moving parts of the screen arrangement The detection zone must be defined as large enough to ensure an overlapping greater than the tolerance zone of the reference boundary 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 to the indications given in the Operating Instructions for the RS4soft configuration and diagnosis software RS4 45 5 7 5 7 1 5 7 2 5 7 3 46 Safeguarding Mobile Machines Please compl
80. s cleaned within 4 the scanner is not turned off Note The order designations are available in Chapter 13 1 Leuze umiflex RS4 87 12 12 1 13 88 Service Your partner in all matters of occupational safety Leuze lumiflex GmbH Co KG offers additional services e Testing the ROTOSCAN RS4 laser scanner e Instruction on the topic Safety at Work e Instruction on the topic Information about Laser Scanners The results of the test are documented in accordance with ISO 9001 for the machine operator Our customer service department is available will be happy to assist you at phone number 08141 53 50 122 or e mail address service lumiflex leuze de Disposal Laser scanners that are no longer in use must be disposed of in an appropriate manner Delivery Package The basic unit consists of e ROTOSCAN RS4 e RS4 connector complete 15 pin interface X1 e RS4 connector complete 9 pin interface X2 e Connecting and operating instructions for ROTOSCAN RS4 4 RS4 4E User s manual for RS4soft Configuration and Diagnostic Software RS4soft on CD ROM incl the RS4soft operating instructions e Mounting screws 4 pieces e Safety notes and guidelines RS4 Leuze 13 1 Accessories and spare parts Brief description Description Order No RS4 MS RS4 mounting system 50033346 for securing and adjusting the RS4 RS
81. s of the safety equipment checked within the required periods but at least once a year by a trained and knowledgeable person e The checklists mentioned above are ideal for regular tests especially checks for safety related changes to the machine the vehicle or the piece of safety equipment Leuze Lumiflex offers a professional specialist service for regular checks You can arrange in a separate order to have all necessary testing and instruction tasks performed by this service www leuze de The results of the test are documented in accordance with ISO 9001 for the machine operator Daily Test by with Test Piece Performed by Responsible Operating Personnel The ROTOSCAN RS4 is a safety oriented laser scanner of Category Typ3 It is extremely important however to check the effectiveness of the detection zone with the test piece daily or after a shift change This ensures that if the parameters or operating mode is changed the protective function is ensured at every point in the detection zone RS4 75 11 4 1 76 Checklist for Daily Test of Stationary Applications by Responsible Operating Personnel 1 Are there any problems in the external state of the protective equipment the cable cable connections and any command devices or any command devices Are the fastening screws in the mounting system firmly connected Are the fastening screws in the RS4 firmly connected Are both protective caps X1 and X2 screwed on and a
82. se time Here as well factors such as additions in the direction of travel for tolerances in the measurement value and reduced braking power due to wear and tear must be taken into consideration Leuze umiflex RS4 23 4 6 24 Other Possible Applications Object and contour measurement Logistics counting measuring controlling Projection control e g in fully automatic parking ramps or lots Safeguarding or monitoring enclosed spaces and many more Information for Planning and Mounting It is essential that the following key points be complied with so that the ROTOSCAN RS4 4 RS4 4E can provide optimum performance The ROTOSCAN RS4 must be placed so that areas of access to the danger zone being monitored are completely covered by the detection zone The mounting position of the scanner should provide protection from humidity dirt and extreme temperatures below 0 C or over 50 C The mounting position must be selected in such a way as to minimize the possibility of mechanical damage Additional protective cover panels or safety bars must be installed at exposed positions Reinforcements cover panels mounting niches and other machine elements may not in any way impair the field of view of the scanner If there are areas of shadow caused by fixed obstacles that were defined as part of the detection zone boundary these should be safeguarded e g by safety grids in order to prevent people standing in them from being
83. sed on the following application data see 5 4 5 Largest width between the axis of Ggpirr 700 mm the rotating mirror and the boundary of the danger zone Access speed K 1600 mm s constant Response time of the RS4 4 Tscan 0 08 s adjustable Response time of the machine or TmacH 0 1s system Stopping time or lag time of the Tia 0 5 s time for braking the machine or system dangerous movement until standstill Factor for increase in lag time Liang 1 1 fixed addition to account for increased lag time Addition for system specific Zsm 83 mm when dust algorithm is measurement error switched off Addition caused by the mounting Zay 125 mm distance between the position that is selected front edge of the undercut to the beam axis of the scanner Height of the sensor H 300 mm scanning plane Safety related constant C 1200 mm 0 4 Height H 1080 mm The formula S Kx Tscan TmacH TLag X Leac C results in a safety distance of S 1600 mm s 0 08 s 0 1 s 0 5 s 1 1 1080 mm 2248 mm The formula S7 S Zoey Zau results in the detection zone depth S7 2248 mm 83 mm 125 mm 2456 mm RS4 39 5 4 8 4 5 4 8 5 40 Sample calculation of a maximum range of a detection zone The formulas 2 2 Smax St Sppirr Sgpirr Gepirr S Zsm yield under consideration of the width of the danger zone results in the ma
84. sitively guided contacts 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 Channels x and y must be integrated for Category 3 in accordance with DIN EN 954 1 Integrating one channel based on z is only permitted with a one channel control system and taking into consideration the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow Leuze RS4 63 8 3 64 Connecting the ROTOSCAN RS4 to a PLC with Corresponding Safety Level Cat 3 or higher EN 954 and Zone Pair Changeover 24 V GND PE 4 k 12345 67 8 9 10 11 12 13 1415 x1 ROTOSCAN RS4 4 Fuse 1 25 A Restart button Decentralized peripherals e g ET200M with failsafe signal subassembly Further processing by a failsafe PLC e g SIMATIC S7 400F ao oo ll Fig 8 3 1 Connecting the ROTOSCAN RS4 to a failsafe PLC with a safety level at least Cat 3 EN 954 and zone pair changeover 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 FP1 X1 6 FP2 X1 7 FP3 and X1 8 FP4 For applications in which the scanner must be separately enabled
85. st be between 0 12 s and 5 s The restart input X1 2 must be connected to an external permanently installed button X1 2 must not be connected with the remaining controls in order to prevent an unintended release with a Restart pulse under some circumstances Force guided normally closed contacts can be monitored in the restart circuit relay monitoring Please note the Chapter 5 planning and mounting information and 9 1 electrical power supply Channels for Zone Pair Changeovers FP 1 to FP 4 To activate the zone pairs apply 24 V see Chapter 9 1 to the following inputs X1 4 FP1 X1 6 FP2 X1 7 FP3 X1 8 FP4 When changing over the zone pairs please note that the new zone pair must be switched on before the previous pair is switched off The procedures is allowed to last a maximum of 1 s If this time period is exceeded or if the previous zone pair is switched off too soon the ROTOSCAN RS4 reports an error by switching off the two OSSDs and the alarm output In addition this state is shown in the indicator field on the scanner LED3 middle and LEDS right will both be lit up and flashing quickly at approx 4 Hz RS4 Leuze 7 3 7 4 Leuze Alarm 1 X1 5 As long as the output X1 5 is switched on the system signals trouble free operation If it is switched off the following states are reported e Interruption of the warning zone is shown by the continuously lit LED 2 in the indicator field o
86. st be kept out of the danger area e Operating personnel must be instructed by trained specialists before starting work Instruction is part of the area of responsibility of the machine operator e 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 Leuze Lumiflex offers a professional specialist service for initial startup You can arrange in a separate order to have all necessary testing and instruction tasks performed by this service www leuze de The results of the test are documented in accordance with ISO 9001 for the machine operator Extended Shutdown of the RS4 If a system is taken out of operation and the RS4 is placed in storage for later use with other machines vehicles the factory settings should be restored Please see the chapter entitled Setting Detault Values in the Scanner in the RS4soft operating instructions RS4 Leuze 11 3 Leuze Regular Tests by a Person Qualified and Authorized to Perform the Task Regular tests must be performed taking into consideration applicable local requirements especially for guidelines on machines and using work material and work safety guidelines The purpose of these tests is to discover changes for example lag times or manipulations on a machine vehicle or piece of safety equipment To do this see the checklists under Chapter 11 5 or 11 6 e Have the effectivenes
87. stance Sap of 500 mm to the side of the vehicle on both sides A one sided minimum safety distance is admissible in certain exceptional cases The specifications of DIN EN 1525 must be complied with The basic value of the detection zone width for an AGV corresponds to the maximum vehicle width including the trailer and the dimensions of the load plus the detection zone additions Zs Furthermore the greatest possible lateral shift of the AGV while making curves must be considered when defining detection zones If the ROTOSCAN RS4 is mounted on vehicles the mounting especially the angle of inclination the vehicles braking power and if applicable play in the vehicle guidance the difference between the optimum and actual line of guidance must be regularly checked in order to guarantee the reliability of detection RS4 Leuze 4 1 Applications for the ROTOSCAN RS4 4 RS4 4E Due to its continuous coverage of the area its wide range and the ability to select among four zone pairs the ROTOSCAN RS4 4 RS4 4E is able to handle even complex applications Stationary Safeguarding of the Danger Area The ROTOSCAN RS4 4 is used to safeguard dangerous working areas at machines and systems where both constant and variable demands are placed on the geometrical shape of the detection zone The aim is to prevent people from entering the danger zone or reaching the danger point with their upper and or lower extremities at the same time without imp
88. stop X Lgtop Ztot Sy Depth of the detection zone in the direction of travel in mm Vmaxacv Maximum speed of the AGV in mm s Tscan Response time of the scanner ins Tscan Response time of the AGV ins Lstop Factor for wear and tear on the brakes ZtoT Total of the system and application specific additions in the direction of travel in mm Zrot Zsm ZpeFL Zarir Zau Zsm Scanner measurement error in mm ZrerL Addition of the reflectors taken into account in mm ZartR Addition for inadequate floor clearance by the AGV in mm Zau Application specific addition in mm Maximum range of detection zone 2 2 Smax St SgpiFF SepirF Gppirr Zs Smax Maximum range of the detection zone in mm St Depth of the detection zone in the direction of travel in mm SBpIFF Largest width of the detection zone in mm Gepirr Largest width of the danger zone in mm Zs Sum ofthe system specific and application specific additions to the side in mm Zs Zsm ZperL Zau Zsm Scanner measurement error in mm ZrerL Addition of the reflectors taken into account in mm see Chapter 5 3 5 Application specific addition in mm Zau RS4 51 52 SMAX a ROTOSCAN RS4 4 b AGV c Detection zone d Axis of the rotating mirror Ggp FF Largest width of the hazardous zone BDIFF Largest width of the detection zone Smax Geometrical maximum distances ST Depth of the detec
89. t offset by using diagonal positioning and inclining the scanner If you do this however make certain it is not possible to crawl under the protective zone 100 mm Fig 5 2 2 Staggered mounting heights to prevent indirect irradiation 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 Methods of Configuring Detection Zones using the PC With its RS4soft configuration and diagnostic software the ROTOSCAN RS4 offers various methods for setting the configurations of detection zones Numerical input A separate dialogue within the user program RS4soft allows the right left and front edges of the detection zone to be set using numerical values in mm Graphic input A separate dialogue within the user program RS4soft allows the basic contours of the detection zone to be entered The contours can be adapted infinitely to the desired size of the detection zone The following shapes are available e circle e rectangle e polygon RS4 Leuze In addition the contours can be infinitely varied by e changing e limiting and e deleting partial segments as desired 5 3 2 Range of the Detection Zone Resolution The maximum range of the detection zone Smax 4m including the additions for an object with a diameter of 70 mm and a reflectance factor of 1 8 e
90. tecting an intrusion An example of the configuration of the ROTOSCAN RS4 4E to give access protection by passage monitoring will be found in Chapter 5 5 ROTOSCAN RS4 4E SF1 Detection zone 1 enabled Reference boundary of the detection zone c Emergency stop and triggering of the manual restart interlock Fig 4 2 1 Access protection by passage monitoring with system check of a reference boundary RS4 Leuze lumiflex 4 3 Safeguarding of danger points based on hand and arm detection If the machine operator in close proximity to the danger zone needs to halt the hazardous movement of the machine or to coordinate the handling of workpieces or their removal from the machine the machine must be provided with protection at the danger point To safeguard danger points in this way a protective system needs to be installed The ROTOSCAN RS4 4E is certified as a system providing hand and arm protection and is able in such a situation to guarantee flexible safety conditions in the workplace This may be combined with alternation of the detection zones In order to safeguard the protective equipment laser scanner and side mounted panels which serve as a reference and provide additional access protection against inadvertent misadjustment or manipulation the detection zones of the ROTOSCAN RS4 4E must be defined on the basis of a reference boundary An example of the configuration of the ROTOSCAN RS4 4E for the protection of danger poin
91. the activated LED 4 detection zone Violation of the activated warning zone The OSSDs are switched active high O0 1 1 0 LED 2 Violation of the warning zone Violation of the LED 3 detection zone The OSSDs are switched off 1 0 0 1 1 LED 1 The sensor function is active measurement LED 4 operation without a violation of the activated LED 5 detection zone The OSSDs are switched active high Warning message signaled by slow flashing at approx 0 25 Hz e g with optical window dirty 0 O 1 O 1 LED 3 The OSSDs are switched off LED 5 Fault message indicated by fast flashing at about 4 Hz e g with defect or safety related fault 101 0 1 LED 1 The sensor function is active measurement LED 3 operation without an interruption of the LED 5 activated zone pair The OSSDs are switched off Restart interlock is active O 1 1 0 1 LED 3 Interruption of the zone pair LED 5 The OSSDs are switched off Restart interlock is active 1 LED is lit up 0 LED is dark undefined Table 10 4 1 Status information of the ROTOSCAN RS4 Upon delivery the ROTOSCAN RS4 is programmed with the largest possible detection zone and with activated startup interlock and manual restart For this reason LED 5 is constantly lit up when the scanner is switched on When starting up your ROTOSCAN RS4 please modify the parameters to meet the specific needs of your application RS4 73 11 74 Maintenance and Testi
92. the device a bal ppa Pr Holger Lehmitz ppa Werner Lehner Director Product Unit Director Product Management safety at work Leuze lumiflex GmbH Co KG Postbank M nchen BLZ 70010080 185 734 807 Kommanditgesalischatt Sitz F rstenfeldbruck Liebigstra e 4 Amtsgericht M nchen HRA 40417 D 82256 F rstenfeldbruck Deutsche Bank BLZ 700 70010 1972900 pers haftende Gesalischan Telefon 49 8141 5350 0 Leuze electronic Geschaftsf hrungs GmbH Owen Telefax 49 8141 5350 190 UST ID Nr DE 129 999 527 Amtsgericht Kirchheim Teck HRB 550 E Mai lumitlex leuze de Gesch tst hrer Dr Harald Gr bel Michael Heyne Internet http www icuze de Vorsitzender ces Verwaltungsrats Meinert Hannemann 102 RS4 Leuze
93. tible 2702 Processing of requests for 3 Invalid diagnostic value requested diagnostics data Software and firmware incompatible 2800 Processing of inputs for 2 2 detection zones active longer than detection zone changeover 1s 2800 Processing of inputs for 3 The detection zone changeover that detection zone changeover occurred does not correspond to the requirement programmed in the scanner 2800 Processing of inputs for 4 More than 2 detection zones detection zone changeover selected during operation 2800 Processing of inputs for 6 Unevaluatable data or detection zone changeover defective data quality for activation of detection zone 2800 Processing of inputs 8 No detection zone activated during during scanner operation scanner operation 2801 Test of inputs for 1 Error during testing of inputs for detection zone changeover detection zone changeover internal fault 2802 Initialization of detection zone 3 The detection zone deactivation that changeover occurred does not correspond to the requirement programmed in the scanner 2802 Initialization of detection zone 4 More than 2 detection zones changeover selected during Power On 2802 Initialization of detection zone 6 Unevaluatable data or defective changeover data quality for deactivation of detection zone 2802 Initialization of inputs during 8 No detection zone activated during power on scanner starting 3016 Monitoring the access 11 Confirmed one time password was authorization with one t
94. tion zone Zaes Total of the additions in the direction of travel Zs Total of the additions to the side Fig 5 7 4 Considering the maximum measurement distance for safeguarding AGVs In accordance with DIN EN 1525 a minimum safety distance of 0 5 m width between the vehicle and its environment must be maintained RS4 Leuze 5 7 8 3 5 7 8 4 Leuze Sample calculation of the depth of a detection zone This example is based on the following typical application data without access against the direction of travel and without retro reflectors Largest width of the danger zone 1400 mm from the axis of the rotating mirror GgpiFF Maximum speed Vuaxaay 1800 mm s Response time RS4 4 selectable Tscan 0 08 s Response time of AGV control Tacv 0 1s Braking distance Sstop 1900 mm Factor for wear and tear on the brakes Lstop 1 1 fixed addition to account for wear and tear on the brakes Measurement error Zsgm 83 mm Distance between AGV and floor ZAFLR 90 mm results in an addition of 50 mm according to Fig 18 5 7 3 for calculating the addition for inadequate floor clearance The formula S Vuaxaev X Tscan TFTs Sstop X Lstop results in a safety distance of S 1800 mm s 0 08 s 0 1 s 1900 mm 1 1 2414 mm 7 2414 mm The formula St S Zsm Zeer ZaFLR Zau results in the following required depth of the detection zone in the direction of travel
95. tored zones can result if the scanner is mounted onto a protruding attachment or if the contour of the machine system is varied in depth RS4 Leuze 5 4 4 1 Leuze 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 Zyyin is 135 mm If it is possible to recess the scanner this is allowed up to a maximum of 40 mm the depth of the 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 accordingly see Chapter 14 13 and 14 14 The height of the undercut must be limited to prevent people from being able to step beneath it Mounting surface Scanning plane Machine side view Machine view from above pe N ESE I O z b s I d 1 i l l o c a a Be Sg e d Site e EN 1 l i f Zumin S Zom fo ee 1 a ROTOSCAN RS4 S Safety distance b Machine Sg Entire width of the c unmonitored zone ST detection zone d Detection zone Z detection zone additions e Height of the undercut ZUMIN depth of the undercut f g Fig 5 4 1 Recessed scanner installation with undercut The additional safeguarding required for the particular application must be taken into account Please note that the
96. tours 16 3 6 Additional Safety Notes for Stationary Use 0 0 0 00 eee eee eee 17 3 7 Additional Safety Notes for Mobile Use 0 0 0000 e eee eee 18 Applications for the ROTOSCAN RS4 4 RS4 4E oo eee 19 4 1 Stationary Safeguarding of the Danger Area ssuuaranunrrn rnnr rn unnn 19 4 2 Access guarding by passage monitoring 0 00002 eee eee eee 20 4 3 Safeguarding of danger points based on hand and arm detection 21 4 4 Mobile Safeguarding of Automatic Guided Vehicles 0 00 0000 22 4 5 Protecting Transporter Trolleys against Collisions 0 0 00 000 22 4 6 Other Possible Applications u n 000 ccc 24 Information for Planning and Mounting 00 c cece eee ee eee eee 24 5 1 Attachment and Dimensions 0 0000 c cc eee 25 5 2 Mounting Adjacent Sensors ics c cceeaycaeee een tess aaawn ee sinsa iiwan a eS 25 S 2 1 Directirradiation 2 c0 essadasken rn esceaiew neste se ebekdedaedeen EE eau 25 5 2 2 Indir ct Irr diation 60 ieee ech iaen ee dete as e eth en een eae eee ee 26 5 3 Information on Setting the Dimensions of Detection Zones 0 0 26 5 3 1 Methods of Configuring Detection Zones using the PC 00 26 5 3 2 Range of the Detection Zone Resolution 0 cece ee eee eee 27 5 3 3 Range of the Warning Zone Resolution 0 2000 c eee eee eee 2
97. ts based on hand and arm protection may be found in Chapter 5 6 OOOO REN y lt gt Soe s XX s mi XX Ky Z XX ut omg M K f 4 SS state I RO v x gt Ny V Mi w 1 N M S 3 iik p i VAA Va a ROTOSCAN RS4 4E b Reference boundarys of the detection zones SF1 Detection zone 1 enabled SF2 Detection zone 2 disabled c Emergency stop and manual triggering of restart interlock acknowledgement for switchover Fig 4 3 1 Safeguarding of danger points based on hand and arm protection with alternation of detection zones Leuze umiflex RS4 21 4 4 Mobile Safeguarding of Automatic Guided Vehicles For this application the ROTOSCAN RS4 4 is installed on automatic guided vehicles in order to monitor the vehicle path The aim is to detect people or objects in the path of the vehicle and to automatically bring the vehicle to a halt Safety systems available up to now such as bumpers or safety bars have allowed only very low driving speeds to be maintained In contrast using the ROTOSCAN RS4 4 as a non contact advance bumper results in the creation of a substantially larger safety zone The vehicles can move faster and down times are reduced to the necessary minimum DZ1 Detection zone 1 for slow speed DZ2 Detection zone 2 for high speed DZ3 Detection zone 3 for a route curving to the left DZ4 Detection zone 4 for a rout
98. tween the leg and the toes must be considered in the calculation For AGVs with a floor clearance of less than 120 mm an addition Zar R must be added This refers only to the travel of direction Bodenfreiheit in mm 120 100 80 60 40 20 0 O 20 40 60 80 100 120 140 160 Zuschlag Zaryss in mm Fig 5 7 3 Diagram for calculating the addition to compensate for inadequate AGV floor clearance RS4 49 5 7 6 5 7 7 50 System Availability There must be a buffer distance of 83 mm between the surrounding contour and the detection zone contour including the additions This distance increases the up time of the AGV since it prevents the surrounding contour from being detected as relevant for generating a switch off signal due to a measurement error Furthermore the dust algorithm of the RS4 4 can be implemented if floating particles may be present in the area This algorithm can be activated in the user program RS4soft and prevents the AGV from being switched off unintentionally Please note Chapter 5 3 5 If the danger zone analysis allows a multiple evaluation detection errors caused by floating particles can be decreased The number of evaluations that is decisive for the response time of the scanner Tscan and thus also requires a larger detection zone can be set in the user program RS4soft In the event of an error event that lasts only briefly f
99. uffer distance of 83 mm between the surrounding contour and the detection zone contour including the additions This distance 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 undercut can be calculated according to the following formula ZUMIN Z 83mm d Zumin Depth of the undercut in mm Required detection zone additions in mm d Resolution of the scanner d 70 mm This is possible since it is absolutely certain that a person will be detectedin front of the undercut Furthermore the dust algorithm of the RS4 can be implemented if floating particles may be present in the area This algorithm which can be activated in the user program RS4soft prevents the machine or system from being switched off unintentionally Please note Chapter 5 3 5 If the danger zone analysis allows a multiple evaluation detection errors caused by floating particles can be decreased The number of evaluations that is decisive for the response time of the scanner Tgcan and thus also requires a larger detection zone can be set in the user program RS4soft In the event of an error event that lasts only briefly for example the effect of extraneous light the scanner performs a one time reboot If automatic
100. ulfil 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 distance ensures that no body part whatever can reach the danger point until the hazardous movement of the machine has come to a complete standstill RS4 41 The safety distance for an access protection system may be calculated based on EN 999 by means of the following formula S KxT C S Safety distance in mm K Approach velocity in mm s here 1600 mm s T Overall time of delay in seconds a total consisting of Response time of the laser scanner here 80 ms Overtravel time of the machine including Based on measurement of the controls overtravel time Cc I Added margin on account of the possibility of manual intrusion here 850 mm Please also have regard in this connection to the diagrams given in this chapter 5 5 4 Definition of the reference boundary SF1 HEE A a To b ROTOSCAN RS4 4E SF1 Detection zone 1 enabled Reference boundary of the detection zone S Safety distance e Height of frame with reference boundary G Danger zone recommended value e gt 1200 mm Fig 5 5 1 Access protection by passage monitoring with system check of a reference boundary 42 RS4 Leuze umiflex 5 6 5 6 1 5 6 2 5 6 3 Leuze The reference boundary must cover at least two sides of the detection zone The detection z
101. witch output outputs OSSD with Vcc 1606 Motor speed monitoring 4 Motor speed deviation zero pulse not detected properly internal fault 1607 Monitoring of duration 5 Motor speed deviation motor not at of a scan rated speed RS4 99 Loca tion Description No Description 1705 Processing of field monitoring light barrier data Signal of a light barrier in optical window monitoring is under the lower limit Dirty optical window 1705 Processing of field monitoring light barrier data Signal of a light barrier of optical window monitoring is above the upper limit Fluid media on the optical window 1906 Test of the external watchdog Watchdog is not enabling the OSSDs There may be a wiring or control error 1906 Test of the external watchdog Watchdog not switching off the OSSDs Internal fault 1906 Test of the external watchdog Switch outputs OSSD have a state other than the one the scanner expected Possible wiring or control error 1906 Test of the external watchdog Watchdog not switching the cutoff path for the laser Internal fault 1907 Test of the external watchdog Event detected by watchdog watchdog switched off motor speed deviation scanner housing may be rotating 1907 Test of the external watchdog Event detected by watchdog watchdog switched off motor speed deviation scanner housing may be rotating
102. ximum distance to be monitored Smax 2456mm 3031mm 2 SgpiFF 700 mm 2248 mm 83 mm 3031 mm Smax 3901 mm Sample calculation of an undercut This example is based on the following application data If the scanner is mounted across from the machine see Fig 5 4 4 the undercut dimension can be reduced by d 70mm The formula ZUMIN Z 83mm d results in a minimum undercut Zumin 83 mm 83 mm 70 mm 96 mm It is not allowed for a person to be able to step beneath the undercut x SOS SNS ANN O ESOSI SSA SSRN Sa SSRS SESS SE ERSS BSN RNN IESSEN ESSIN on Aesoos SN RRR NISN aioe seatsosatransoaatronentaniens 0 ESOSI NONS 09At SOSS SRESS ES SESES SESE D EEEO RONS ri EEROR SSON itil SSO MPL OOOH SB Sse SSSA SSS saint Fig 5 4 6 The undercut RS4 5 5 5 5 1 5 5 2 5 5 3 Leuze Access protection Please have regard to the General Notes on Safety in Chapter 3 Object of protection The object of protection is the safeguarding e of individuals when they access a danger zone The ROTOSCAN RS4 4E will detect the passage of individuals and the intrusion of an entire human body into the scanning field 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 a
103. y with the safety notes in Chapter 3 The Purpose of Safeguarding is for protection e to protect people when entering variable danger zones e to protect objects located in the vehicle path e to protect the automatic guided vehicle and its load Mounting Position For the purpose of safeguarding the path of a vehicle the ROTOSCAN RS4 4 is mounted on the front of a vehicle in each direction of travel preferably in the center The scanner and hence the beam axis must be aligned horizontally in order to achieve a consistent scanning height Please comply with the safety notes in Chapter 3 7 Mounting Height As a rule the scanner should be mounted as low as possible in order to prevent people from crawling beneath the detection zone This specification is limited due to such factors as uneven floors or the deflection of the springs in the AGV The maximum mounting height must be selected so that an object cylinder with a diameter of 200 mm in the prone position is reliably detected see DIN EN 1525 The detection must be tested at the position of maximum depth within the detection zone For AGV applications sufficient resolution of detection is achieved when an object upright cylinder with a diameter of 70 mm can be detected throughout the detection zone RS4 Leuze 5 7 4 Leuze E Zces 5 ROTOSCAN RS4 4 AGV Height of the test piece max 200 mm Recommended maximum height of the sca

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